3D Billboard Foam Inserts with Reinforced Webbing

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Solution Overview

Problem

Existing three-dimensional billboard displays require auxiliary structural support or air inflation equipment, and internally reinforced foam, which complicates installation and transportation, and may not provide the desired aesthetic and durability.

Innovation Solution

A flexible banner with integrated reinforcement webbing supports three-dimensional foam inserts, which are assembled to form a predetermined shape, covered with a flexible cover, eliminating the need for auxiliary support and air inflation, and allowing for tool-free, efficient installation and transportation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single-piece foam unit is used for three-dimensional embellishment, then the structural integrity is improved, but the manufacturing complexity and transportation efficiency deteriorate due to custom-shaping and internal reinforcement requirements

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The foam embellishment is divided into multiple modular foam blocks that can be separately manufactured, transported, and assembled. Each block is a simple geometric shape without internal reinforcements, reducing manufacturing complexity while maintaining structural integrity through the interlocking assembly of multiple segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple foam blocks are nested or interlocked together to form the complete three-dimensional embellishment structure. The blocks fit together like puzzle pieces, creating a stable structure without requiring internal reinforcements within each individual block.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If a single-piece foam unit with internal reinforcement is used, then the durability is improved, but the transportation efficiency and storage space deteriorate

Engineering Contradiction:

ImprovedurabilityVSAvoidtransportation efficiency

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The foam structure is segmented into multiple small blocks that can be efficiently packaged and transported. When assembled, these blocks form a durable three-dimensional structure comparable to or exceeding single-piece foam, while significantly reducing transportation volume and storage requirements.

Inventive Principle:

Principle #1Segmentation

3Stability of the object's composition

If auxiliary structural support components are added to carry the foam embellishment, then the structural stability is improved, but the device complexity and installation difficulty deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidauxiliary structure requirements

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Instead of adding auxiliary support structures to hold the foam, the foam blocks themselves are designed to be self-supporting through their interlocking geometry. The modular blocks create inherent structural stability without requiring external supports, brackets, or additional framework.

Inventive Principle:

Principle #13The other way round (Inversion)

4Object-affected harmful factors

If spray-coating is applied to the foam embellishment, then the aesthetic appearance and weather resistance are improved, but the manufacturing time and cost deteriorate

Engineering Contradiction:

Improveweather resistanceVSAvoidmanufacturing time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

A flexible weather-resistant cover or film is applied to the foam blocks instead of spray-coating. This cover provides protection from elements and aesthetic appearance without requiring time-consuming spray applications, and can be easily installed and removed.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUSRE50131E1Three dimensional billboard display using foam inserts and flexible cover

Publication Date: 2024.09.17 CAROLAN EDWARD FRANCIS

AI summary

A three-dimensional billboard display system features a flexible sheet of banner material having displayed content on a display side thereof, and a two-dimensional footprint area on the display side that is discretely identifiable from the displayed content. A flexible cover fastened to the flexible sheet in a position overlying the two-dimensional footprint area on the display side and enclosing a three-dimensional space between said cover and said flexible sheet. One or more inserts form a three-dimensional body of predetermined shape inside the three-dimensional space, the flexible cover spanning in taut condition over the three-dimensional body, thereby imparting the predetermined shape to the three-dimensional space and imparting the flexible cover with a three-dimensional form bulging outwardly from the display side of the flexible sheet. A reinforcement layer features a mesh or netting of criss-crossing webbing straps on a backside of the flexible sheet to carry the weight of the 3D embellishment.