Internal Support Structure for Stand-Alone Pop-Up Assembly
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Solution Overview
Problem
Existing three-dimensional pop-up structures rely on extended bases or protruding support members, which are aesthetically unpleasing, require additional space for display and storage, and obscure the exterior features when closed, limiting lighting options and safety due to the need for external support to maintain the open position.
Innovation Solution
A three-dimensional stand-alone pop-up assembly that moves between a closed and open position using an internal support structure comprising a spreader, center support, and internal base, eliminating the need for an extended base or protruding member, allowing for various lighting and sound features and enabling compact storage and display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an extended base is used to support the pop-up structure in the open position, then the structure can maintain its three-dimensional form, but the base extends beyond the footprint of the structure requiring additional display and storage space
Solution Approach 1:
The base is designed to nest within the footprint of the pop-up structure when folded, eliminating the need for extended base areas. The base panels are configured to collapse inward and stack within the structural boundaries, allowing compact storage and display while maintaining full structural functionality when opened.
Solution Approach 2:
The support mechanism transitions from a two-dimensional extended base to a three-dimensional internal support system. Vertical support elements and internal bracing structures provide the necessary stability without requiring horizontal extension beyond the structure's footprint, utilizing the vertical dimension to achieve structural integrity.
2Stability of the object's composition
If an extended base is used to hold the pop-up in the open position, then the structure can stand alone, but the exterior features are obscured when closed
Solution Approach 1:
The base and support structures are nested within the structural boundaries when closed, allowing the exterior surface to be fully visible without obstruction. The compact folded configuration eliminates overhanging elements that would otherwise block the view of design features on the front and side surfaces.
3Strength
If tabs are added to the center support for reinforcement, then the center support can resist bending and tearing, but the device complexity increases
Solution Approach 1:
The center support utilizes composite construction combining paper or cardstock layers with integrated scoring and folding patterns. The material composition and structural geometry work together to provide enhanced strength and resistance to bending and tearing without requiring additional reinforcing tabs or complex fastening mechanisms.
4Stability of the object's composition
If the extended base is held in the open position, then the pop-up structure can maintain its three-dimensional form, but the elastic nature of materials causes the base to pull into a closed position
Solution Approach 1:
The base incorporates counterbalancing elements and friction-based holding mechanisms that resist the elastic restoring force attempting to collapse the structure. Weighted components or friction-enhanced joints provide counteracting forces to maintain the open position without requiring continuous external support.
Solution Approach 2:
The base is pre-configured with scoring, folding patterns, and joint designs that create natural stopping points and holding positions. These preliminary structural features guide the base through controlled movement and enable it to maintain the open position against elastic forces without requiring active intervention.
Data Source
AI summary
A three dimensional stand alone pop up assembly and method for making the same, the assembly comprising outer structural wall panels connected with an internal support structure having a spreader, center support element and base components. The assembly moves between a first position, whereby the support structure is folded within the wall panels of the outer structure, and a second position whereby outer structural panels are unfolded into a three-dimensional stand-alone pop-up structure supported in the open position by the internal support structure. The assembly utilizes an internal support structure which folds internally and alleviates the need for an extended base or protruding member. The assembly accommodates a variety of lighting and sound features and can be configured in a variety of three dimensional stand alone pop up designs.