Modular Display Panel System with Automated Milling and Trifunctional Connectors
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Solution Overview
Problem
Existing backdrop display systems for stage and set design are often custom-made and lack consistency in edge straightness and quality, leading to visible seams when multiple panels are connected.
Innovation Solution
A modular display panel system utilizing dimensionally accurate framing components and connectors created using automated milling techniques, allowing for quick assembly of multiple panels into a larger display with minimal visible seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-made theater flats are used, then flexibility in design is improved, but manufacturing precision and dimensional consistency deteriorate
Solution Approach 1:
The display system is divided into modular panels with standardized dimensions and interchangeable components. Each panel is a self-contained unit with consistent framing, allowing custom configurations while maintaining manufacturing precision through standardized parts.
Solution Approach 2:
Universal connectors and standardized framing components are used across all panels, enabling the same manufactured parts to serve multiple design configurations. This allows design flexibility through arrangement rather than custom fabrication.
2Ease of manufacture
If multiple panels are connected using traditional methods (lash line cleats, screws, coffin locks), then assembly is possible, but assembly time and complexity increase
Solution Approach 1:
Multiple connection functions are merged into a single integrated connector system. The standardized connectors combine alignment, attachment, and locking functions into one component that can be installed quickly without multiple separate operations.
Solution Approach 2:
Connectors are pre-positioned and pre-aligned during panel manufacturing. This preliminary action ensures that during assembly, panels can be connected quickly without requiring complex alignment procedures or multiple adjustment steps.
3Ease of manufacture
If panels are connected with visible seams, then manufacturing is simpler, but display quality and appearance deteriorate
Solution Approach 1:
The edges of panels are manufactured with enhanced precision and uniformity specifically at the connection interfaces. This local quality focus ensures seamless alignment at seams while allowing standard manufacturing processes for the main panel surfaces.
Solution Approach 2:
Edge alignment features and reference surfaces are pre-formed during manufacturing. This preliminary preparation of edges ensures that when panels are connected, the seams align perfectly without requiring complex adjustment or masking procedures.
4Stability of the object's composition
If L-jack braces are used to support theater flats, then stability is improved, but storage space requirements increase
Solution Approach 1:
The support structure uses collapsible or retractable elements that can be extended when needed for stability during display, then collapsed or folded into a compact configuration for storage. This dynamic transformation allows the same structure to provide both stability and space efficiency.
Solution Approach 2:
Support components are designed to nest within each other or fold into the panel structure itself when not in use. This nesting capability allows the support elements to occupy minimal storage space while providing full stability when deployed.
Data Source
AI summary
A modular display panel system providing a plurality of modular display panels that can be connected together to form a larger display than any of the display panels. The display panel system has at least one modular display panel that can be releasably secured to at least one other modular display panel. The modular display panel has a panel, a frame assembly, and a jack assembly. The panel providing a display surface on the front and configured to be releasably secured to the frame assembly. The frame assembly having a rectangular structure and providing a first stile, a second stile, a top plate, a bottom plate, and at least one toggle. The first stile having at least one connector and a trifunctional mortise; and the second stile having at least one second connector and a trifunctional mortise. The jack assembly provides a jack leg pivotably secured to the frame assembly, and a locking brace pivotably secured to the jack leg.