Modular Sign Spacer Assembly Flat-to-3D Transformation
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Solution Overview
Problem
Existing knock-down tube and slip signs require cumbersome and time-consuming manual assembly, as they are typically provided in a collapsed configuration with separate graphic panels that need to be attached to the sign structure, making it difficult to erect the box structure with panels attached.
Innovation Solution
A corrugated paperboard modular sign with a spacer assembly coupled to the graphic panels, allowing the sign to transform quickly and easily from a knock-down to an erected configuration, secured by features like key flaps and apertures, which can be supported by a tube or existing structures like register signs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If knock-down signs are provided with separate graphic panels that need to be attached to the sign structure, then the sign can be shipped in a collapsed configuration for storage, but the assembly process becomes cumbersome and time-consuming
Solution Approach 1:
The graphic panel is merged with the spacer assembly through die-cutting and folding, creating an integrated unit where the graphic panel forms part of the spacer structure. This eliminates the need to separately attach graphic panels to the sign structure, reducing assembly steps and time while maintaining the collapsible nature of the sign for storage
2Ease of manufacture
If graphic panels are pre-glued to the blank knock-down sign, then assembly might be simplified, but it becomes extremely difficult to erect the box structure with panels attached
Solution Approach 1:
The sign structure is segmented into distinct functional components: the spacer assembly (which provides structural support and collapse capability), the graphic panel (which provides visual information), and the support structure interface. This segmentation allows each component to perform its function independently while being easily assembled together, avoiding the problem of pre-glued panels interfering with structural erection
3Adaptability or versatility
If the sign structure includes unique shapes or graphic panels extending past other panels to accommodate marketing needs, then the sign can provide specialized marketing functionality, but a separate graphic panel must be coupled to the front panel
Solution Approach 1:
The graphic panel is merged with the spacer assembly through die-cutting and folding operations, creating an integrated unit where the graphic panel becomes part of the spacer structure itself. This eliminates the need for separate graphic panel attachment and reduces overall structural complexity while maintaining marketing versatility
Data Source
AI summary
A modular sign including a spacer assembly affixed to graphic panels is provided. The modular sign is movable between a knock-down configuration and an erected configuration. In the knock-down configuration, the spacer assembly lays flat on a back surface of the graphic panels. In the erected configuration, the spacer assembly is positioned behind the graphic panels so as to provide a support structure for the graphic panels while simultaneously being at least partially concealed by the graphic panels. The modular sign is moved from the knock-down configuration to the erected configuration by rotating the graphic panels up and away from a flat surface and is secured in the erected configuration by inserting a key flap into a keyhole. Once the modular sign is in the erected configuration, it can be installed onto a tube and/or another support structure, such as a register sign.