Integral Optical Tiles with Angled Connection Areas
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Solution Overview
Problem
Existing methods for creating optical panels with projecting tiles fail to efficiently form integral, angled connections between tiles and substrates, leading to inadequate support and manufacturing complexity.
Innovation Solution
A method involving a substrate with punched-out tiles that are integrally formed from a single piece of material, where each tile is connected to the substrate at a connection area projecting upward with angled edges, utilizing a combination of circular and linear segments for enhanced support and ease of manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tiles are attached to substrate using existing methods, then optical images can be formed on building surfaces, but structural support is insufficient and manufacturing complexity increases
Solution Approach 1:
The patent merges the tile and substrate into a single integral structure formed from one piece of material. The connection area is formed as part of the substrate itself, eliminating the need for separate attachment mechanisms. This combining approach provides superior structural support while simplifying manufacturing to a single-forming process.
Solution Approach 2:
The connection area is segmented into multiple linear connection segments that extend from the substrate surface. This segmentation provides enhanced structural support by distributing the load across multiple attachment points while maintaining the integral nature of the single-piece construction.
2Strength
If tiles are formed as integral pieces with substrate, then structural support is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connection area extends beyond the minimum required attachment point, with linear connection segments that project upward from the substrate surface. This excessive extension of the connection area provides manufacturing tolerance, making it easier to achieve proper tile alignment and attachment while maintaining strong structural support.
3Ease of manufacture
If connection areas project upward from substrate surface, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The connection area is merged with the substrate as a single integral feature formed during the same manufacturing process. The linear connection segments are formed as part of the substrate geometry, eliminating the need for separate attachment components and simplifying manufacturing to a single-forming operation.
Solution Approach 2:
The linear connection segments create angled surfaces that facilitate tile attachment. The geometric configuration of these segments provides natural alignment features and attachment surfaces that simplify the manufacturing process while maintaining structural integrity.
Data Source
AI summary
A panel comprising a substrate having a top substrate surface and a bottom substrate surface. The substrate includes a plurality of tiles extending outwardly from the top substrate surface of substrate. The tiles having a top tile surface and a bottom tile surface. The tiles and the substrate are integral and formed of a single piece of material. Each tile is connected to the substrate at a connection area. Each connection area projects upwardly from the top substrate surface of the substrate and includes a bottom connection edge connected to the top substrate surface of the substrate at a first angle and a top connection edge connected to a bottom tile surface of one of the tiles at a second angle. The tiles form an optical image on the panel.