Rear Projection Substrates Uniform Thickness Rotational Molding
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Solution Overview
Problem
The fabrication of contoured rear projection substrates for animatronic or robotic characters is labor-intensive and costly, with issues such as non-uniform thickness and the need for expensive, toxic coatings, leading to high rejection rates and increased production time.
Innovation Solution
A method using rapid prototyping, specifically stereolithography, to concurrently form rear projection substrates with adjacent structural elements, achieving uniform thickness and optical qualities without additional coatings, by selectively curing UV-curable photopolymer resins to create translucent, white plastic with reduced thickness for the projection surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If vacuum forming is used to form the base substrate, then the substrate can be formed with curved or non-planar surfaces, but the substrate thickness becomes non-uniform leading to high rejection rates
Solution Approach 1:
The patent changes the fundamental forming parameter from vacuum forming (which creates non-uniform thickness) to rotational molding (which maintains uniform thickness while achieving curved surfaces). This parameter change resolves the contradiction by allowing the substrate to have both the desired curved shape and uniform thickness simultaneously.
Solution Approach 2:
The patent utilizes the phase transition of the polymer material from solid to molten state during rotational molding, allowing the material to flow and conform to the mold cavity while maintaining uniform thickness distribution, thereby achieving both curved surfaces and uniform thickness.
2Reliability
If RP coating is applied to the base substrate, then the desired optical properties are achieved, but the process becomes expensive and time-consuming with multiple coating applications
Solution Approach 1:
The patent merges the substrate formation and optical property achievement into a single step by incorporating optical additives directly into the polymer material during rotational molding. This eliminates the separate RP coating process, reducing both time and cost while maintaining reliable optical properties.
Solution Approach 2:
The patent performs the optical property enhancement in advance by mixing optical additives into the polymer material before molding. This preliminary action eliminates the need for subsequent coating operations, significantly reducing production time and complexity.
3Reliability
If multiple coating applications are used to achieve desired optical qualities, then the optical properties are improved, but the cost and complexity of the fabrication process increase
Solution Approach 1:
The patent combines multiple coating functions into a single material formulation by incorporating optical additives into the polymer. This merging reduces fabrication process complexity from multiple coating applications to a single molding operation while maintaining superior optical qualities.
Solution Approach 2:
The patent changes the approach from post-forming coating to in-material optical enhancement by adding optical additives to the polymer compound. This parameter change simplifies the fabrication process while achieving reliable optical properties in a single step.
4Reliability
If the RP substrate is formed separately and then attached to the support structure, then the RP element can be optimized for optical properties, but the fabrication process becomes labor-intensive and costly
Solution Approach 1:
The patent merges the RP substrate and support structure into a single integrated component formed by rotational molding. This integration maintains optimized optical properties through material additives while dramatically simplifying the fabrication process by eliminating separate forming and attachment operations.
Solution Approach 2:
The patent creates a multi-functional polymer material that simultaneously provides structural support and optimal optical properties for rear projection through the incorporation of optical additives. This universal material eliminates the need for separate RP substrate and support structure components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the fabrication process, reduces costs, and improves the uniformity and quality of the substrates, allowing for efficient production of animatronic or robotic components with integrated rear projection capabilities.
Implementation Method 1
selectively curing UV-curable photopolymer resins
Data Source
AI summary
A three dimensional (3D) object with a rear projection (RP) surface. The 3D object includes an RP element, which behaves as an RP substrate or surface. A structural portion of the 3D object has a first thickness, and the RP element has a second thickness that is less than about one half of the first thickness. The RP element is formed of a translucent white plastic for example, such that it is translucent to provide an RP element integrally formed with an adjacent structural element which is opaque with or without additional coating or treatment.