Self-Supporting Sign Single-Fold Unitary Sheet Design
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Solution Overview
Problem
Existing self-supporting signs require complex configurations, such as folding and adhesive coupling, and often necessitate large material amounts, making them cumbersome and inefficient for storage and deployment.
Innovation Solution
A self-supporting sign design featuring a unitary sheet with a base and upper portion that can be folded once about a central line, allowing the sign to transition from a flat to a use configuration with the base horizontal and upper portion raised, utilizing a combination of primary and laminate layers for rigidity, and optionally incorporating retaining members for holding additional items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional sign designs are used, then the sign can stand without a separable base, but complex folding and adhesive coupling is required making assembly cumbersome
Solution Approach 1:
The sign is divided into distinct functional segments: a base portion and an upper portion that can be independently formed and then joined through a single folding action. This segmentation allows each part to be optimized for its specific function while simplifying the overall assembly process.
Solution Approach 2:
The base portion and upper portion are pre-formed with predetermined geometries before final assembly. The fold line is pre-positioned to enable a single, simple folding action that transforms the flat configuration into the three-dimensional standing sign, eliminating the need for complex multi-step assembly.
2Productivity
If multiple folding and coupling steps are used, then the sign can be constructed, but large amounts of material are required and deployment becomes inefficient
Solution Approach 1:
The sign employs a dynamic folding mechanism that transitions from a flat, space-efficient configuration during storage and shipping to a three-dimensional standing configuration during use. The single fold line enables this dynamic transformation, allowing the sign to be compact for transport yet fully functional when deployed.
Solution Approach 2:
The base portion and upper portion are merged into a single integrated structure through the folding action, eliminating the need for separate components and reducing overall material usage. The fold line serves as both a structural element and a joining mechanism, combining multiple functions into a single feature.
3Device complexity
If the sign uses a unitary sheet with single fold, then material usage is reduced and assembly is simplified, but the sign must maintain rigidity in the raised configuration
Solution Approach 1:
The sign utilizes composite construction by combining a base portion and upper portion made from the same or different materials. The laminate layers provide structural rigidity while allowing the fold line to maintain flexibility for the single folding action. This composite approach enables both simplicity of assembly and sufficient strength for the raised configuration.
Solution Approach 2:
The fold line is positioned and dimensioned to provide localized flexibility where needed, while the rest of the base portion and upper portion maintain sufficient rigidity to support the sign in its raised configuration. The local geometry at the fold line is optimized to balance flexibility for assembly with stability for use.
Data Source
AI summary
Self-supporting signs and methods of manufacturing same are provided herein. In one embodiment, a self-supporting sign comprises a generally planar base portion and a generally planar upper portion extending from the base portion. The upper portion is foldable relative to the base portion about a fold line for movement between a storage configuration in which the base and upper portions are generally coplanar and a use configuration in which the base portion is generally horizontal and the upper portion is raised relative to the base portion. Only folding about the fold line is necessary to move from the storage configuration to the use configuration, and the base and upper portions are sufficiently rigid such that the upper portion remains at the use configuration after being moved to the use configuration. The upper portion may be offset from the base portion between about 50° and 90° when at the use configuration.