Tapered Beveled Base Plate Nodes for Custom UV Printing
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Solution Overview
Problem
Conventional base plates for interlocking building bricks are limited in size, lack durability, and do not allow for customization of colors and images, restricting users' ability to create large, uniform, and themed constructions.
Innovation Solution
The development of base plates with a tapered and beveled node structure that facilitates interlocking with various brick types and includes an integrated interlocking mechanism for larger composite plates, combined with a method using UV ink printing for custom color and image application on post-production plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional base plates are mass-produced with fixed dimensions, then manufacturing efficiency is improved, but size variety and customization are limited
Solution Approach 1:
The base plate is divided into multiple modular panels that can be assembled together to create larger custom-sized base plates. Each panel contains interlocking mechanisms that allow flexible combination of multiple panels in different configurations, enabling customization of overall base plate size while maintaining efficient mass production of individual standard panels.
2Ease of manufacture
If conventional base plates are made thin for ease of manufacture, then manufacturing simplicity is improved, but durability and resistance to deformation are reduced
Solution Approach 1:
The base plate transitions from a two-dimensional thin sheet to a three-dimensional structure with raised nodes and recesses. This dimensional change adds structural rigidity and durability while maintaining manufacturing efficiency through injection molding processes that can create complex 3D geometries in a single production step.
3Productivity
If traditional printing processes are used on base plates with projecting studs, then mass production capability is maintained, but image quality and scratch resistance are compromised
Solution Approach 1:
The printing process is performed after the base plate structure is fully manufactured, rather than during production. This post-production printing allows for high-quality, precise image application to the finished 3D surface, and the UV-curing process creates scratch-resistant printed surfaces that can withstand subsequent handling and use.
4Ease of manufacture
If base plates are produced in limited standard sizes, then manufacturing cost is reduced, but utility for large constructions is limited
Solution Approach 1:
Multiple standard-sized panels are combined through interlocking mechanisms to create larger base plate assemblies. This merging approach allows consumers to achieve large total areas by assembling multiple manufactured panels, maintaining the cost benefits of mass-producing standard panels while providing the capability to create large custom-sized base plates.
5Ease of manufacture
If separate base plates are used to achieve large constructions, then manufacturing feasibility is maintained, but structural stability and interconnection are reduced
Solution Approach 1:
The base plate panels feature asymmetric interlocking mechanisms with male and female connection elements that provide stable structural joining. The asymmetric design ensures proper alignment and secure connection between panels, enhancing the overall structural stability of assembled large base plate constructions while maintaining manufacturing feasibility.
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
Enables the creation of larger, more durable base plates that can support multiple brick types and allows for high-quality, scratch-resistant custom prints across a wider range of viewing angles, enhancing the visual appearance and functionality of LEGO brick constructions.
Implementation Method 1
The UV ink is applied to the base plate from a UV ink printer
Data Source
AI summary
A base plate for supporting a plurality of interlocking building bricks includes a planar sheet having a top surface and a bottom surface, with a plurality of nodes projecting from the top surface. The plurality of nodes includes a node having a vertical cylindrical wall and a horizontal top wall, the vertical cylindrical wall tapering along its vertical height; the node also having a bevel extending around a circumference of the node at an edge where the vertical cylindrical wall transitions to the horizontal top wall. A method of assembling a composite base plate includes securing two component base plates to one another via a common backing material. A method of printing on a base plate includes applying ultraviolet ink to at least the top surface of the base plate from an ultraviolet light printer, the base plate having a plurality of studs or nodes projecting from the top surface.