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(11) | EP 1 345 758 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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| (54) |
ARTICLE AND METHOD OF MAKING GEGENSTAND UND VERFAHREN ZU DESSEN HERSTELLUNG ARTICLE ET PROCEDE DE FABRICATION |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
Field of the Invention
[0001] The present invention relates to a substrate which is formed into a three dimensional article.
BACKGROUND OF THE INVENTION
[0002] Fiber reinforced composite structures enjoy the benefit of being lightweight while providing mechanical advantages such as strength. However, in many applications, molded plastic, wood or metal structures are preferred due to the cost involved, since they are relatively easy to fabricate. Often times however, articles, such as package or storing crates, are prone to damage due to the rough handling involved or are limited in their stacking ability due to weight and strength considerations. While fiber reinforced composite structures would be more desirable, the expense involved in making a somewhat complex three dimensional (3D) structure is a consideration.
[0003] This is because composite structures start off typically with a woven flat substrate of fibers. The substrate then has to be shaped into the form of the article which is then coated with a resin and thermoformed or cured in the desired shape. This may be readily done for relatively flat or smooth surfaces. However, for angled surfaces such as at the junction of the sides, corners and bottoms of a box or crate, cutting or darting is required. This is somewhat labor intensive and adds to the cost of manufacture. For things typically considered to be iriexpensive, for example a packaging crate, the added expense may outweigh the benefits of it being reinforced.
[0004] While woven 3D structures may be woven by specialized machines, the expense involved is considerable and rarely is it desirable to have a weaving machine dedicated to creating a simple structure.
[0005] In addition to creating 3-D structures made out of fiber reinforcement, it is also desirable to make 3-D structures out of 2-D sheet material which may be sheet metal, plastic, cloth, paper, cardboard, etc.
[0006] DE-A-19 716 637 describes a sheet of foldable honeycomb and method of folding this sheet according to the preamble of claims 1 and 8.
[0007] Accordingly, while three dimensional articles, reinforced or otherwise, are desirable in many applications, there exists a need to reduce the cost involved in the method of their manufacture. By doing so it may also allow for their relative mass production and wide spread application.
SUMMARY OF THE INVENTION
[0008] It is therefore a principal object of the invention to minimize or eliminate the need to cut and dart sheets of material for 3D structures.
[0009] It is a further object as part of this to simplify the manufacture of such structures and reduce the labor requirement.
[0010] These and other objects and advantages will be apparent from the present invention according to claims 1 and 8. The present invention is directed toward providing a specially designed sheet of material for a 3D structure. It starts off as a 2D structure that is then formed into a 3D structure, particularly one having deep draws. To provide for this, the sheet of material is formed in a manner that has areas which would gather and distort the edges of the 3D structure which is formed by folding the sheet. The edges of the remaining portions of the sheet which formed the boundary of the removed area can be left as is or can be seamed using methods such as welding, thermal bonding or adhesive bonding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Thus by the present invention its objects and advantages will be realized the description of which should be taken and in conjunction with the drawings wherein:
Figure 1 illustrates the construction of a flat 2D sheet of material incorporating the teachings of the present invention.
Figures 2A-2D illustrates the sequence of folding the sheet to produce deep draws.
Figure 3 illustrates a 2D sheet having multiple areas removed to create a complex structure upon folding or drawing down.
Figure 4 is a perspective view of a 3D structure formed from the sheet shown in Figure 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Turning now more particularly to the drawings, like parts will be similarly numbered. In Figure 1, there is shown a flat 2D sheet of material 10 which illustrates the present invention. The sheet 10 may be made of sheet metal, plastic, cloth, paper, cardboard or any other material suitable for the purpose.
[0013] For purposes of this illustration in Figure 1, the sheet 10 has been divided into regions or areas 12 through 28 divided along fold lines 30-36. The sheet material has either been removed or the sheet formed without it leaving an open space.
[0015] Turning now to Figures 2A-2D, shown in Figure 2A is the flat 2D sheet 10. The sheet 10 is then folded along fold lines 30 and 32. The sheet 10 is then folded along fold lines 34 and 36 which are perpendicular to the fold lines 30 and 32 as shown in Figure 2C. In this process since there is no material in region 20 the adjacent areas are allowed to be folded into an abutting relationship as shown in Figure 2D. The edge or corner 38 so formed can be left as is or can be seamed by way of, for example, welding, thermal bonding, adhesive bonding or other means suitable for the purpose. Folding can be done automatically or by other means suitable for this purpose.
[0016] The foregoing advantageously avoids the need for cutting or darting, thereby reducing the amount of labor required and the ultimate cost of the article. The present invention allows for the increased automation of the fabrication and therefore broadens the applications for which such structures may be used.
[0017] Turning now briefly to Figure 3 there is shown a flat 2D sheet 110. Sheet 110 illustrates a plurality of regions 120 wherein the sheet material has been removed. With such a sheet 110, it may be folded and shaped into a complex structure 130 as shown in Figure 4. Of course other shapes can be created by varying the size and location of the regions where the material is removed.
material forming the sheet in a first portion (12, 14, 16, 18, 22, 24, 26, 28) of the sheet ;
a second portion (20 ; 120) of the sheet where there is no material, said second portion having two first edges parallel to each other and two second edges parallel to each other and perpendicular to said first edges, said first edges and second edges defining the second portion ; and
wherein the sheet has two first fold lines (30,32) respectively along and on both sides of said first edges and which continues to the edge of the first portion and two second fold lines (34, 36) respectively along and on both sides of said second edges and which continues to the edge of the first portion
characterised in that said two first edges and said two second edges of said second portion are continuous.forming the sheet to create a first portion (12, 14, 16, 18, 22, 24, 26, 28) of the sheet with sheet material;
removing a portion of the sheet to create a second portion (20 ; 120) of the sheet where there is no material which has two first edges parallel to each other and two second edges parallel to each other and perpendicular to said first edges, said first edges and second edges defining the second portion ; and
folding said sheet along two sets of first fold lines (30,32) respectively along and on both sides of said first edges and which continues to the edge of the first portion and then folding the sheet in a second direction respectively along and on both sides of said second edges and which continues to the edge of the first portion to create two sets of second fold lines which are perpendicular to the first fold lines characterised in that said two first edges and said two second edges of said second portion are continuous and causing the second portion to collapse causing the first portion to come into an abutting relationship along the first and second fold lines.
Material, welches eine erste Blattfläche bildet (12, 14, 16, 18, 22, 24, 26, 28);
eine zweite Blattfläche (20; 120) ohne Material, wobei diese zweite Blattfläche zwei erste, parallel zueinander verlaufende Ränder und zwei zweite, ebenfalls parallel zueinander verlaufende, zu den genannten ersten Rändern senkrecht stehende Ränder aufweist, und wobei die genannten ersten und zweiten Ränder die zweite Blattfläche definieren; und
wobei das Blatt zwei erste Faltlinien (30, 32) aufweist, die jeweils längs der genannten ersten Ränder auf deren beiden Seiten verlaufen und sich bis zum Rand der ersten Blattfläche fortsetzen, und zwei zweite Faltlinien (34, 36), die jeweils längs der genannten zweiten Ränder auf deren beiden Seiten verlaufen und sich bis zum Rand der ersten Blattfläche fortsetzen,
dadurch gekennzeichnet, dass die genannten zwei ersten Ränder und die genannten zwei zweiten Ränder der genannten zweiten Blattfläche kontinuierlich sind.
Herstellen eines Blattes mit einer ersten Blattfläche (12, 14, 16, 18, 22, 24, 26, 28), die aus Blattmaterial besteht;
Entfernen eines Teiles des Blattes unter Erzeugung einer zweiten Blattfläche (20; 120) ohne Blattmaterial, welche zwei erste, parallel zueinander verlaufende Ränder und zwei zweite, ebenfalls parallel zueinander verlaufende, zu den genannten ersten Rändern senkrecht stehende Ränder aufweist, und wobei die genannten ersten und zweiten Ränder die zweite Blattfläche definieren; und
Falten des genannten Blattes entlang zweier Gruppen erster Faltlinien (30, 32) jeweils entlang und auf beiden Seiten der genannten ersten Ränder, und wobei das Falten bis zum Rand der ersten Blattfläche fortgesetzt wird, und anschliessendes Falten des Blattes in einer zweiten Richtung jeweils entlang und auf beiden Seiten der genannten zweiten Ränder, und wobei das Falten bis zum Rand der ersten Blattfläche fortgesetzt wird, um zwei Gruppen zweiter Faltlinien zu bilden, die senkrecht zu den ersten Faltlinien verlaufen,
dadurch gekennzeichnet, dass die genannten zwei ersten Ränder und die genannten zwei zweiten Ränder der genannten zweiten Blattfläche kontinuierlich verlaufen und die zweite Blattfläche verschwinden lassen, wodurch in der ersten Blattfläche, entlang der ersten und zweiten Faltlinien, Anstösse erzeugt werden.
de la matière formant une première partie de la feuille (12, 14, 16, 18, 22, 24, 26, 28);
une deuxième partie (20; 120) de la feuille sans matière, ladite deuxième partie comprenant deux premières arêtes parallèles entre elles, et deux deuxièmes arêtes parallèles entre elles et perpendiculaires aux premières arêtes, lesdites premières arêtes et lesdites deuxièmes arêtes définissant la deuxième partie de la feuille ; et
dans laquelle la feuille comprend deux premières lignes de pliage (30, 32) s'étendant le long desdites premières arêtes et des deux côtés de celles-ci et allant jusqu'à l'arête de la première partie de la feuille, et deux deuxièmes lignes de pliage (34, 36) s'étendant le long desdites deuxièmes arêtes et des deux côtés de celles-ci et allant jusqu'à l'arête de la première partie de la feuille,
caractérisée en ce que lesdites deux premières arêtes et lesdites deux deuxièmes arêtes de ladite deuxième partie de la feuille sont continues.
la préparation de la feuille pour former une première partie (12, 14, 16, 18, 22, 24, 26, 28) de la feuille contenant de la matière ;
l'enlèvement d'une portion de la feuille pour former une deuxième partie (20 ; 120) de la feuille sans matière et qui comprend deux premières arêtes parallèles entre elles, et deux deuxièmes arêtes parallèles entre elles et perpendiculaires aux premières arêtes, lesdites premières arêtes et lesdites deuxièmes arêtes définissant la deuxième partie de la feuille ; et
le pliage de ladite feuille le long de deux jeux de premières lignes de pliage (30 ; 32) s'étendant le long desdites premières arêtes et des deux côtés de celles-ci et allant jusqu'à l'arête de la première partie de la feuille, et deux deuxièmes lignes de pliage (34, 36) s'étendant le long desdites deuxièmes arêtes et des deux côtés de celles-ci et allant jusqu'à l'arête de la première partie de la feuille, pour créer deux jeux de secondes lignes de pliage qui sont perpendiculaires aux premières lignes de pliage,
caractérisé en ce que lesdites deux premières arêtes et lesdites deux deuxièmes arêtes de ladite deuxième partie de la feuille sont continues et provoquent une disparition de la deuxième partie ce qui amène la première partie de la feuille à former une configuration d'aboutement le long des premières et deuxièmes lignes de pliage.