Note: Descriptions are shown in the official language in which they were submitted.
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ARTICLE AND METHOD OF MAKING
Cross-Reference to Related Applications
This application is a continuation-in-part of
U.S. Serial Number 09/796,942 filed March 1, 2001
entitled "Reinforced Article and Method of Making"
which is a continuation-in-part of U.S. Serial
Number 09/749,318, filed December 27, 2000 entitled
"Reinforced Article and Method of Making" the
disclosures of which are incorporated herein by
reference
Field of the Invention
The present invention relates to a substrate
which is formed into a three dimensional article.
BACKGROUND OF THE INVENTION
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.
This is because composite structures start off
typically with a woven flat substrate of fibers.
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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 juizction 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 inexpensive, for example
a packaging crate, the added expense may outweigh
the benefits of it being reinforced.
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.
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.
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
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.
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It is a further object as part of this to
simplify the manufacture of such, structures and
reduce the labor requirement.
These and other objects and advantages will be
apparent from the present invention. 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 DRAV~1INGS
Thus by the present invention its objects and
advantages will be realised 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 ~A-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.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIME~dT
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
may be made of sheet metal, plastic, cloth,
paper, cardboard or any other material suitable for
the purpose.
10 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.
Once the sheet 10 is constructed, it can then
be formed into the desired shape.
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.
The foregoing advantageously avoids the need
for cutting or darting, thereby reducing the amount
of labor required and the ultimate cost of the
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article. The present invention allows for the
increased automation of the fabrication and
therefore broadens the applications for which such
structures may be used.
5 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.
Thus by the present invention its objects and
advantages are realized and although preferred
embodiments have been disclosed and described in
detail herein, its scope should not be limited
thereby rather its scope should be determined by
that of the appended claims.
