U.S. patent application number 11/746375 was filed with the patent office on 2007-11-15 for precision folded vehicular structural and aesthetic component and sheet therefor.
This patent application is currently assigned to Industrial Origami, Inc.. Invention is credited to Max W. Durney.
Application Number | 20070262128 11/746375 |
Document ID | / |
Family ID | 38694677 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070262128 |
Kind Code |
A1 |
Durney; Max W. |
November 15, 2007 |
Precision folded vehicular structural and aesthetic component and
sheet therefor
Abstract
A sheet material is provided for forming a precision folded
structural and aesthetic component of a contoured three-dimension.
The sheet material may include a forward-panel bend line separating
a forward panel and a fold panel, the forward-panel bend line may
be curved to impart contour on at least the fold panel upon bending
of the sheet material about the forward-panel bend line, and a fold
line extending along the fold panel, the fold line may be
substantially straight to impart the contour of the fold panel to
the upper panel upon bending of the sheet material about the fold
line. The sheet material may include an upper panel, a first
upper-panel-flange bend line separating a forward upper flange from
a warp zone of the upper panel, the first upper-panel-flange bend
line may be curved to impart a first contour on one or more of the
first upper flange and the warp zone, a second upper-panel-flange
bend line separating a second upper flange from the warp zone, the
second upper-panel-flange bend line may be curved to impart a
second contour on one or more of the second upper flange and the
warp zone, and first and second curved warp zone bend lines
separating the warp zone from a remainder of the upper panel, the
first and second curved warp zone bend lines configured to localize
bending along the bend line and substantially isolate warpage
within the warp zone. A method of forming the same is also
disclosed.
Inventors: |
Durney; Max W.; (San
Francisco, CA) |
Correspondence
Address: |
MORGAN, LEWIS & BOCKIUS, LLP
ONE MARKET SPEAR STREET TOWER
SAN FRANCISCO
CA
94105
US
|
Assignee: |
Industrial Origami, Inc.
San Francisco
CA
|
Family ID: |
38694677 |
Appl. No.: |
11/746375 |
Filed: |
May 9, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60799217 |
May 9, 2006 |
|
|
|
60799215 |
May 9, 2006 |
|
|
|
Current U.S.
Class: |
229/132 |
Current CPC
Class: |
B62D 25/14 20130101;
B21D 11/20 20130101 |
Class at
Publication: |
229/132 |
International
Class: |
B65D 5/00 20060101
B65D005/00 |
Claims
1. A sheet material for forming a contoured three-dimensional
structure, the sheet material comprising: a forward-panel bend line
separating a forward panel and a fold panel, the forward-panel bend
line being curved to impart a pre-selected contour on at least the
fold panel upon bending of the sheet material about the
forward-panel bend line; and a fold line extending along the fold
panel, the fold line being shaped to impart the pre-selected
contour of the fold panel to the upper panel upon bending of the
sheet material about the fold line.
2. A sheet material according to claim 1, wherein the fold line is
substantially straight.
3. A sheet material according to claim 1, further comprising a
supplemental fold line separating the fold panel from a
supplemental fold panel, the supplemental fold line being
substantially straight to impart the contour of the first fold
panel to the second fold panel upon bending of the sheet material
about the supplemental fold line, wherein the contour of the
forward-panel bend line is imparted to the upper panel via the fold
panel and the second fold panel upon bending the fold line and the
supplemental fold line.
4. A sheet material according to claim 1, further comprising a
forward-panel-flange bend line separating the forward panel and a
forward-panel flange, the forward-panel-flange bend line being
curved to impart contour on one or more of the forward panel and
the forward-panel flange upon bending of the sheet material about
the forward-panel-flange bend line.
5. A sheet material according to claim 3, wherein the
forward-flange bend line is S-shaped thereby imparting both concave
and convex contour on the forward panel.
6. A sheet material according to claim 1, wherein the forward-panel
bend line is downwardly concave to impart an upwardly convex
contour on at least a portion of the upper panel.
7. A sheet material according to claim 1, wherein a first distance
between the forward-panel bend line to the first fold panel is
different than a second distance between the first fold line and
the second fold line whereby a forward edge of the upper panel
defined by the second fold line is spaced from the forward
panel.
8. A sheet material according to claim 7, wherein the first
distance is shorter than the second distance thereby recessing the
forward panel beyond the forward edge.
9. A sheet material according to claim 1, further comprising a
first upper-panel-flange bend line separating a forward upper
flange from a warp zone of the upper panel, the first
upper-panel-flange bend line being curved to impart a first contour
on one or more of the first upper flange and the warp zone; a
second upper-panel-flange bend line separating a second upper
flange from the warp zone, the second upper-panel-flange bend line
being curved to impart a second contour on one or more of the
second upper flange and the warp zone; and first and second curved
warp zone bend lines separating the warp zone from a remainder of
the upper panel, the first and second curved warp zone bend lines
configured to localize bending along the bend line and
substantially isolate warpage within the warp zone.
10. A sheet material according to claim 9, wherein both the first
and second warp zone bend lines terminate at an intersection point;
and both the first and second warp zone bend lines have compound
curvatures, in which portions of the bend lines adjacent the
intersection point have smaller radii of curvature thereby
prohibiting creasing within the warp zone adjacent the intersection
point.
11. A sheet material according to claim 1, wherein at least one of
said bend lines and said fold lines is formed with a plurality of
slits through the sheet of material, adjacent slits are positioned
alternating on either said of said at least one of said bend lines
of fold lines.
12. A sheet material according to claim 1, wherein at least one of
said bend lines and said fold lines is formed with a plurality of
displacements, wherein adjacent displacements are positioned
alternating on either side of said at least one of said bend lines
or fold lines.
13. A three-dimensional structure comprising the sheet material
according to claim 1.
14. A method of forming a three-dimensional structure comprising:
providing the sheet material according to claim 1; bending the
sheet of material along the forward-panel bend line; and bending
the sheet of material along the fold line.
15. A sheet material for forming a contoured three-dimensional
structure, the sheet material comprising: an upper panel; a first
upper-panel-flange bend line separating a forward upper flange from
a warp zone of the upper panel, the first upper-panel-flange bend
line being curved to impart a first contour on one or more of the
first upper flange and the warp zone; a second upper-panel-flange
bend line separating a second upper flange from the warp zone, the
second upper-panel-flange bend line being curved to impart a second
contour on one or more of the second upper flange and the warp
zone; and first and second curved warp zone bend lines separating
the warp zone from a remainder of the upper panel, the first and
second curved warp zone bend lines configured to localize bending
along the bend line and substantially isolate warpage within the
warp zone.
16. A sheet material according to claim 15, wherein the first
upper-panel-flange bend line is downwardly concave in a first
direction and the second upper-panel-flange bend line is downwardly
concave in a second direction that is not parallel to the first,
wherein the warp zone elastically deforms to accommodate the
different contours of the first and second upper-panel-flange bend
lines.
17. A sheet material according to claim 15, wherein both the first
and second bend lines terminate at an intersection point; and both
the first and second bend lines have compound curvatures, in which
portions of the bend lines adjacent the intersection point have
smaller radii of curvature thereby prohibiting creasing within the
warp zone adjacent the intersection point.
18. A sheet material according to claim 15, wherein at least one of
said bend lines and said fold lines is formed with a plurality of
slits through the sheet of material.
19. A sheet material according to claim 18, wherein adjacent slits
are positioned alternating on either said of said at least one of
said bend lines of fold lines.
20. A sheet material according to claim 15, wherein at least one of
said bend lines and said fold lines is formed with a plurality of
displacements, wherein adjacent displacements are positioned
alternating on either side of said at least one of said bend lines
or fold lines.
21. A three-dimensional structure comprising the sheet material
according to claim 15.
22. A method of forming a dashboard comprising: providing the sheet
material according to claim 15; bending the sheet of material along
the first and second upper-panel bend lines, wherein the first and
second warp zone bend lines allow warpage within the warp to
accommodate the varying contour imparted by the first and second
dashboard-flange bend lines.
23. A sheet material for forming a contoured three-dimensional
dashboard, the sheet material comprising: a dash-panel-flange bend
line separating a dash panel and a dash-panel flange, the
dash-panel-flange bend line being curved to impart contour on one
or more of the dash panel and the dash-panel flange upon bending of
the sheet material about the dash-panel-flange bend line; a
dash-panel bend line separating the dash panel and a first fold
panel, the dash-panel bend line being curved to impart contour on
at least the first fold panel upon bending of the sheet material
about the dash-panel bend line; a first fold line separating the
first fold panel from a second fold panel, the first fold line
being substantially straight to impart the contour of the first
fold panel upon the second fold panel upon bending of the sheet
material about the first fold line; a second fold line separating
the second fold panel from a dashboard panel, the second fold line
being substantially straight to impart the contour of the second
fold panel to the dashboard panel upon bending of the sheet
material about the second fold line; a first dashboard-flange bend
line separating a forward dashboard flange from a warp zone of the
dashboard panel, the first dashboard-flange bend line being curved
to impart a first contour on one or more of the first dashboard
flange and the warp zone; a second dashboard-flange bend line
separating a second dashboard flange from the warp zone, the second
dashboard-flange bend line being curved to impart a second contour
on one or more of the second dashboard flange and the warp zone;
and first and second curved warp zone bend lines separating the
warp zone from a remainder of the dashboard panel, the first and
second curved warp zone bend lines configured to localize bending
along the bend line and substantially isolate warpage within the
warp zone.
24. A sheet material according to claim 23, wherein the
dash-panel-flange bend line is S-shaped thereby imparting both
concave and convex contour on dash panel.
25. A sheet material according to claim 23, wherein the dash-panel
bend line is downwardly concave to impart an upwardly convex
contour on at least a portion of the dashboard panel.
26. A sheet material according to claim 23, wherein a first
distance between the dash-panel bend line to the first fold line is
different than a second distance between the first fold line and
the second fold line whereby a forward edge of the dashboard panel
defined by the second fold line is spaced from the dash panel.
27. A sheet material according to claim 26, wherein the first
distance is shorter than the second distance thereby recessing the
dash panel beyond the forward edge.
28. A sheet material according to claim 23, wherein both the first
and second bend lines terminate at an intersection point; and both
the first and second bend lines have compound curvatures, in which
portions of the bend lines adjacent the intersection point have
smaller radii of curvature thereby prohibiting creasing within the
warp zone adjacent the intersection point.
29. A dashboard comprising the sheet material according to claim
23.
30. A method of forming a dashboard comprising: providing the sheet
material according to claim 23; bending the sheet of material along
the dash-panel-flange bend line; bending the sheet of material
along the dash-panel bend line; bending the sheet of material along
the first and second fold lines; and bending the sheet of material
along the first and second dashboard-flange bend lines, wherein the
first and second warp zone bend lines allow warpage within the warp
to accommodate the varying contour imparted by the first and second
dashboard-flange bend lines.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 60/799,215 filed on May 9, 2006, the entire
contents of which is incorporated herein by this reference.
[0002] This application also claims also priority to U.S. Patent
Application No. 60/799,217 filed on May 9, 2006, the entire
contents of which is also incorporated herein by this
reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates, in general, to designing and
precision bending of material sheets to form contoured
three-dimensional structures having both structural and aesthetic
components, and to methods for their use, and more particularly, to
bent and warped structures and methods of forming the same.
[0005] 2. Description of Related Art
[0006] Various methods are known for forming three-dimensional
structures from two-dimensional sheet materials. For example, press
brakes, stamping equipment and other cold-forming metal equipment
have long been used to form sheet metal into three-dimensional
objects.
[0007] More recently, the use of computer numerically controlled
(CNC) devices have been used to treat sheet materials to facilitate
bending about predetermined bend lines. For example, laser cutting,
water jet cutting, stamping, punching, molding, casting, stereo
lithography, roll forming, machining, chemical-milling,
photo-etching and the like have been used to form slits or grooves
in sheet materials along predetermined bend lines to facilitate and
control bending along the bend lines.
[0008] Exemplar of the prior art is U.S. Pat. No. 6,640,605 to
Gitlin et al. which discloses a method of bending sheet material to
form three-dimensional structures, including housings and casings,
interior and exterior structures, and various covers and
supports.
[0009] Such prior methods of bending sheet materials about
predetermined bend lines are generally successful in forming
three-dimensional objects but the three-dimensional shapes that may
be produced by such methods are limited. For example, such methods
are generally employed to form three dimensional objects having
planar regions extending between adjacent bend lines, or curved
regions extending between adjacent bend lines which generally
follow the curvature of the adjacent bend lines. To date, however,
laying out predetermined bend lines on sheet materials is generally
not conducive to forming complex three-dimensional structures which
have complexly-curved contoured areas bounded between adjacent bend
lines.
[0010] For instance, early vehicles generally included a framework
providing structural integrity, to which body panels and
non-structural components were attached. Such general configuration
allowed designers and manufactures to provide varying ornamentation
to the attached components to provide an overall pleasing aesthetic
appearance to the vehicle.
[0011] With the more recent advent of unibody construction,
vehicles are often provided with a one-piece frame and body
structure which includes both structural and non-structural
aesthetic elements. Nonetheless, subassemblies attached to or
within a unibody frame continued to include one or more structural
members providing structural integrity to the frame, and one or
more ornamental panels attached to the structural member(s).
[0012] For example, instrument panel structures ("I/P structures")
are structures that provide support for the steering column, the
instrument cluster and other dashboard components, as well as
provide a structural element to the vehicle and the mounting points
for airbags and the like. Such I/P generally includes one or more
skeletal or internal structural members that are attached to the
unibody frame, generally adjacent the A-pillar, and may provide
additional structural integrity to the frame. External ornamental
members, for example, dashboard panels and the like, are attached
to the internal structural members and provide the vehicle interior
with a finished and pleasing appearance.
[0013] More recently, I/P structures having more complex geometries
have been formed with hydroforming and other stamping processes.
Nonetheless, such I/P structures are still generally intended as
skeletal or internal structural members to which dashboard panels
are attached. As such, the number of parts required to finish a
dashboard of an automobile are relatively high, and the labor
required to assemble the various components is not
insignificant
[0014] What is needed is an improved method of forming contoured
three-dimensional structures from sheet materials which overcomes
the above and other disadvantages of known structures and
methods.
BRIEF SUMMARY OF THE INVENTION
[0015] In summary, one aspect of the present invention is directed
to a sheet material is provided for forming a contoured
three-dimensional structure. The sheet material includes a
forward-panel bend line separating a forward panel and a fold
panel, which forward-panel bend line is curved to impart contour on
at least the fold panel upon bending of the sheet material about
the forward-panel bend line, and a fold line extending along the
fold panel. The fold line may be substantially straight to impart
the contour of the fold panel to the upper panel upon bending of
the sheet material about the fold line.
[0016] The sheet material may include a supplemental fold line
separating the fold panel from a supplemental fold panel. The
supplemental fold line may be substantially straight to impart the
contour of the first fold panel to the second fold panel upon
bending of the sheet material about the supplemental fold line,
wherein the contour of the forward-panel bend line may be imparted
to the upper panel via the fold panel and the second fold panel
upon bending the fold line and the supplemental fold line.
[0017] The sheet material may include a forward-panel-flange bend
line separating the forward panel and a forward-panel flange. The
forward-panel-flange bend line may be curved to impart contour on
one or more of the forward panel and the forward-panel flange upon
bending of the sheet material about the forward-panel-flange bend
line. The forward-flange bend line may be S-shaped thereby
imparting both concave and convex contours on the forward
panel.
[0018] The forward-panel bend line may be downwardly concave to
impart an upwardly convex contour on at least a portion of the
upper panel. A first distance between the forward-panel bend line
and the first fold line may be different than a second distance
between the first fold line and the second fold line whereby a
forward edge of the upper panel defined by the second fold line may
be spaced from the forward panel. The first distance may be shorter
than the second distance thereby recessing the forward panel
rearward from the forward edge.
[0019] The sheet material may include a first upper-panel-flange
bend line separating a forward upper flange from a warp zone of the
upper panel. The first upper-panel-flange bend line may be curved
to impart a first contour on one or more of the first upper flange
and the warp zone. A second upper-panel-flange bend line may
separate a second upper flange from the warp zone. The second
upper-panel-flange bend line may be curved to impart a second
contour on one or more of the second upper flange and the warp
zone. First and second curved warp zone bend lines may separate the
warp zone from a remainder of the upper panel. The first and second
curved warp zone bend lines may be configured to localize bending
along the bend line and substantially isolate warpage within the
warp zone. Both the first and second warp zone bend lines may
terminate at an intersection point. Both the first and second warp
zone bend lines may have compound curvatures. Portions of the bend
lines adjacent the intersection point may have smaller radii of
curvature thereby prohibiting creasing within the warp zone
adjacent the intersection point.
[0020] In one embodiment, at least one of the bend lines and the
fold lines may be formed with a plurality of slits through the
sheet of material. Adjacent slits may be positioned alternating on
either side of the at least one of the bend lines or fold lines. At
least one of the bend lines and the fold lines may be formed with a
plurality of displacements. Adjacent displacements may be
positioned alternating on either side of the at least one of the
bend lines or fold lines.
[0021] Another aspect of the present invention is directed to
three-dimensional structures including the sheet material described
above. A further aspect of the present invention is directed to a
method of forming a three-dimensional structure including the steps
of providing the sheet material described above, bending the sheet
of material along the forward-panel bend line, and bending the
sheet of material along the fold line.
[0022] Still another aspect of the present invention is directed to
a sheet material for forming a contoured three-dimensional
structure including an upper panel, a first upper-panel-flange bend
line separating a forward upper flange from a warp zone of the
upper panel, the first upper-panel-flange bend line being curved to
impart a first contour on one or more of the first upper flange and
the warp zone, a second upper-panel-flange bend line separating a
second upper flange from the warp zone, the second
upper-panel-flange bend line being curved to impart a second
contour on one or more of the second upper flange and the warp
zone, and first and second curved warp zone bend lines separating
the warp zone from a remainder of the upper panel. The first and
second curved warp zone bend lines are configured to localize
bending along the bend line and substantially isolate warpage
within the warp zone.
[0023] The first upper-panel-flange bend line may be concave in a
first direction and the second upper-panel-flange bend line may be
concave in a second direction that is not parallel to the first,
wherein the warp zone elastically deforms to accommodate the
different contours of the first and second upper-panel-flange bend
lines.
[0024] In one embodiment, both the first and second bend lines
terminate at an intersection point. Both the first and second bend
lines may have compound curvatures. Portions of the bend lines
adjacent the intersection point may have smaller radii of curvature
thereby prohibiting creasing within the warp zone adjacent the
intersection point.
[0025] In one embodiment, at least one of the bend lines and the
fold lines may be formed with a plurality of slits through the
sheet of material. Adjacent slits may be positioned alternating on
either of the at least one of the bend lines of fold lines. At
least one of the bend lines and the fold lines may be formed with a
plurality of displacements. Adjacent displacements may be
positioned alternating on either side of the at least one of the
bend lines or fold lines.
[0026] Another aspect of the present invention is directed to
three-dimensional structures including the sheet material described
above. A further aspect of the present invention is directed to a
method of forming a three-dimensional structure including the steps
of providing the sheet material described above, and bending the
sheet of material along the first and second upper-panel bend
lines. The first and second warp zone bend lines may allow warpage
within the warp to accommodate the varying contour imparted by the
first and second dashboard-flange bend lines.
[0027] Still a further aspect of the present invention is directed
to a sheet material for forming a contoured three-dimensional
dashboard, the dashboard, and methods of forming the dashboard. The
sheet material may include a dash-panel-flange bend line separating
a dash panel and a dash-panel flange, the dash-panel-flange bend
line may be curved to impart contour on one or more of the dash
panel and the dash-panel flange upon bending of the sheet material
about the dash-panel-flange bend line, a dash-panel bend line
separating the dash panel and a first fold panel, the dash-panel
bend line may be curved to impart contour on at least the first
fold panel upon bending of the sheet material about the dash-panel
bend line, a first fold line separating the first fold panel from a
second fold panel, the first fold line may be substantially
straight to impart the contour of the first fold panel upon the
second fold panel upon bending of the sheet material about the
first fold line, a second fold line separating the second fold
panel from a dashboard panel, the second fold line may be
substantially straight to impart the contour of the second fold
panel to the dashboard panel upon bending of the sheet material
about the second fold line, a first dashboard-flange bend line
separating a forward dashboard flange from a warp zone of the
dashboard panel, the first dashboard-flange bend line may be curved
to impart a first contour on one or more of the first dashboard
flange and the warp zone, a second dashboard-flange bend line
separating a second dashboard flange from the warp zone, the second
dashboard-flange bend line may be curved to impart a second contour
on one or more of the second dashboard flange and the warp zone,
and first and second curved warp zone bend lines separating the
warp zone from a remainder of the dashboard panel, the first and
second curved warp zone bend lines configured to localize bending
along the bend line and substantially isolate warpage within the
warp zone.
[0028] The dash-panel-flange bend line may be S-shaped thereby
imparting both concave and convex contours on the dash panel. The
dash-panel bend line may be downwardly concave to impart an
upwardly convex contour on at least a portion of the dashboard
panel. A first distance between the dash-panel bend line and the
first fold line may be different to a second distance between the
first fold line and the second fold line whereby a forward edge of
the dashboard panel defined by the second fold line may be spaced
from the dash panel. The first distance may be shorter than the
second distance thereby recessing the dash panel beyond the forward
edge.
[0029] In one embodiment, both the first and second bend lines
terminate at an intersection point. Both the first and second bend
lines may have compound curvatures. Portions of the bend lines
adjacent the intersection point may have smaller radii of curvature
thereby prohibiting creasing within the warp zone adjacent the
intersection point.
[0030] In another embodiment, the sheet material includes a dash
panel delineated by a plurality of curved bend lines, each bend
line being shaped and configured to impart a pre-selected contour
on the dash panel upon bending of the sheet material about the
curved bend lines, and a cross beam delineated by a plurality of
straight bend lines being shaped and configured to form an upper
beam web, and an upper beam flange, and a lower beam flange,
wherein the cross-sectional shape of the cross beam is set by one
or more caps provided on the sheet material.
[0031] The method of forming a dashboard may include providing the
sheet material described above, bending the sheet of material along
the dash-panel-flange bend line, bending the sheet of material
along the dash-panel bend line, bending the sheet of material along
the first and second fold lines, and bending the sheet of material
along the first and second dashboard-flange bend lines, wherein the
first and second warp zone bend lines allow warpage within the warp
to accommodate the varying contour imparted by the first and second
dashboard-flange bend lines.
[0032] Yet another aspect of the present invention is directed to a
sheet material for forming a precision folded vehicle member having
structural and aesthetic components. The sheet material may include
a dash panel delineated by a plurality of curved bend lines, each
bend line being shaped and configured to impart a pre-selected
contour on the dash panel upon bending of the sheet material about
the curved bend lines, and a cross beam delineated by a plurality
of straight bend lines being shaped and configured to form an upper
beam web, an upper beam flange, and a lower beam flange, wherein
the cross-sectional shape of the cross beam is set by one or more
caps provided on the sheet material.
[0033] The precision folded structural and aesthetic component
having contoured three-dimensional structure, the sheet therefor,
and the methods of forming same of the present invention have other
features and advantages which will be apparent from or are set
forth in more detail in the accompanying drawings, which are
incorporated herein, and the following Detailed Description of the
Invention, which together serve to explain the principles of the
present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The present invention will become more fully understood from
the detailed description given hereinbelow and the accompanying
drawings which are given by way of illustration only, and thus are
not limitative of the present invention, and wherein:
[0035] FIG. 1 is a plan view of an exemplary two-dimensional sheet
material configured for bending into a contoured three-dimensional
structure in accordance with the present invention;
[0036] FIG. 2 is an enlarged partial view of the two-dimensional
sheet material of FIG. 1, taken along detail 2-2 of FIG. 1;
[0037] FIG. 3 is an upper front perspective view of the
two-dimensional sheet of material of FIG. 1 after bending in
accordance with the present invention;
[0038] FIG. 4 is another upper front perspective view of FIG. 3
after bending in accordance with the present invention;
[0039] FIG. 5 is a lower perspective view of FIG. 3;
[0040] FIG. 6 is a plan view of another exemplary two-dimensional
sheet material configured for bending into a contoured
three-dimensional structure in accordance with the present
invention;
[0041] FIG. 7A is a plan view of a two-dimensional sheet material
configured for precision folding to form of another exemplary
embodiment of a vehicle structure in accordance with the present
invention;
[0042] FIG. 7B is an enlarged detail of the sheet material of FIG.
7A taken within detail 7B-7B of FIG. 7A;
[0043] FIGS. 8A-8E is a series of perspective views illustrating
the folding the sheet material along the bend lines of FIG. 7 in
accordance with the present invention;
[0044] FIGS. 9A-9E are enlarged perspective views of FIGS. 8A-8E,
respectively;
[0045] FIG. 10 is a further enlarged perspective view of the
vehicle structure of FIGS. 8E and 9E, as viewed from the front
right of the vehicle structure;
[0046] FIG. 11 is a further enlarged perspective view of the
vehicle structure of FIGS. 8E and 9E, as viewed from the rear right
of the vehicle structure;
[0047] FIG. 12 is a further enlarged perspective view of the
vehicle structure of FIGS. 8E and 9E, as viewed from the front left
of the vehicle structure;
[0048] FIG. 13 is yet a further enlarged perspective view of the
vehicle structure of FIG. 12;
[0049] FIG. 14 is a further enlarged perspective view of the
vehicle structure of FIGS. 8E and 9E, as viewed from the bottom of
the vehicle structure; and
[0050] FIG. 15 is partial perspective view of the vehicle structure
of FIGS. 8E and 9E as mounted on a vehicle.
DETAILED DESCRIPTION OF THE INVENTION
[0051] Reference will now be made in detail to various embodiments
of the present invention(s), examples of which are illustrated in
the accompanying drawings and described below. While the
invention(s) will be described in conjunction with exemplary
embodiments, it will be understood that present description is not
intended to limit the invention(s) to those exemplary embodiments.
On the contrary, the invention(s) is/are intended to cover not only
the exemplary embodiments, but also various alternatives,
modifications, equivalents and other embodiments, which may be
included within the spirit and scope of the invention as defined by
the appended claims.
[0052] Generally, the present invention provides for forming
contoured three-dimensional structures from two-dimensional sheet
materials. In particular, flat two-dimensional sheet materials are
configured for bending along predetermined bend lines to form
three-dimensional structures having complexly curved regions which
may enhance both structural features and aesthetic features of the
structure.
[0053] For the purposes of the present invention, "two-dimensional
sheet materials" refers to sheet materials which are globally flat
such that they may be stacked upon one another, but which may have
various locally stamped, punched, and/or other features which may
be cosmetic or structural.
[0054] Generally, the sheet materials include one or more bend
lines or fold lines, which are configured to facilitate bending
along a predetermined path, such that a contour corresponding to a
curvature of the bend line is imparted upon a portion of the sheet
material upon bending the sheet material along the bend line. The
contour may be imparted upon an adjacent portion of the sheet
material, or transferred to a remote portion of the sheet material,
as will become evident below. Alternatively, or in addition,
contours corresponding to the curvatures of multiple bend lines are
imparted upon a warp zone delineated by intersecting bend or fold
lines, in which warpage is confined and accommodates the various
contours. Preferably, the warpage is confined within the warp zone
and creasing is prohibited. The sheet materials of the present
invention also include straight bend lines which facilitate the
formation of structural elements, and in the illustrated
embodiment, a hollow cross beam.
[0055] For the purposes of the present invention, a "bend line" is
a predetermined path about which the sheet material is bent
resulting in plastic deformation along the bend line thereby
forming a three-dimensional shape. A "fold line" is a bend line in
which portions of the sheet material on either side of the bend
line are bent to substantially lay over one another. One will
appreciate that the sheet material may also experience some degree
of elastic deformation along the bend line in addition to plastic
deformation.
[0056] One will appreciate that various means may be used to form
the bend lines of the present invention to facilitate bending along
the bend lines. For example, the precision bending technology of
Industrial Origami may be used to design and/or provide the bend
lines of the present invention, which technology is described in
U.S. Pat. Nos. 6,481,259 for Method For Precision Bending Of A
Sheet Of Material And Slit Sheet Therefor and 6,877,349 for Method
For Precision Bending Of Sheet Of Materials, Slit Sheets
Fabrication Process, as well as in the following U.S. Patent
Application Publication Nos. 2003/0037586 Method For Precision
Bending Of Sheet Of Materials, Slit Sheets Fabrication Process,
2004/0134250 for Techniques For Designing And Manufacturing
Precision-Folded, High Strength, Fatigue-Resistant Structures And
Sheet Therefor, 2004/0206152 for Sheet Material With Bend
Controlling Displacements And Method For Forming The Same,
2005/0005670 for Method Of Designing Fold Lines In Sheet Material,
2005/0061049 for Process Of Forming Bend-Controlling Structures In
A Sheet Of Material, The Resulting Sheet And Die Sets Therefor,
2005/0064138 for Method For Precision Bending Of Sheet Of
Materials, Slit Sheets Fabrication Process, 2005/0097937 for Sheet
Material With Bend Controlling Grooves Defining A Continuous Web
Across A Bend Line And Method For Forming The Same, 2005/0126110
for Techniques For Designing And Manufacturing Precision-Folded,
High Strength, Fatigue-Resistant Structures And Sheet Therefor,
2005/0257589 for Sheet Material With Bend Controlling Displacements
And Method For Forming The Same, 2006/0021413 for
Fatigue-Resistance Sheet Slitting Method And Resulting Sheet,
2006/0053857 for Tool System For Bending Sheet Materials And Method
Of Using Same, and 2006/0075798 for Sheet Material With Bend
Controlling Displacements And Method For Forming The Same, the
entire content of which patents and applications is incorporated
herein by this reference.
[0057] Turning now to the drawings, wherein like components are
designated by like reference numerals throughout the various
figures, attention is directed to FIG. 1 which illustrates a flat
sheet material 30 that is configured to form a three-dimensional
structure. In the illustrated embodiment, the sheet material is
configured to form a three-dimensional structure 32 in the form of
a dashboard assembly shown in FIG. 3. In the illustrated
embodiment, the dashboard is configured and dimensioned for use in
an automobile. However, the dashboard may be configured for use
with other types of vehicles, industrial controls or other machine
assemblies. One will appreciate, however, that the sheet material
may be configured to form a multitude of three-dimensional
structures including, but not limited to, mechanical structural
elements, vehicular body panels, other vehicular structure and the
like. Suitable materials for the sheet material include, but are
not limited to thin and thick gauge sheet metals such as sheet
steel, sheet stainless, sheet aluminum and other metals and alloys,
plastics, and other ductile materials. One will also appreciate
that the sheet materials may be unpainted, pre-painted, and/or
laminated with coatings and/or other structural and/or
non-structural materials such as films, foams, meshes, and/or other
suitable materials.
[0058] In the illustrated embodiment, sheet material 30 includes a
dash-panel-flange bend line 35 which separates a forward panel in
the form of an instrument or dash panel 37 and a dash-panel flange
39, as shown in FIG. 1. The dash-panel-flange bend line 35 is
generally configured to localize elastic deformation during bending
along a predetermined path, as are the below mentioned bend lines
and fold lines. For example, the dash-panel-flange bend line 35 may
be in the form of events 40 disposed on either side of bend line 35
in order to facilitate and precisely control bending along the bend
line 35, which events 40 are more clearly shown in FIG. 2. Events
40 may be in the form of slits, grooves, displacements and other
suitable means described in the above-mentioned patents and
applications of Industrial Origami, the entire content of which is
incorporated herein by this reference.
[0059] Although the bend lines will be discussed in terms of
"dash-panel-flange bend line" and other specific terms set forth
below, and although the regions of the sheet material adjacent the
bend lines will be discussed in terms of "dash panel", "dash-panel
flange", and other specific terms set forth below, these terms are
generally relative in that they are used to describe and set forth
their general orientation to one another and their respective bend
line. As such, the terms should not be considered specifically
limiting and instead should be considered as setting forth spatial
orientations of the bend lines and relevant portions of the sheet
material.
[0060] In some aspects, the dash-panel flange is similar to
conventional flanges in that it may provide structural integrity to
the dash panel, namely by stiffening what may otherwise be a fairly
flexible sheet of material. In accordance with the present
invention, however, the dash-panel-flange bend line is configured
to impart a contour to one or both of the dash panel and the dash
panel flange. The dash-panel-flange bend line may have an
"S"-shaped curvature which will impart a corresponding contour on
both the dash panel and the dash-panel flange upon bending of the
sheet material about the dash-panel-flange bend line. One will
appreciate that the dash-panel-flange bend line may have other
curved shapes including, but not limited to, convex, concave, and
wavy shapes, so as to impart contour on either or both of the
adjacent dash panel or the dash-panel flange. One will further
appreciate that the bend line may be straight in the event that no
contour is desired for either the dash panel or the dash-panel
flange.
[0061] With reference to FIG. 1, sheet material 30 also includes a
dash-panel bend line 42 that separates a dash panel 37 and a first
fold panel 44. The dash-panel bend line 42 is curved to impart
contour to the first fold panel 44 upon bending of the sheet
material about the dash-panel bend line 42 in a manner similar to
that of dash-panel-flange bend line 35 described above. In the
illustrated embodiment, dash-panel bend line 42 is downwardly
concave such that it imparts an upwardly convex contour on the
first fold panel 44 upon bending as shown in FIGS. 4 and 5. One
will appreciate that, depending upon the curvature of the
dash-panel bend line 42, and the relative angle that dash panel 37
is bent relative to first fold panel 44, the curvature of the
dash-panel bend line 42 may be imparted to one or both of the dash
panel 37 and the first fold panel 44. As best seen in FIG. 5 dash
panel 37 is outwardly concave. One will also appreciate that the
curvature of the dash-panel bend line may also vary in accordance
with the present invention in that it may be upwardly concave,
wavy, and/or otherwise curved.
[0062] Referring again to FIG. 1, sheet material 30 also includes a
first fold line 46 separating first fold panel 44 from a
supplemental or second fold panel 47. In this embodiment, the first
fold line 46 is substantially straight in order to impart the
contour of the first fold panel 44, which corresponds to the
curvature of dash panel bend line 42, to the second fold panel 47
upon bending of the sheet material about the first fold line 46. As
the first fold line 46 is substantially straight, and as the second
fold panel 47 is substantially folded to lie over the first fold
panel 44, first fold line 46 will impart substantially the contour
of the first fold panel 44 to second fold panel 47, as shown in
FIG. 5. A supplemental or second fold line 49 separates the second
fold panel 47 from a dashboard panel 51. The second fold line 49 is
also substantially straight in order to impart substantially the
contour of the second fold panel 47 to the dashboard panel 51 upon
bending of the sheet material about the second fold line 49, as
shown in FIG. 5.
[0063] In the illustrated embodiment, a first distance D1 between
dash-panel bend line 42 to first fold line 46 is different from an
a second distance D2 between the first fold line 46 and second fold
line 49, as shown in FIG. 1. Such configuration causes a forward
edge 53 of the dashboard panel 51 defined by second fold line 49 to
be spaced from the dash panel 37 as shown in FIG. 5. As shown in
FIG. 1, the first distance D1 is shorter than the second distance
D2 thereby recessing the dash panel 37 beyond the forward edge 53
as shown in FIGS. 3-5.
[0064] In another embodiment of the present invention, the
dimensional sheet material 30a is similar to sheet material 30
described above but includes fold lines having curved sections as
shown in FIG. 6. Like reference numerals have been used to describe
like components of sheet materials 30 and 30a.
[0065] In this embodiment, a downwardly curved dash-panel bend line
42a separates dash panel 37a and a first fold panel 44a in a manner
similar to that discussed above. In this embodiment, a contoured
first fold line 46a separates first fold panel 44a from a second
fold panel 47a, and includes a curved central portion 46a'
intermediate two straight portions. Fold-line apertures 70 separate
the curved and straight portions of the first fold line 46a and
thereby prohibit any creasing which may occur in the transition
zone between the curved and straight portions. Similarly, a
contoured second fold line 49a separates the second fold panel 47a
from the dashboard panel 51a, and includes a curved central portion
49a' intermediate two straight portions. The fold-line apertures 70
may extend to and separate the curved and straight portions of the
second fold line 49a, and thus prohibit creasing which may occur in
the transition zone between the curved and straight portions.
[0066] In operation and use, sheet material 30a is used in
substantially the same manner as of sheet material 30 discussed
above.
[0067] Turning now to another aspect of the present invention,
complex or compound contours corresponding to the curvatures of
multiple bend lines can be imparted to a warp zone, and the
resulting warpage due to the complex or compound contours may be
confined within the warp zone, as the warp zone is delineated by
intersecting bend or fold lines. With reference to FIG. 1, sheet
material 30 includes a first dashboard-flange bend line 54 which
separates a forward dashboard flange 56 from a warp zone 58 of
dashboard panel 51. The first dashboard-flange bend line 54 is
curved to impart a first contour on the warp zone 58. Similarly, a
second dashboard-flange bend line 60 separates a second dashboard
flange 61 from the warp zone 58, which bend line 60 is also curved
to impart a second contour on the warp zone 58. One will appreciate
that either or both of the dashboard-flange bend lines may impart
contour on either the flanges or the warp zone 58, or if desired,
on both a respective flange and the warp zone 58.
[0068] First and second curved warp zone bend lines 63 and 65
delineate and separate warp zone 58 from a remainder 67 of the
dashboard panel 51. The first and second curved warp zone bend
lines 63 and 65 are configured to localize bending affected by
bending the dashboard-flange bend lines along the warp zone bend
lines. As such, the warp zone bend lines 63 and 65 substantially
isolate warpage within the warp zone 58. Both the first and second
warp zone bend lines 63 and 65 terminate at an intersection point
68. Also, both the first and second warp zone bend lines 63 and 65
have compound curvatures. Preferably, which portions 63' and 65' of
the warp zone bend lines 63 and 65 adjacent the intersection point
68 have smaller radii of curvature than portions further out. Such
decreased radii of curvature may prohibit creasing within the warp
zone 58 adjacent the intersection point 68. In the illustrated
embodiment, the radii of curvature of both portions extend in the
same direction (e.g., both portions 63' and 65' are both concave
downwardly). Such same-direction concavity may similarly prohibit
creasing within the warp zone 58 adjacent the intersection point
68.
[0069] In operation and use, the sheet materials are preferably
preformed with the bend lines and fold lines, that is, the sheet
materials may be provided with events 40, shipped flat, and bent on
site at the desired destination. The sheet materials may be bent
sequentially along each individual line, or simultaneously about
two or more bend lines.
[0070] In another illustrated embodiment as shown in FIGS. 7-15,
attention is directed to FIG. 7A which illustrates a flat sheet
material 130 that is configured to form a three-dimensional
structure 132 in the form of an instrument panel structure (I/P
structure) shown in FIG. 8E. In the illustrated embodiment, the I/P
structure is configured and dimensioned for use in an automobile,
however, one will appreciate, however, that the sheet material may
be configured to form a multitude of three-dimensional structures
including, but not limited to, mechanical structural and aesthetic
elements, vehicular structure and the like.
[0071] In the illustrated exemplary embodiment, the sheet material
includes a number of straight bend lines 133 and warp zone bend
lines 135. The warp zone bend lines 135 are generally configured to
localize elastic deformation during bending along a predetermined
path, as are the below mentioned warp zone bend lines and fold
lines. For example, the warp zone bend lines 135 may be in the form
of events 137 disposed on either side of the warp zone bend line in
order to facilitate and precisely control bending along the warp
zone bend line, which events 137 are more clearly shown in FIG. 7B.
Events 137 may be in the form of slits, grooves, displacements and
other suitable means described in the above-mentioned patents and
applications of Industrial Origami, the entire content of which is
incorporated herein by this reference.
[0072] Generally, the straight bend lines 133 are provided to form
an instrument panel crossbeam 139 as shown in FIG. 11, which
extends the length of the vehicle dashboard and is dimensioned and
configured for attachment to the vehicle adjacent the A-pillars, as
is discussed in greater detail below. Warp zone bend lines 135 are
provided to form a right lower dash panel 161. The primary purpose
of the crossbeam 139 is to provide structural integrity to the I/P
structure as well as the vehicle, while the primary purpose of the
dash panel is to provide body panels having a pleasing contour to
add to the aesthetic appearance of the interior. By folding the
sheet material along the bend lines in the order illustrated in
FIGS. 8A-8E, the two dimensional sheet material forms the
three-dimensional I/P structure of the present invention.
[0073] With reference to FIGS. 9A and 9B, left and right tunnel
flanges 142 and 144 are bent with respect to left and right tunnel
flange folds 146 and 147, which in turn are bent with respect to a
forward console flange 149, and which in turn is bent with respect
to a bottom beam flange 151 to provide the intermediate structure
shown in FIG. 9B. The tunnel flanges and associated flanges are
dimensioned and configured to cooperate with a drive train tunnel
in an otherwise well-known manner.
[0074] With reference to FIGS. 9B and 9C, the bottom beam flange
151 is bent with respect to an upper beam flange 153, which in turn
is bent with respect to a bottom beam web 154, which in turn is
bent with respect to a lower beam flange 156 to provide the
intermediate structure shown in FIG. 9C. Thus far, straight bends
have been formed which is forming in part a box beam which will
traverse the vehicles interior between the A-pillars of the
vehicle.
[0075] With reference to FIGS. 9C and 9D, the lower beam flange 156
is bent with respect to an upper dash panel 158. Also, left and
right lower dash panels 160 and 161 are bent with respect to the
upper dash panel 158, which also causes the left lower dash panel
160 to bend with respect to the right lower dash panel 161. While
such action also forms in part the box beam, such action also
creates complexly contoured curvatures, as will be discussed in
greater detail below.
[0076] With reference to FIGS. 9D and 9E, left and right beam flaps
163 and 165 are bent with respect to the lower dash panels 160 and
161, as is the central console flap 167. Each of the flaps includes
flap fastener apertures 168 which will ultimately align with beam
fastener apertures 170 as shown in FIG. 1. In order to promote
structural integrity and to assist alignment, the left and right
beam flaps 163 and 165 are provided with left and right caps 172
and 174 which each have a profile that corresponds with the
cross-sectional profile of the box beam on either end of the I/P
structure. For example, FIG. 11 illustrates how the profile of the
right cap 174 indexes or provides the cross-sectional shape of
right end of the box beam, while FIG. 12 illustrates the manner in
which the profile of the left cap 172 indexes or provides the
cross-sectional shape of the left end of the box beam. In many
aspects the box beam of the present invention is similar to those
discussed in detail in, and thus has the same advantages as those
discussed in detail in, the above-mentioned patents and
applications, the entire contents of which is incorporated herein
by this reference.
[0077] In accordance with another aspect of the present invention,
the I/P structure is also configured to impart a wide-flange
contour upper and lower dash panels as shown in FIG. 7A. In
particular, complex or compound contours corresponding to the
curvatures of multiple curved warp zone bend lines 135 are imparted
to contour zones, in which the left lower dash panel 160 forms a
gently sweeping contour generally following the contour of the warp
zone bend line 135 separating the left lower dash panel 160 from
the upper dash panel 158 and the right lower dash panel 161. In
contrast, the right lower dash panel 161 is bounded by intersecting
warp zone bend lines 135 and thus warps to accommodate the various
contours imparted thereon. The warpage of right lower dash panel
161 is largely confined as the right lower dash panel 161 is
delineated by intersecting warp zone bend lines 135.
[0078] Turning now to the remaining figures, FIG. 10 illustrates
the right front view of the folded I/P structure and thus shows the
curvature of the left lower dash panel 160 and the complex
curvature of the right lower dash panel 161. The lower dash panels
160 and 161 are provided with trim apertures 175 and 177 which
allow trim to be fastened to the I/P structure. For example,
leather trim may be affixed to the I/P structure utilizing these
apertures. The left lower dash panel 160 further includes indicia
179 and corresponding openings for various switches and other
vehicular controls. In the illustrated embodiment, the indicia is
etched or routed directly in the sheet material providing an
opportunity to backlight the indicia and to avoid the need for
addition parts bearing such indicia.
[0079] With reference to FIGS. 11 and 12, the cross beam is
provided with left and right openings 181 and 182 to facilitate
attachment to a vehicle unibody frame. For example, bolts 184 may
extend from a vehicle unibody mount 186 adjacent the A-pillar 188
of the vehicle, as shown in FIG. 15.
[0080] For convenience in explanation and accurate definition in
the appended claims, the terms "left" or "right", "up" or "upper",
"down" or "lower", "inside" and "outside" are used to describe
features of the present invention with reference to the positions
of such features as displayed in the figures.
[0081] In many respects the modifications of the various figures
resemble those of preceding modifications and the same reference
numerals followed by subscripts "a" designate corresponding
parts.
[0082] The foregoing descriptions of specific exemplary embodiments
of the present invention have been presented for purposes of
illustration and description. They are not intended to be
exhaustive or to limit the invention to the precise forms
disclosed, and obviously many modifications and variations are
possible in light of the above teachings. The exemplary embodiments
were chosen and described in order to explain certain principles of
the invention and their practical application, to thereby enable
others skilled in the art to make and utilize various exemplary
embodiments of the present invention, as well as various
alternatives and modifications thereof. It is intended that the
scope of the invention be defined by the Claims appended hereto and
their equivalents.
* * * * *