U.S. patent application number 12/341951 was filed with the patent office on 2009-08-06 for high-strength three-dimensional structure and method of manufacture.
This patent application is currently assigned to Industrial Origami, Inc.. Invention is credited to Michael E. Bales, Michael S. Binion, Max W. Durney, Jimmy H. Wang.
Application Number | 20090194089 12/341951 |
Document ID | / |
Family ID | 40824704 |
Filed Date | 2009-08-06 |
United States Patent
Application |
20090194089 |
Kind Code |
A1 |
Durney; Max W. ; et
al. |
August 6, 2009 |
HIGH-STRENGTH THREE-DIMENSIONAL STRUCTURE AND METHOD OF
MANUFACTURE
Abstract
A structure including a sheet of material bent along bend lines
to form a plurality of walls defining an interior volume having a
predetermined cross-section. A fold-out tab portion in one of the
walls has a peripheral shape complementary to the predetermined
cross-section. At least one side of the tab engages an immediately
adjacent, corresponding wall thereby defining the predetermined
cross-section. The structure may include a bend line defining a
first portion and a second portion of the sheet of material, each
portion including a pre-formed bend angle flange. The pre-formed
bend of the first portion is aligned with the pre-formed bend of
the second portion. A section of the first portion may also overlap
a section of the second portion thereby forming a
multiple-sheet-thick framework. An oven housing with sidewalls, a
top and a back, and a removable bottom adjustably disposed within
the oven compartment is also disclosed.
Inventors: |
Durney; Max W.; (San
Francisco, CA) ; Bales; Michael E.; (Cleveland,
TN) ; Binion; Michael S.; (Cary, NC) ; Wang;
Jimmy H.; (Daly City, 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: |
40824704 |
Appl. No.: |
12/341951 |
Filed: |
December 22, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61016434 |
Dec 21, 2007 |
|
|
|
61102346 |
Oct 2, 2008 |
|
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Current U.S.
Class: |
126/19R ;
72/379.2 |
Current CPC
Class: |
B21D 51/06 20130101;
F24C 15/08 20130101; B21D 11/10 20130101 |
Class at
Publication: |
126/19.R ;
72/379.2 |
International
Class: |
F24C 15/00 20060101
F24C015/00; B21D 31/00 20060101 B21D031/00 |
Claims
1. A three-dimensional structure comprising: a housing formed from
at least one two-dimensional sheet of material including a
plurality of bend lines defining outer sides of the housing, at
least two of the bend lines including a positioning structure
therealong; and an inner structure within the housing, the inner
structure having a periphery and a plurality of support flanges
extending outward from the periphery, each support flange extending
towards a respective bend line of the housing and including a
fastening structure on an outer edge thereof; wherein the fastening
structure of each inner structure support flange is configured to
cooperate with a respective positioning structure of the housing to
support the inner structure within the housing.
2. The structure according to claim 1, wherein the positioning
structure is a bend-controlling displacement.
3. The structure according to claim 2, wherein each bend line
includes a plurality of bend-controlling displacements.
4. The structure according to claim 1, wherein at least one support
flange is configured to be fastened to the housing without discrete
fasteners.
5. The structure according to claim 1, wherein at least two of the
plurality of support flanges extend from opposite sides of the
inner structure.
6. The structure according to claim 1, wherein the inner structure
is formed of at least one inner sheet of material, and the at least
one inner sheet includes an inner bend line, and wherein at least
one of the support flanges of the inner structure is monolithically
formed with the at least one inner sheet, and the inner bend line
defines a border between at least one of the support flanges and an
inner side.
7. The structure according to claim 6, wherein the at least one
support flange is substantially straight.
8. The structure according to claim 6, wherein the at least one
support flange extends from the inner structure to the housing at
substantially 45 degrees from a plane defined by the inner
side.
9. The structure according to claim 1, wherein the inner structure
is formed of at least one sheet of material, and the at least one
sheet includes a plurality of inner bend lines, and wherein at
least two support flanges of the inner structure are monolithically
formed with the at least one sheet, and wherein the inner bend
lines define a border between the inner side and the at least two
support flanges.
10. The structure according to claim 6, wherein at least one
fastening structure includes a tab, and a respective positioning
structure includes an aperture along a respective bend line of the
housing, and wherein the tab is inserted into the aperture thereby
fastening a respective support flange of the inner structure to the
housing.
11. The structure according to claim 6, wherein the inner structure
is formed from at least two sheets of material each having an inner
bend line.
12. The structure according to claim 11, wherein one of the two
sheets and at least one of the support flanges of the inner
structure are monolithically formed, and wherein the inner bend
line of the one of the two sheets defines a border between the
inner side and at least one of the support flanges.
13. The structure according to claim 12, wherein the other of the
two sheets includes a lip portion, wherein the inner bend line of
the other of the two sheets defines a border between another inner
side and the lip portion, and the lip portion extends towards the
inner structure.
14. The structure according to claim 1, wherein the lip portion is
fastened to the at least one of the support flanges.
15. The structure according to claim 1, wherein the lip portion
fastens to the at least one flange without discrete fasteners.
16. The structure according to claim 1, wherein the housing is
configured for mounting a modular control panel thereto.
17. The structure according to claim 16, wherein the housing
includes at least one aperture providing a guide path for
electrical wiring.
18. The structure according to claim 17, wherein the
three-dimensional structure is an appliance.
19. The structure according to claim 18, wherein the
three-dimensional structure is an oven.
20. A method of manufacturing a three-dimensional structure, the
method comprising: preparing a sheet of material for bending along
a plurality of bend lines into a housing, at least some of the bend
lines defined by a plurality of positioning structures, at least
some of the bend lines defining sides and contours of the
three-dimensional structure; providing an inner structure including
an inner skeletal structure formed along the periphery of the inner
structure, the inner skeletal structure comprising a plurality of
inner structure edges and substantially straight flanges, the inner
structure edges being joined together at comers of the inner
structure, each flange extending from an inner structure edge
towards a bend line of the housing, at least one of the flanges
including a fastening structure on an outer edge thereof;
positioning the inner structure on the sheet of material such that
the fastening structure engages a respective one of the positioning
structures; and bending the sheet of material along the bend lines
into a housing formed around the inner structure, wherein the
flanges support the inner structure relative to the outer
structure.
21-31. (canceled)
32. A three-dimensional structure comprising: a sheet of material
for bending along a plurality of bend lines, each bend line defined
by a plurality of bend-inducing structures, the sheet of material
including a first peripheral flange portion along a first of the
bend lines extending along a first panel portion of the sheet of
material, and a second peripheral flange portion along a second of
the bend lines extending along a second panel portion of the sheet
of material, wherein the first peripheral flange portion aligns
with a portion of the second panel portion sheet and the second
peripheral flange portion aligns with a portion of the first panel
portion such that the first and second bend lines are immediately
adjacent and substantially parallel to one another.
33. The structure according to claim 1, wherein one of the sheets
of material is bent along the respective bend lines to form a
portion of the housing, the portion of the housing having a
plurality of walls defining an interior volume and having a
predetermined cross-section, at least one bend line defining a
fold-out tab portion in one of the walls, the tab having a
peripheral shape complementary to the predetermined cross-section,
wherein when the tab portion is folded, at least one side of the
tab engages an immediately adjacent, corresponding wall thereby
defining the predetermined cross-section of the plurality of
walls.
34. A structure according to claim 33, wherein the tab portion
nests within the interior volume.
35. A structure according to claim 34, wherein the periphery of the
tab portion abuts at least two corresponding walls of the plurality
of walls.
36. A structure according to claim 34, the plurality of walls
forming a wall structure, wherein the tab portion is configured to
support the wall structure.
37. A structure according to claim 35, wherein the tab portion is
configured as a cross-brace for the walls.
38-39. (canceled)
40. A structure according to claim 33, wherein the tab portion
fastens to any of the plurality of walls.
41. (canceled)
42. A structure according to claim 33, wherein the tab portion
snaps into the interior volume.
43. A structure according to claim 1, wherein the at least one
sheet of material includes a coating.
44-63. (canceled)
64. The structure according to claim 1, wherein the inner structure
is an oven compartment having sidewalls, a top and a back, the
structure further comprising a removable bottom disposed within the
oven compartment and adjustably mounted with respect to the
sidewalls.
65. An oven according to claim 64, wherein at least one of the
sidewalls and back include mounts for slidably engaging the
bottom.
66-70. (canceled)
71. An oven according to claim 64, wherein the bottom includes: a
heater element; at least one insulating layer adjacent the heater
element; a top pan disposed above the heater element and the
insulating layer; and a bottom pan disposed below the heater
element and the insulating layer.
73. An oven according to claim 64, further comprising a second
cooking compartment positioned below the oven compartment within
the housing, wherein the bottom is configured to form a top of the
second cooking compartment.
74. An oven according to claim 73, wherein the bottom is configured
to heat the second cooking compartment.
75-84. (canceled)
85. An oven according to claim 64, wherein the bottom is vertically
adjusted.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/016,434 filed Dec. 21, 2007, entitled
HIGH-STRENGTH THREE-DIMENSIONAL STRUCTURE AND METHOD OF
MANUFACTURE, the entire contents of which is incorporated herein
for all purposes by this reference.
[0002] This application claims priority to U.S. Provisional Patent
Application No. 61/102,346 filed Oct. 2, 2008, entitled FOLDED
THREE-DIMENSIONAL STRUCTURE, the entire contents of which is
incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates, in general, to flexible
manufacturing processes such as preparing sheets of material for
bending using punching, stamping, roll-forming, and similar
processes and then bending the sheets into rigid three-dimensional
structures. Various aspects of the invention relate to forming
cooking appliances with adjustable configurations.
[0005] 2. Description of the Related Art
[0006] Conventional techniques for mass producing three-dimensional
structures require complex, work-intensive assembly processes.
Typically, separate sheet materials and solid components are
fastened together to form the structure. As the end-product
increases in complexity, the assembly process becomes exponentially
more complex and costly. Such conventional techniques suffer from a
lack of flexibility and cost pressures.
[0007] By way of example, conventional appliances, such as cooking
ranges, require the design and engineering of assembly lines and
manufacturing systems as complex as some of the products produced.
As such, the assembly lines and production facilities can not be
modified easily. The appliance arrangements and configurations are
likewise limited to increase efficiencies of scale and minimize
unit costs.
[0008] Conventional cooking ranges and ovens include a skeletal
frame and housing supporting one or more cooking compartments. Each
compartment includes a top, body, and base member which are formed
of multiple sheets of material and other components fastened
together into a three-dimensional structure. The range or appliance
further requires a complex structure to add rigidity to the
product, such as front and rear frame structures. Each type of
range also requires a unique assembly process. For example, a
cooking range with a warming drawer requires different compartments
and a different skeletal structure than one which includes two
cooking compartments.
[0009] To take advantage of efficiencies of scale, assembly lines
and processes are set up for each unique cooking range
configuration. Customarily, manufacturers design a "range line" to
accommodate various sizes and configurations. Manufacturers prepare
specific tooling for each range line. When significant engineering
design changes are made, the manufacturing line must be revised
accordingly. Likewise, changes can not be made easily or cost
efficiently between range lines, for example, when switching
between a multiple-oven design and a single-oven design.
[0010] Furthermore, manufacturers must estimate the total products
to be made of each range line when ordering parts. A large number
of specific parts must be provided, each keyed to a specific range
line. When production increases or decreases, the cost of materials
and waste increases. For these and other reasons, the tool-up
investment can be millions of dollars for a typical line of
appliances and tens of millions of dollars for high-volume
appliance lines.
[0011] More recently, methods have been developed for forming
three-dimensional products, such as cooking appliances, from
two-dimensional sheets of material. Such methods generally reduce
tooling and production costs and increase manufacturing
flexibility. Various methods of preparing sheet materials for
precision folding along a desired bend line have been developed to
this end. For example, U.S. Pat. Nos. 6,481,259, 6,877,349,
7,032,426, 7,152,449 and 7,152,450 describe various methods of
preparing and folding sheet materials for forming three-dimensional
objects having relatively high tolerances from substantially planar
two-dimensional sheets. The folding-structures shown and described
in the above patents promote so-called edge-to-face engagement and
other phenomena to facilitate folding along a desired bending
line.
[0012] The methods and structures described in the above-mentioned
patents may be used to form three-dimensional structures for a
variety of applications. With the recognition of the advantages of
such methods, there is a need to expand the useful application of
such methods.
[0013] The above methods provide three-dimensional structures with
strength and rigidity in comparison to welded structures, but in
many instances it may be desirable to provide three-dimensional
structures capable of withstanding increased loading. For example,
it may be desirable to form large complex structures having
sufficient strength to satisfy design requirements without using
(or at least reducing the need for) additional modifications to
increase strength. Such additional modifications might include
welding or attaching strengthening members like plates, gussets or
other reinforcing members over joints, increasing the thickness of
material, or using support structures. In some cases, even the use
of support structures can not increase the structural strength to a
sufficient degree. In other cases, the use of such additional
structures, which increases the bill of materials, is
cost-prohibitive.
[0014] In the context of cooking appliances, for example, there is
the additional problem of accumulation of grease, food, and other
materials upon cooking surfaces. Such grease and debris is messy,
unsightly, and smells. Grease also presents a fire hazard at high
operating temperatures. The accumulation of grease and other matter
also decreases the performance of appliances by lowering the
thermal reflectivity of the interior surfaces. The use of the
above-described folding technologies has been lacking thus far
because slits, grooves, and the like provide especially troublesome
sources--in the slits and along the crook of the bends-for the
accumulation and trapping of grease.
[0015] Conventional appliances have used disposable liners and
self-cleaning cycles to reduce or eliminate the build-up of grease.
Cooking utensils such as pots and pans commonly utilize non-stick
coatings, but at present, such coatings have been uneconomical for
application to oven compartments. One reason for the high cost of
applying coatings to conventional ovens arises from the large
surface area to be covered. Because conventional ovens are
assembled from a large number of parts, each of which requires
whole covering in the treatment the total surface area to be
covered is exponentially large. In addition, coatings such as
polymers (e.g. Teflon.RTM. or PTFE) and vitreous enamels chip and
peel off surfaces easily during assembly when subjected to bending,
twisting, and hits from various moving parts involved with
conventional manufacturing processes. For this reason, such
coatings, if used at all, are applied after assembly.
[0016] The peeling of coatings is especially troublesome when used
on sheet materials prepared for folding. During folding, the sheet
of material along the bend line is subjected to bending, twisting,
and stretching. Inelastic and rigid coatings easily peel off the
sheet along the bend line. Even more flexible coatings tend to
separate due to the different rate of stretching between the
coating and the sheet surface to which it adheres.
[0017] Another concern of appliance manufacturers is maximizing the
amount of cooking space without increasing the dimensions of the
overall appliance or sacrificing structural integrity. The use of
additional support structures and the like to bent sheets or
assembled frames reduces the amount of space available for
cooking.
[0018] What is needed is a three-dimensional structure and method
of manufacture which overcomes the above and other disadvantages.
What is needed is a structure that can be manufactured with
flexible and cost-efficient manufacturing techniques.
[0019] What is needed is a rigid structure with reduced associated
costs. What is needed is an adjustable structural configuration and
design.
[0020] What is needed is a three-dimensional structure formed from
a folded sheet of material that minimizes the problems with bend
lines described above.
BRIEF SUMMARY OF THE INVENTION
[0021] Various aspects of the invention are directed to a
three-dimensional structure including a housing formed from at
least one two-dimensional sheet of material including a plurality
of bend lines defining outer sides of the housing, at least two of
the bend lines including a positioning structure therealong; and an
inner structure within the housing, the inner structure having a
periphery and a plurality of support flanges extending outward from
the periphery, each support flange extending towards a respective
bend line of the housing and including a fastening structure on an
outer edge thereof. The fastening structure of each inner structure
support flange is configured to cooperate with a respective
positioning structure of the housing to support the inner structure
within the housing.
[0022] In various embodiments, the positioning structure is a
bend-controlling displacement. Each bend line may include a
plurality of bend-controlling displacements.
[0023] At least one support flange may be configured to be fastened
to the housing without discrete fasteners. At least two of the
plurality of support flanges may extend from opposite sides of the
inner structure. The inner structure may be formed of at least one
inner sheet of material, and the at least one inner sheet includes
an inner bend line, and at least one of the support flanges of the
inner structure may be monolithically formed with the at least one
inner sheet, and the inner bend line defines a border between at
least one of the support flanges and an inner side. The at least
one support flange may be substantially straight. The at least one
support flange may extend from the inner structure to the housing
at substantially 45 degrees from a plane defined by the inner
side.
[0024] In various embodiments, the inner structure is formed of at
least one sheet of material, and the at least one sheet includes a
plurality of inner bend lines, and at least two support flanges of
the inner structure are monolithically formed with the at least one
sheet, and the inner bend lines define a border between the inner
side and the at least two support flanges.
[0025] At least one fastening structure may include a tab, and a
respective positioning structure includes an aperture along a
respective bend line of the housing, and wherein the tab is
inserted into the aperture thereby fastening a respective support
flange of the inner structure to the housing. The inner structure
may be formed from at least two sheets of material each having an
inner bend line. One of the two sheets and at least one of the
support flanges of the inner structure may be monolithically
formed, and the inner bend line of the one of the two sheets
defines a border between the inner side and at least one of the
support flanges. The other of the two sheets may include a lip
portion, wherein the inner bend line of the other of the two sheets
defines a border between another inner side and the lip portion,
and the lip portion extends towards the inner structure. The lip
portion may be fastened to the at least one of the support flanges.
The lip portion may fasten to the at least one flange without
discrete fasteners.
[0026] The housing may be configured for mounting a modular control
panel thereto. The housing may include at least one aperture
providing a guide path for electrical wiring.
[0027] In various embodiments, the three-dimensional structure is
an appliance. In various embodiments, the three-dimensional
structure is an oven.
[0028] Various aspects of the present invention are directed to a
three-dimensional structure including a sheet of material bent
along a plurality of bend lines, the bent sheet of material forming
a plurality of walls defining an interior volume and having a
predetermined cross-section, at least one bend line defining a
fold-out tab portion in one of the walls. The tab has a peripheral
shape complementary to the predetermined cross-section. At least
one side of the folded tab engages an immediately adjacent,
corresponding wall thereby defining the predetermined cross-section
of the plurality of walls.
[0029] In various embodiments, the tab portion nests within the
interior volume. In various embodiments, the periphery of the tab
portion abuts at least two corresponding walls of the respective
plurality of walls. The tab portion may be configured to support
the wall structure and further configured as a cross-brace for the
walls.
[0030] The plurality of bend lines may be defined by a plurality of
bend-facilitating structures. The bend-facilitating structures may
be displacements.
[0031] In various embodiments, the tab portion fastens to any of
the plurality of walls. The tab portion may fasten to the wall
without fasteners. The tab portion may snap into the interior
volume.
[0032] In various embodiments, the sheet of material includes a
coating. The three-dimensional structure may be part of an oven
housing, and the sheet of material may be pre-treated with a non-
stick coating. The structure may be an appliance. The appliance may
be a cooking range.
[0033] Various aspects of the invention are directed to a
three-dimensional structure including a structure formed from a
sheet of material configured for bending along a plurality of bend
lines, each bend line defined by a plurality of bend-inducing
structures, the sheet of material including a first peripheral
flange portion along a first of the bend lines extending along a
first panel portion of the sheet of material, and a second
peripheral flange portion along a second of the bend lines
extending along a second panel portion of the sheet of material.
The first peripheral flange portion may overlap a portion of the
second panel portion sheet and the second peripheral flange portion
may overlap a portion of the first panel portion such that the
first and second bend lines are immediately adjacent and parallel
to one another thereby forming a multiple-sheet-thick framework of
along a periphery of the three-dimensional structure. The
three-dimensional structure may further include a rigid inner
structure having a substantially straight support flange. The
support flange may extend from the inner structure toward the first
and second bend lines.
[0034] Various aspects of the invention are directed to a
three-dimensional structure including a structure formed from at
least one sheet of material configured for bending along a
plurality of bend lines, each bend line defined by a plurality of
bend-inducing displacements in the thickness direction of the sheet
of material, the bend lines of the at least one sheet defining a
first portion and a second portion of the at least one sheet of
material. The bend-inducing structures forming the first portion
may nest within the bend-inducing structures forming the second
portion when the at least one sheet of material is folded into a
three-dimensional structure.
[0035] Various aspects of the invention are directed to a
three-dimensional structure including a sheet of material for
bending along a plurality of bend lines, each bend line defined by
a plurality of bend-inducing structures, the sheet of material
including a first peripheral flange portion along a first of the
bend lines extending along a first panel portion of the sheet of
material, and a second peripheral flange portion along a second of
the bend lines extending along a second panel portion of the sheet
of material. The first peripheral flange portion may align with a
portion of the second panel portion sheet and the second peripheral
flange portion may align with a portion of the first panel portion
such that the first and second bend lines are immediately adjacent
and parallel to one another.
[0036] Various aspects of the present invention are directed to a
three-dimensional structure including a structure formed from a
sheet of material. The sheet of material is configured for bending
along a bend line, the bend line defined by a plurality of
bend-facilitating structures. The bend line defines a first portion
and a second portion of the sheet of material. Each of the first
portion and the second portion includes a pre-formed bend angle
flange defined by a hard, pre-formed bend and extending from an end
opposite the bend line. The sheet of material is bent along the
bend line such that the pre-formed bend of the first portion is
aligned with the pre-formed bend of the second portion.
[0037] Various aspects of the present invention are directed to a
three-dimensional structure including a structure formed from a
sheet of material. The sheet of material is configured for bending
along a bend line, the bend line defined by a plurality of
bend-facilitating structures. The bend line defines a first portion
and a second portion of the sheet of material. Each of the first
portion and the second portion includes a pre-formed bend angle
flange defined by a hard, pre-formed bend and extending from an end
opposite the bend line. The sheet of material is bent along the
bend line such that a section of the first portion overlaps a
section of the second portion thereby forming a
multiple-sheet-thick framework.
[0038] In various embodiments, the bend-facilitating structures are
displacements. In various embodiments, the three-dimensional
structure forms a miter joint. The first section and second section
may abut one another. The first section and second section may be
pressed together. The first section and second section may lie
substantially flat against each other. In various embodiments, each
of the pre-bends are positioned adjacent one another. The bend line
may be remote from each of the pre-formed bend angle flanges.
[0039] In various embodiments, the sheet of material includes a
plurality of bend lines, the sheet of material configured for
bending along the bend lines into a three-dimensional structure.
The first pre-formed bend angle flange and the second pre-formed
bend angle flange may form a corner of the three-dimensional
structure.
[0040] In various embodiments, the overlap of the first section and
second section seal an inner portion of the bend line after bending
is complete. In various embodiments, the sheet of material includes
a coating. The structure may be part of an oven housing, and the
sheet of material may be pre-treated with a non-stick coating. The
structure may form part of an appliance. The appliance may be a
cooking range.
[0041] Various aspects of the present invention are directed to an
oven including an oven compartment having sidewalls, a top and a
back, and a removable bottom disposed within the oven compartment
and adjustably mounted with respect to the sidewalls.
[0042] In various embodiments, at least one of the sidewalls and
back include mounts for slidably engaging the bottom. The mounts
may be rack mounts. An end or portion of the bottom may be
configured to engage the mounts on the back. The sidewalls may
include racks for engaging at least one of shelves, drawers, and
racks.
[0043] In various embodiments, the oven compartment may including
an oven housing for housing the oven compartment. The oven
compartment may engage inner walls of the housing.
[0044] In various embodiments, the bottom includes a heater
element, at least one insulating layer adjacent the heater element,
a top pan disposed above the heater element and the insulating
layer, and a bottom pan disposed below the heater element and the
insulating layer. The bottom may include apertures for heat
transfer from the heater element to the oven compartment.
[0045] The oven may include a second cooking compartment positioned
below the oven compartment, the bottom being configured to form a
top of the second cooking compartment. The bottom may be configured
to heat the second cooking compartment.
[0046] In various embodiments, walls of the oven compartment may be
formed from a single sheet of material configured to bend along a
plurality of bend lines. The bend lines may be defined by a
plurality of bend-facilitating structures.
[0047] In various embodiments, the cooking surfaces in the oven
housing are pre-treated with a non- stick coating.
[0048] The three-dimensional structures and methods of the present
invention have a number of features and advantages which will be
apparent from or are set forth in more detail in the accompanying
drawings, which are incorporated in and form a part of this
specification, and the following Detailed Description of the
Invention, which together serve to explain the principles of the
present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 is a perspective view of an exemplary cooking range
in accordance with various aspects of the present invention.
[0050] FIG. 2 is a perspective view of the cooking range of FIG. 1,
illustrating the cooking range with the stovetop range, warming
drawer, and front doors removed.
[0051] FIG. 3 is a front view of the cooking range of FIG. 2.
[0052] FIG. 4 is a perspective view of the cooking range of FIG.
2.
[0053] FIG. 5 is a perspective view of the oven compartment of FIG.
1, illustrating the housing and front frame member removed.
[0054] FIG. 6 is a perspective view of the top of the oven
compartment of FIG. 1.
[0055] FIG. 7A is an enlarged perspective view of the oven body of
FIG. 1, illustrating the mounts in the sidewalls and the top
removed. FIG. 7B is an enlarged view of features of the oven body
of FIG. 7A.
[0056] FIG. 8 is an enlarged front view of the oven compartment and
body of FIG. 1, illustrating the bottom on lower mounts and a
plurality of connection terminals.
[0057] FIG. 9A is a rear view of the bottom of FIG. 1, illustrating
the heater element disposed between a top pan, bottom pan, and
insulating layer and grooves in the sides of the bottom for
engaging mounts in the oven compartment.
[0058] FIG. 9B is a side view of the bottom of FIG. 9A.
[0059] FIG. 10A is a front view of the range of FIG. 2.
[0060] FIG. 10B is a front view of exemplary configurations of the
range of FIG. 2, illustrating the bottom in various exemplary
positions and orientations.
[0061] FIG. 11 is a perspective view of the rear, underside of the
bottom of FIG. 9.
[0062] FIG. 12 is a perspective view of the underside of the bottom
of FIG. 11, illustrating the bottom with the bottom pan
removed.
[0063] FIGS. 13A-13C-1 are schematic views of a corner of the oven
compartment of FIG. 2, illustrating bending of the sheet along a
bend line and positioning within a housing. FIG. 13C-2 is an
enlarged schematic view of a portion of the oven compartment wall
of FIG. 13C-1.
[0064] FIGS. 13D-13E are schematic views of a corner of an oven
compartment similar to that of FIG. 2, illustrating bending of the
sheet along a bend line to form a curved overlap structure.
[0065] FIGS. 13F-13G are schematic views of a corner of an oven
compartment similar to that of FIG. 2, illustrating bending of the
sheet along a bend line to form a rounded corner.
[0066] FIG. 13H is a schematic view of a corner of an oven
compartment similar to that of FIG. 2, illustrating a corner
without a bend line.
[0067] FIG. 13I is a schematic view of corners of an oven
compartment similar to that of FIG. 2, illustrating bending of the
sheet along bend lines to form various corner configurations.
[0068] FIG. 13J is a schematic view of a corner of an oven
compartment similar to that of FIG. 2, illustrating bending of the
sheet along a bend line to form various corner configurations.
[0069] FIG. 13K is a schematic view of a corner of an oven
compartment similar to that of FIG. 2, illustrating bending of the
sheet along a bend line to form various corner configurations.
[0070] FIG. 14 is a perspective view of the oven compartment of
FIG. 2 positioned adjacent the back panel structure and sidewall of
the housing.
[0071] FIG. 15A-1 is a perspective view of the back panel structure
of the range of FIG. 1. FIG. 15A-2 is an enlarged view of the
corner post of the range of FIG. 1.
[0072] FIG. 16 is an enlarged perspective view of the back panel
structure of FIG. 15, illustrating a corner post with a bent tab
portion.
[0073] FIGS. 17A-17J are schematic figures illustrating a process
for forming a three-dimensional structure similar to that shown in
FIG. 1. FIGS. 17A-1, 17B-1 to 17B-4, 17E-1, 17F-1, and 17F-2 are
enlarged views of features of the sheets of FIG. 17.
[0074] FIG. 18 is a perspective view of an exemplary oven assembly
in accordance with various aspects of the present invention.
[0075] FIG. 19 is a pictorial view of two sheets of material which
may be used to form a housing of the oven assembly of FIG. 18.
[0076] FIG. 20 is a pictorial view of the two sheets of material
shown in FIG. 19 having been bent along peripheral bend lines to
form peripheral flanges.
[0077] FIG. 21A through FIG. 21P are sequential perspective views
of a method of manufacturing the oven box of FIG. 18 in accordance
with some aspects of the present invention.
[0078] FIG. 22 is a perspective view of an exemplary oven box of
the oven assembly of FIG. 18.
[0079] FIG. 23A is a cross-sectional view of the oven of FIG. 21N
taken along the line 6-6 of FIG. 21N, illustrating positioning of
an inner structure inside a housing similar to FIG. 13. FIG. 23B,
23C and 23D are cross-sectional views of alternatives thereof.
[0080] FIG. 24 is a perspective view of the oven of FIG. 18
illustrating mounting of an instrument panel in accordance with the
present invention.
[0081] FIG. 25 is an enlarged perspective view of the oven of FIG.
24 illustrating the mounting points for a door assembly in
accordance with the present invention.
[0082] FIG. 26 is a perspective view of the oven of FIG. 18 shown
assembled on the workbench.
[0083] FIG. 27 is a perspective view of a fastener configuration of
the oven of FIG. 18 in accordance with the present invention.
[0084] FIG. 28 is a perspective view of the sheet of material and
workbench of FIG. 21A illustrating folding of the sheet of material
in accordance with the present invention.
[0085] FIG. 29A is a perspective view of another exemplary oven box
of the oven assembly of FIG. 18, while FIGS. 29B, 29C and 29D show
the oven box in various stages of assembly.
[0086] FIG. 30 is a perspective view of a portion of the oven box
of FIG. 29 illustrating enameling in-the-flat.
DETAILED DESCRIPTION OF THE INVENTION
[0087] 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.
[0088] Turning now to the drawings, wherein like components are
designated by like reference numerals throughout the various
figures, FIG. 1 shows a folded three-dimensional structure,
generally designated 230, in accordance with some aspects of the
present invention. In one exemplary embodiment, the
three-dimensional structure is a housing structure with a hinged
cover and inner compartment, for example, an appliance, such as
cooking appliances and combinations, a dishwasher, a washing
machine, or a dryer, or a container, such as a safe, a toolbox, or
a cabinet. For convenience, various embodiments will be described
herein with respect to the exemplary case of a cooking range.
However, one skilled in the art will understand that the present
invention as described herein is generally applicable to numerous
applications requiring flexible and precise manufacturing of
three-dimensional structures.
[0089] Thus, the depiction of an appliance is merely exemplary. The
teachings of the present inventions for precision bending are also
applicable to the production of numerous other three-dimensional
(3D) structures including, but not limited to, electronic component
chassis, automotive components and chassis, transport components
and chassis, construction components and chassis, appliances parts
and chassis, truck components and chassis, architectural components
and structural members, aerospace components, commercial coolers,
HVAC systems, and more. The structures and method of the present
inventions may be applied in various applications whether
residential, commercial, or industrial. That is, the teachings of
the present application are applicable to a wide variety of
three-dimensional products and structures including those that are
formed by folding two- dimensional sheet materials. Such 3D
structures may also benefit in that the present invention would
allow reducing the 3D structures to their flat forms to facilitate
repackaging and reshipping. Such features are suitable for
producing reusable shipping containers and the like.
[0090] One will appreciate that more recent techniques for
manufacturing appliances and the like may involve preparing major
components from one or more folded sheets of material. The use of
folded sheets reduces the tools, parts, time and assembly steps
required to manufacture the structure. Such techniques utilize
technology for preparing sheet materials for precision folding
along a desired bend line. For example, U.S. Pat. Nos. 6,481,259,
6,877,349, 7,032,426, 7,152,449 and 7,152,450, incorporated herein
in their entirety for all purposes, describe various methods of
preparing and folding sheet materials for forming three-dimensional
objects having relatively high tolerances from substantially planar
two-dimensional sheets.
[0091] In many aspects, the sheet materials of the present
inventions are similar to those disclosed by U.S. Pat. No.
6,481,259, U.S. Pat. No. 6,877,349, U.S. Pat. No. 7,152,449, U.S.
Pat. No. 7,152,450, U.S. patent application Ser. No. 10/821,818
(Pub. No. 2005/0005670), U.S. Pat. No. 7,032,426, U.S. Pat. No.
7,263,869, U.S. Pat. No. 7,222,511, U.S. patent application Ser.
No. 11/357,934 (Pub. No. 2006/0261139), U.S. patent application
Ser. No. 10/952,357 (Pub. No. 2005/0064138), U.S. patent
application Ser. No. 11/384,216 (Pub. No. 2006/0207212), U.S.
patent application Ser. No. 11/080,288 (Pub. No. 2005/0257589),
U.S. patent application Ser. No. 11/374,828 (Pub. No.
2006/0213245), U.S. patent application Ser. No. 11/180,398 (Pub.
No. 2006/0021413), U.S. patent application Ser. No. 11/290,968
(Pub. No. 2006/0075798), U.S. patent application Ser. No.
11/411,440 (Pub. No. 2007/0113614), U.S. Provisional Patent
Application No. 60/665,577, U.S. patent application Ser. No.
11/386,463 (Pub. No. 2006/0277965), and U.S. Provisional Patent
Application No. 60/854,846, the entire contents of which patents
and patent applications are incorporated herein for all purposes by
reference.
[0092] With reference to FIGS. 1-2, cooking range 230 includes a
housing 232 and range components, generally designated 233, some of
which may be pre-assembled components and others of which may be
assembled on-site. In some aspects, the cooking range is similar to
conventional cooking ranges, such as the ones disclosed by U.S.
Pat. No. 2,423,863 to Wales, the entire content of which is
incorporated herein by this reference.
[0093] The cooking range may be provided with a cooking range top
or stove top, generally designated 235, oven 237, and warming
drawer 139. As will be described below, the cooking range of the
present invention allows for changing the range configuration with
greater ease. For example, the cooking range may be provided with
multiple ovens, a microwave, warming drawers, utility drawers,
various cooking tops, and other components and consumer
features.
[0094] Suitable materials for the cooking range and components
include, but are not limited to steel, stainless steel, aluminum,
ceramics, porcelain, composites, and the like. It may be desirable
to treat one or more of the range and components for aesthetic or
functional purposes, such as to increase reflectivity or reduce
build-up of grease. Such treatments may include the addition of a
coating material such as paint, porcelain, enamel, polymer, and the
like. A portion or all of the cooking surfaces may be treated with
a non-stick coating including, but not limited to,
polytetrafluoroethene, polytetrafluoroethylene (PTFE), and vitreous
enamels. Laminates, chemical treatment, polishing, the use of
liners, and the like may also be utilized depending on the
application.
[0095] The material may be pre-treated, meaning, treated prior to
folding and/or assembly. The material may also be treated after
such processing. In comparison to conventional treatment processes,
the method of forming the structure in accordance with the present
invention yields several advantages. In the example of applying
non-stick coatings, application and firing of porcelain in-the-
flat is faster and more consistent. Cleaning, polishing, and many
other treatment and finishing processes can be performed better and
at reduced costs when done on flat sheets versus odd-shaped,
three-dimensional structures.
[0096] Referring to FIGS. 2-8, exemplary oven 237 includes an oven
compartment 240 having sidewalls 242, a top 244, and a back 246,
which together form a body 247, and a bottom 249. Conventional oven
compartments are fabricated from separate sheets of materials
welded or joined together to form the wall sections. In various
embodiments, oven compartment 240 may be formed from one sheet of
material folded into oven compartment 240 and secured in place. The
oven compartment may also be formed of a sheet folded to form the
body and a top lid fastened thereto.
[0097] The front of the body may be covered with a conventional
front frame member 251 or left open. The front frame member adds
rigidity to the oven compartment and also serves to fasten the
compartment within housing 239. The oven compartment includes
flanges 253 along the front edge that fasten to the front frame
member. The oven compartment includes various other flanges and
fastening structures for positioning the compartment within the
housing. Unlike conventional appliances, the structure of the
present invention does not require an intricate front frame
structure to lend rigidity to the overall structure and system. The
front frame member described may be a thin sheet of material.
Although it may be configured as a rigid structural member, one
will appreciate that the compartment described has improved
rigidity in and of itself. Thus, in comparison to conventional
appliances, the appliance and oven compartment of the present
invention reduces the bill of materials and complexity of the
system while increasing flexibility.
[0098] Oven body 247 may include features integrated into the
structure to cooperate with shelves, racks, subassemblies,
rotisseries, and the like. For example, the compartment includes
racks 254 that engage conventional shelves. The compartment may
also include other features such as apertures to exhaust air and a
convection fan.
[0099] Compartment 240 includes bottom 249, which can be attached
to or released from the compartment. The bottom may engage body 247
or may support the body. In various embodiments, the bottom is
disposed within the oven compartment and may be removed. The
position of the bottom within the compartment may be adjusted
thereby modifying the oven compartment size and configuration
without modifying the whole oven.
[0100] Referring specifically to FIGS. 9-12, bottom 249 includes a
heater element 256, an insulating layer 258, a top pan 260, and a
bottom pan 261. The insulating layer is positioned below the heater
element and provides thermal insulation to the bottom pan. The top
pan and bottom pan enclose the heater element and insulating layer
on at least two sides. The rear end of the bottom may remain open
to aid in plugging the heater element into the back of the oven.
The front of the bottom is shown closed by the top pan to protect
consumers from the heater element and to provide a pleasing
aesthetic front.
[0101] Top pan 260 has a recessed top portion 263 with an outer lip
265. The outer lip helps to retain food and grease on the top of
bottom 249. In some cases, it may be desirable to provide a
disposable or removable liner on top 263 to aid the cleaning
process.
[0102] Top pan 260 includes apertures 273 to allow combustion
and/or convection heat to escape from bottom 249, and in
particular, from heater element 256. Fans and other elements may be
provided to facilitate airflow through the bottom.
[0103] While the bottom has been described in the context of a
electric heating, one will appreciate that the bottom may be
modified depending on the application. The bottom and/or oven may
be configured for gas, electric, or other heating configurations.
For example, in the case of an electric oven without convection,
the bottom may be sealed without apertures. The bottom may also be
configured for radiant, infrared, microwave or combinations of the
same to name a few. The heater element configuration may also be
modified depending on the desired performance parameters and other
factors.
[0104] Referring back to FIGS. 7-12, oven body 247 is configured to
receive bottom 249. In various embodiments, mounts 267 are provided
on sidewalls 242 and/or back 246 to engage and fix the bottom in
the oven body. The mounts shown in FIGS. 7-8 slidably engage the
bottom. Specifically, sides of the bottom include v-shaped grooves
268 configured to engage rails formed as mounts. The height of the
bottom relative to the sidewalls may be adjusted by sliding the
bottom on a selected set of mounts.
[0105] The bottom and oven compartment may be modified as would be
understood by one skilled in the art from the foregoing. For
example, the bottom may engage the oven compartment walls with
clips, hooks, tabs, and similar fastening devices. Removal or
adjustment may not be required for all applications. In various
embodiments, the bottom is permanently fastened into a selected
position in the oven compartment during assembly. The means for
fastening the bottom in the oven compartment include, but are not
limited to, rivets, twist-tabs, buttons, and more.
[0106] The oven compartment may include any other configuration to
receive the bottom at various locations as will be understood from
the foregoing. The mounts may be integrally formed with the
sidewalls of the oven compartment. The mounts may include a linear
section and a grooved section to lock the bottom into position
and/or positive haptic feedback during assembly. In various
embodiments, the back of the oven body may be configured with
grooves, slots, fasteners, and the like to engage bottom 249. The
mounts may also serve as rack mounts whereby the unused mounts can
receive shelves and the like.
[0107] During assembly, one pair of the plurality of mounts is
selected depending on the oven configuration. The bottom is
positioned on the mounts and secured in position. Connection
terminals 270 may be provided for each of mount pairs 267. Thus,
the bottom slides into place and engage a respective connection
terminal. Thereafter the housing is assembled around the oven
compartment. The bottom may also be configured to connect to the
oven compartment via alternative arrangements. For example,
flexible wiring may be used such that a single connection terminal
can connect to the bottom in a variety of positions.
[0108] The positioning of the bottom in the oven may vary depending
on the application. For example, if the bottom position is intended
to be adjusted by a consumer, the oven may include mounts or other
receiving members to adjustably receive and release the bottom. By
contrast, if the bottom is intended to be positioned by the
manufacturer based on a product type, the bottom may be configured
to permanently fix into position in the oven. Additionally, the
appliance may likewise be configured based on the intended use. For
example, the oven may include a single large door to cover the
entire oven compartment if the bottom is to be adjusted by a
consumer or fitted with multiple doors if the bottom is to be
permanently fixed by the manufacturer. The doors may also be
configured based on the application and appliance configuration.
For example, the doors may swing out laterally as opposed to
opening in an up-and-down fashion.
[0109] One will appreciate that the structure described provides
increased modularity over conventional structures and appliances.
One will understand from the description herein that the structures
and components may be modified to adjust the height, width, and
other specifications simply and precisely. The position and
orientation of various assemblies may be modified in accordance
with the present invention. For example, the dimensions and
orientation may be modified by changing the shape of the sheet of
material and positioning the bottom in a different location.
[0110] As shown in FIG. 10, a variety of configurations may be
obtained simply by adjusting the height and configuration of bottom
249 within oven compartment 240. Thus, a single oven compartment
can accommodate a variety of oven configurations. Moreover, the
configuration may be adjusted merely by selecting a location for
the bottom without complicated changes to the manufacturing set-up,
assembly process, parts ordering process, and the like.
[0111] In various embodiments, bottom 249 is positioned above the
bottom of oven compartment sidewalls 242 and a second cooking or
warming compartment is provided below the bottom. The second
cooking compartment may be heated from above by bottom 249, or
additional heating elements may be utilized such as one positioned
in the floor of the range. The bottom may also be configured for a
vertical orientation whereby a side-by-side configuration is
provided. The appliance and oven may also include more than one
bottom in various configurations.
[0112] In various embodiments, oven body 247 is formed from a
folded, single sheet of material. The sheet of material is prepared
for bending along a bend line 279 and folded during the process of
making the cooking range 230. The sheet may be a monolithic sheet
of material or several sheet joined together. In many aspects, the
sheet materials of the present inventions are similar to those
disclosed by the above-mentioned '259, '349, '426, '449, and '450,
as well as U.S. patent application Ser. No. 10/821,818 (Pub. No.
2005/0005670), U.S. Pat. No. 7,032,426, U.S. Pat. No. 7,263,869,
U.S. Pat. No. 7,222,511, U.S. patent application Ser. No.
11/357,934 (Pub. No. 2006/0261139), U.S. patent application Ser.
No. 10/952,357 (Pub. No. 2005/0064138), U.S. patent application
Ser. No. 11/384,216 (Pub. No. 2006/0207212), U.S. patent
application Ser. No. 11/080,288 (Pub. No. 2005/0257589), U.S.
patent application Ser. No. 11/374,828 (Pub. No. 2006/0213245),
U.S. patent application Ser. No. 11/180,398 (Pub. No.
2006/0021413), U.S. patent application Ser. No. 11/290,968 (Pub.
No. 2006/0075798), U.S. patent application Ser. No. 11/411,440
(Pub. No. 2007/0113614), U.S. Provisional Patent Application No.
60/665,577, U.S. patent application Ser. No. 11/386,463 (Pub. No.
2006/0277965), and U.S. Provisional Patent Application No.
60/854,846, the entire contents of which patents and patent
applications are incorporated herein in their entirety for all
purposes by reference thereto.
[0113] Other bend-facilitating structures are envisioned as being
within the scope of the present invention. Such structures
generally enable locating and positioning a respective bend line
during bending. For example, the structures may be used to
determine a location in the sheet of material where the bend will
occur and may also position respective parts, including edges,
faces, and the like, of the sheet of material during bending. The
structures may be further configured to facilitate bending of the
sheet of material with minimal use of tools and force.
[0114] Some applications may call for surfaces with increased
reflectivity, reduced accumulation of grease, and other
characteristics. It has been found that coatings and laminates can
provide an effective way to alter the characteristics of the
materials forming the oven compartment. However, coatings,
laminates, and the like tend to chip or peel off when used in
conjunction with folded sheets prepared using the above techniques.
The sheet of material undergoes bending, twisting, and stretching
that make it difficult to effectively coat the sheet in the region
of the bend line.
[0115] With particular reference to FIGS. 7 and 13-14, a sheet of
material 275 may include a structure to improve the use of folding
techniques with surface and material preparations. The sheet of
material is prepared with a plurality of bend-facilitating
structures that define a bend line 279. The bend-facilitating
structures may slits, grooves, displacements, perforations, and the
like.
[0116] In various embodiments, the sheet of material and bend line
are prepared to form an overlap structure 281 that seals the bend
line at a remote location from the oven interior. The bend line
divides the sheet material into a first portion 282 and a second
portion 284. Each of the first portion and the second portion
includes a pre-formed bend angle flange 286 defined by a pre-formed
bend 303'. The angle flange extends from an end opposite the bend
line at an angle such that the sheet on each side of the bend line
forms an angle. During bending, the first portion and the second
portion approach each other until they abut one another. "Abut"
refers to a point at which the first and second portion apply a
contact force against other. Thus, one portion overlays the other
thereby forming a multiple-sheet-thick framework. "Overlap
structure" as used herein refers to the structure formed by folding
the sheet of material having pre-formed angle flanges until the
first and second portions are adjacent one another.
[0117] The sheet may also be formed and bent such that hard,
pre-formed bends 303' align and lie adjacent each other. In various
embodiments, the sheet of material is configured such that ends of
the sheet are bent slightly past a point at which the pre-formed
bends make contact. In various embodiments, the pre-formed bends
are each slightly less than 135.degree.. The sheet of material is
bent along the bend line until the pre-formed bends make contact,
which is slightly before 90.degree.. Thereafter, the sheet is bent
further until a 90.degree. corner is formed and the sheet is
slightly pre-loaded with a compressive force on the contact point
between the pre-formed bend angles. In this way, pressure is
applied to enhance the seal of the portion of the sheet which
overlaps.
[0118] Although described as "pre-formed," one will appreciate that
the angle may be formed before or after the other processes
described herein. For example, the flanges may be formed from a
substantially flat sheet prior to or after bending along the bend
line.
[0119] As described herein, "pre-formed bend" refers to a rigid,
fixed bend. For example, sheet material 275 resembles angle
brackets joined along a bend line. Each pre-formed angle is formed
by working the material or using other conventional techniques to
effectuate a rigid bend angle. By contrast to the bending
techniques referred to above, working the material causes the
material to undergo permanent changes and hold its shape. From
another viewpoint, the pre-formed bend is differentiated by the
bend line because the bend line acts likes a hinge whereas the
pre-formed bend is relatively rigid. Indeed, working the material
to form the pre-formed bend is intended to change the shape of the
sheets and resist bending back. Although the bending techniques
referred to above promote bending, such techniques do not resist
bending back towards the original shape without the addition of
features such as snaps and angle locks. In comparison, the
pre-formed bend is formed using conventional techniques that fix
the angle and shape much like the original shape of the sheet. The
energy required to change the bend angle would be akin to that
required to bend any other portion of the sheet.
[0120] As shown in FIG. 13B-13C, the framework described forms what
resembles reverse miter joint. In the folded position, the first
and second portion lie substantially flat against each other. The
pre-formed bend angle flange extends from the first and second
portion at a pre-formed or pre- determined bend angle. The
pre-formed bend angle defines a base of the bend angle flanges, and
the base of each portion may lie adjacent each other. The bend line
lies at an opposite end of the first and second portion from the
pre-formed bend angle. Thus, the bend line is situated remote from
the engagement region of the pre-formed bend angles.
[0121] Although the structure has thus far been described as
portions of the sheet abutting one another to form a
multiple-sheet-thick framework, one will appreciate that other
configurations and modifications may be employed in accordance with
the present invention.
[0122] Referring to FIGS. 13D-13E, an alternative framework in
accordance with various aspects of the present invention is shown.
A sheet of material 275' is similar to sheet of material 275. The
sheet of material includes a bend line 279'. The bend line may be
defined by a plurality of bend-facilitating structures. In various
embodiments, the sheet of material and bend line are prepared to
form an overlap structure 281' similar to overlap structure 281
described above. The bend line divides the sheet material into a
first portion 282' and a second portion 284'. Each of the first
portion and second portion includes curved portions 284' proximate
the bend line. The first portion includes a pre- formed bend angle
flange 286' defined by a pre-formed bend 303'. The angle flange
extends from an end opposite the curved portion. When the sheet of
material is bent along the bend line, the first portion and the
second portion approach until the curved portions engage or contact
one another. The engagement of the curved portions serves to
fluidly seal the bend line.
[0123] Referring to FIGS. 13F-13G, an alternative framework in
accordance with various aspects of the present invention is shown.
A sheet of material 275'' is similar to sheets of material 275 and
275'. The sheet of material includes a bend line 279''. Instead of
a substantially straight pre-formed bend angle flange, the sheet of
material includes curved flange portions extending from pre-formed
bend curves 306''. When the sheet of material is bent, sections of
the sheet form an overlap structure and the curved flanges form a
smooth or rounded corner. The smoother corner provides further
sealing from food crumbs, grease, and the like. Although the curved
flange portions are smooth curves and mirror each other, other
shapes and configurations may be employed in accordance with the
present invention.
[0124] Referring to FIGS. 13H-13K, various other framework
configurations are within the scope of the invention. The sheet of
material may be prepared such that the overlap structure is
positioned within the bent structure or inside the interior volume
after bending (shown, e.g., in FIG. 13J). The overlap structure may
also have various shapes and configurations. With reference to
FIGS. 13D-13E and 26K, the overlap structure may have a hook shape.
It has been found that such a shape reduces leakage of microwave
energy and radiation.
[0125] The treatment of the bend line may differ depending on the
application. Modifications may be made to increase the stiffness
and rigidity of the resulting structure such as welding or
fastening the sheet together after bending.
[0126] Other applications may require the structure to be fluid
tight. In such applications, it may be desirable to provide an
elastic, fluid-resistant material such as a rubber on the interior
of the first and second portions such that contact between the two
forms a tight seal. Some applications may not require a tight seal
of the bend line, in which case the sheet may only be partially
bent and the first and second portion do not abut one another.
"Seal" does not refer to a perfect air- or fluid-tight seal.
Rather, "seal" refers to shutting out most of the visible light and
is to be further defined in the context of the application for
which it is to be applied. For example, seal may require points of
contact in the context of providing strength to the structure or
limiting the risk of food and grease getting caught in the corner
and inner portion of the bend line. In the case of fluid-tight
structures, "seal" will refer to sealing out a particular
fluid.
[0127] One will understand that the overlap structure may be
modified and utilized in other aspects of the resulting
three-dimensional structure. For example, bottom 249 may be formed
from a sheet of material with an overlap structure. The overlap
structure may be configured as a flange to engage the housing for
increased stability or to engage mounts 267. The overlap structure
may be formed by alignment of portions of sheets without a bend
line. As shown for example in FIGS. 13H, pre-formed bend angle
flanges on separate sheets may align with each other without the
use of a bend line. Various aspects of the present invention as
shown and described may be modified to achieve lower cost and/or
increased performance and flexibility.
[0128] The structure of the present invention provides several
advantages in comparison to conventional sheets of material with
multiple, overlapping folds. As shown in FIGS. 13A-13G and 14, the
overlap structure isolates bend line 279 at a remote location from
an interior volume 288 of the oven. The overlap structure also
provides the benefits of folding techniques while retaining a
sealed corner 289 of the oven compartment. Thus, even if coatings
or other treatments are not applied to the bend line, the benefits
remain with respect to the functional part of the oven, in
particular, the inner cooking surfaces of the oven compartment.
[0129] The overlap structure described may also be utilized in
various other applications aside from appliances and cooking
ranges. For example, the structure may be modified for application
including, but not limited to, the formation of electronic
component chassis, automotive components and chassis, transport
components and chassis, construction components and chassis, and
more.
[0130] The method of making oven compartment 240 and housing 239
will now be briefly described. The complete manufacture of the
exemplary cooking range will not be described in detail. For
example, the manufacture of the stove top subassembly and assembly
to the cooking range will not be described. Instead, the following
discussion is intended to illustrate to one skilled in the art the
structure and method of the present invention and how it relates to
other techniques for the manufacture of the overall product.
[0131] As described above, the oven body may be formed from a
single sheet of material folded along a plurality of bend lines as
described above. Although shown as separate panels, the housing may
likewise be formed from a folded sheet of material. Because the
three-dimensional structure, including the oven compartment, may be
formed from one or more folded sheets of material, the sheets can
be treated prior to folding. For example, a non-stick coating may
be applied to the sheet before assembly. In contrast to
conventional assembly processes which involve many moving parts,
complicated systems, and attachment of various components, the
method of forming a structure of the present invention is simple
and utilizes fewer parts and moving machinery. Thus, there is less
likelihood of the surface being nicked, chipped, or dented.
[0132] Housing 239 provides the core skeletal structure of range
230. The housing includes a back panel structure 291 and side
panels 293. The side panels form the cosmetic exterior of the
structure in addition to providing necessary rigidity.
[0133] The housing houses or encloses oven body 247 (shown in FIG.
7). In various embodiments, the oven body is positioned in the
housing such that bend line 279 is positioned adjacent to the
corner of the housing (e.g. FIG. 13C). The positioning of the sheet
in the crook of the housing corner and rigid angle flanges mutually
reinforces the oven body and housing. In this manner, the housing
and inner structure are engaged or locked such that side-to-side
movement imposes a compressive force on the sheet of material and
oven compartment. The configuration of the oven compartment and
housing thus acts as cross-brace to impart additional rigidity to
the system.
[0134] Referring to FIGS. 15-16, back 291 generally has a
rectangular cross-section and provides a stand-off between the rear
end of the working components of the range and the wall against
which it will be placed. The electrical system, gas or electrical
connection, and other components utilize the space provided by the
back panel structure.
[0135] Back panel structure 291 acts as the backbone of the
housing. Back panel includes a plurality of thin walls forming
hollow sections. The back structure includes various flanges,
corners, tabs, and the like to increase rigidity and provide access
to the interior volume. In various embodiments, each side of the
back panel structure includes posts 295 formed by a hollow volume
defined by thin wall sections 296.
[0136] The back panel structure is formed from a sheet of material
bent along a plurality of bend lines to form various wall sections.
The bend lines are positioned and configured such that the bent
sheet of material defines a predetermined cross-section of posts
295. Using the precision bending techniques described in the above
referenced patents, the sheet of material may be prepared for
precision bending to precisely control the final shape of the
structure. The sheet of material may be prepared with
bend-controlling displacements, such as slits or grooves, to
facilitate and control bending. In this manner, the back panel can
be precisely formed to match with the rest of range structure 230
and perform its necessary function.
[0137] The sheet of material forming the back panel structure
includes at least one bend line defining a fold-out tab portion
(e.g. FIG. 15). The fold-out tab portion is formed in one of the
walls of the bent structure such that it folds down into the
predetermined cross-section or interior volume of the post. The tab
has a peripheral shape complementary to the predetermined
cross-section of the post.
[0138] When the tab is folded into the post interior, at least one
side engages or becomes proximate an immediately adjacent wall.
Thus, the tab nests within the post and defines in part the
cross-section by providing a stop or resistance to movement of the
wall. As force is transmitted through the range, the post
structures will want to move but will be limited by the tab. Any
movement of the posts will apply a compressive force on the tab
which will in turn apply an opposite force thus limiting movement.
In this manner, the tab acts as a cross-brace for the posts. As
would be understood by one skilled in the art from the foregoing,
the tab may define the shape of the post wall structure by engaging
at least one wall and may brace the structure by engaging at least
two walls. In various embodiments, the tab is configured to
"matchbox" the wall structure.
[0139] The tab and post structure may be modified as will be
understood by one skilled in the art. The tab may be dimensioned to
correspond with the dimensions of the post cross-section to create
an interference fit whereby the tab abuts the inner wall surfaces.
Alternatively, the tab may be disposed inside the post such that
all or a portion of the periphery is merely adjacent the walls. The
tab may also be configured to engage or secure to one of the walls
of the post. For example, the tab may be held in place by
"snapping" into the space defined by the walls. The tab may also be
fastened to the walls using other fastener-less configurations or
fasteners including, but not limited to, hooks, tab-in- slot,
snaps, adhesives, rivets, and the like. Although shown folded down
to an angle substantially orthogonal from the post walls, the tab
may be folded down in various fashion depending on the post
configuration.
[0140] Similar tabs and flanges may be provided through range
structure 230. Fold-out tabs may be provided in back panel
structure 291 to secure the structure to the oven compartment
and/or housing side panels. For example, the tabs may be configured
to provide an attachment point for fasteners on the side panels.
The tabs may also be provided secure adjacent panels or components
together enhance structural rigidity or to aid in assembly of
components.
[0141] The three-dimensional structure may be formed by a variety
of processes. Referring to FIGS. 17A-17J, in various embodiments,
the three-dimensional structure is formed from a coil stock of
material 275b'. The coil is unrolled into a long sheet of material
275b.
[0142] In various embodiments, sheet 275b may be treated or
processed before being wound into the coil. For example, the
material may be treated with a coating, such as a non-stick
coating. The sheet may be treated at various stages in the process
or after final assembly of the three-dimensional structure,
meaning, during a finishing step.
[0143] The sheet is fed through machinery configured to form
features in the sheet of material as it is fed. Such features
include bend-facilitating structures 274b. Other features may be
formed in the sheet depending on the application and manufacturing
requirements. For example, mounting structures, apertures, tabs,
shelves, and the like may be formed in the sheet material. The
features may be formed by stamping with lances, punches, draw
processes, and the like. The features may be formed in the sheet of
material in a transverse direction in one or more steps as the
sheet of material is fed. Components may also be attached to the
sheet in situ.
[0144] Other features may be added to the sheet upstream as it is
unwound from the coil stock. Such features include, but are not
limited to, functional components and subassemblies. The features
may be added using adhesives, welding, fasteners, and similar
processes.
[0145] After forming the bend-facilitating structures in sheet
275b, the sheet may be subjected to roll forming up or down the
line. Referring to sequence (A) through (E) in FIG. 13A, the sheet
may be subjected to hits to produce successive bending along bend
lines in a longitudinal direction. The bends may be done gradually
or in stages. Bending may be performed along bend lines
sequentially or in parallel fashion. The roll forming may also be
performed in any order with the forming of features in the
sheet.
[0146] The process includes severing the sheet of material from the
coil stock before or after the forming of one or more features. The
sheet may be rough cut and later finished. The sheet may also be
precisely cut thereby producing a finished product in a single
step.
[0147] As will be understood from the above, the process described
allows for fast and efficient processing. A stock coil of material
may be fed through a simple, modified assembly to form a sheet
product 310' in a reduced number of steps. As shown in FIGS.
17B-17C, some of the bending may be performed on the line before
cutting. The resulting product may then be formed by further
bending of the product along the bend lines. Thus, the sheet can be
prepared and bent into a 3D structure with a few simple
stations.
[0148] Turning to FIGS. 13 and 17, various components and
subassemblies may be fabricated separately from several sheets. In
various embodiments, a panel 312' is formed for insertion into the
resulting three-dimensional structure. Panel 312' may be configured
similar to bottom 249 described above such that it may be
adjustably positioned within the appliance compartment to be
formed. The panel includes an outer lip or flange 314 that extends
around the periphery of the panel. One will appreciate that the
flange may also be formed as an overlap structure similar to that
described above. Sheet 275b includes a corresponding lip feature
88, which can be formed in the sheet by the above process.
[0149] As the sheet is bent long the bend lines, an overlap
structure 281b is formed at the comers (shown in FIG. 17F). The
sheet further wraps panel 312'. The panel is secured inside the
bent structure by fastening lip 314' to corresponding lip 316' on
what becomes the interior wall (shown in FIG. 17F). A number of
panels may be provided within the bent structure to modify the
layout and configuration of the three-dimensional structure to be
formed.
[0150] Referring to FIGS. 17I-17J, a three-dimensional structure
may be formed by bending the sheet product along bend lines.
Thereafter, additional features may be added and the structure may
be finished. In various embodiments, mounting brackets are added to
the bent structure to brace the structure and provide a mounting
surface for doors. Feet, labels, insulation, wiring, and other
features and assemblies are further added during finishing.
[0151] One will understand that the process described may be
modified depending on the application. The order of various steps
may be modified. The manner in which features and events in the
sheet are formed may be modified and/or performed with different
processes. The dimensions of the three- dimensional product to be
formed may also be easily modified by changing the width of the
stock coil material and/or the shape and location and timing of the
severing, slitting, or punching of the sheet. Other modifications
and variations are envisioned within the scope of the
invention.
[0152] Turning now to FIG. 18 an exemplary folded,
three-dimensional structure, generally designated 30, is shown in
accordance with some aspects of the present invention. The
exemplary structure 30 may be modified for integration with the
exemplary range appliance described above or as a separate
appliance. In some respects, structure 30 is similar to structure
230 above.
[0153] In one exemplary embodiment, three-dimensional structure 30
is a housing structure with a hinged cover, for example, an
appliance, such as an oven, a dishwasher, a washing machine, or a
dryer; a container, such as a safe, a toolbox, or a cabinet; or an
enclosure.
[0154] An exemplary oven is generally formed from two dimensional
sheet members, some of which may be pre-assembled components and
others of which may be assembled on-site. FIG. 21A through FIG. 21P
illustrate an exemplary method of forming a three-dimensional
structure in accordance with various aspects of the present
invention. By contrast to the process of forming structure 230
described above and illustrated in FIG. 17, the method of forming
exemplary structure 30 allows for shipping parts in-the-flat and
assembling remotely. The process described below also calls for
greater interrelation of parts and more manual labor in the
process; however, one will appreciate that the processes of the
present inventions may be modified depending on the
application.
[0155] An optional workbench 32, described in more detail below,
provides a stable platform for folding and forming the various
subparts of the three-dimensional structure. In an exemplary
embodiment, the workbench has extensions in three directions to
provide a working surface for forming sides of the oven. As the
front of the oven includes an oven door, instrumentation, and the
like, these components may be pre-assembled as sub-assemblies at
another location and affixed to the housing structure during
assembly. However, these components may also be assembled using
similar methods to those described herein. In fact, most, if not
all, of the oven's structural components and body may be formed by
bending sheets of material prepared in accordance with the
principles described herein and using methods such as the ones
disclosed by the above-mentioned '934 and '216 applications.
[0156] With reference to FIG. 18, an exemplary three-dimensional
structure in the form of an inner oven chamber includes a
substantially box-like inner core structure 33 formed from one or
more two- dimensional sheets of material 35. In the exemplary
embodiment, the inner structure 33 is formed of five sheets,
however, one will appreciate that the inner structure may be formed
of one, two, three or more sheets of material. As will be described
below, each sheet of material may be a rigid member with no bend
lines or may have one or bend lines 37 to facilitate bending into a
three-dimensional structure to form the inner structure. In the
alternative, the inner structure may be an integrally pre- formed
three-dimensional structure.
[0157] The inner structure is positioned within a housing 39, which
is also formed from one or more two-dimensional sheets of material
40 folded into a three-dimensional structures. Sheets of material
40 may also be configured for bending along a plurality of bend
lines 42 in a manner similar to the above-mentioned sheets. The
plurality of bend lines further define sides or panels 44 and
contours of the housing. In an exemplary embodiment, each side 44
forms a substantially planar face of the housing structure (see,
e.g., FIG. 24), however, one will appreciate that the other shapes
and structures may be defined. For example, the sheets may be
stamped with ribbing and/or other structural features and/or
ornamental details that may strengthen, facilitate assembly, and/or
otherwise improve structural integrity or aesthetics.
[0158] The bend lines of the inner structure and the housing
include a plurality of positioning structures 46 to facilitate and
dictate the location of bending of one outer side relative to
another outer side along one or more bend lines. In one exemplary
embodiment, at least one positioning structure 46a on a first panel
portion 47a is configured to nest within another positioning
structure 46a on second panel portion 49b such that the panel
portions lay flat along the outside of the housing.
[0159] In one embodiment, the positioning structures 46 are formed
on one or both of the housing and the inner structure and/or any
number of other components to be transported in-the-flat and
thereafter folded into a three-dimensional structure, that is, in a
substantially two-dimensional state and later folded into a
three-dimensional structure. In an exemplary embodiment, a
plurality of bend-inducing structures are formed in the thickness
direction of sheets 35 and 40.
[0160] In an exemplary embodiment, the sheets of material forming
the housing includes peripheral flange portions 53 along respective
bend lines 42 extending along panel portions 54 of the sheet of
material. The bend lines extend along the periphery of the panel
portions to form the peripheral flange portions. As best seen in
FIG. 21G, the peripheral flange portions include outer tabs or
flaps along panel portions 54. In an exemplary embodiment, the
peripheral flange portions extend from the bend lines defining the
outer perimeter of the panels. During the bending process, the
peripheral flanges are bent along respective bend lines before the
panel portions are folded.
[0161] The peripheral flanges serve several purposes. As shown in
FIG. 21M through FIG. 210, peripheral flanges 53 provide a portion
of the sheet to couple together housing 39 when folding around
inner structure 33. The peripheral flanges also overlap each other
along edges 51 of the housing such that the edges and comers of the
housing have multiple layers of the sheet. For example, when the
peripheral flange and a respective panel portion 54 fold over
another panel side 54b of the housing, the peripheral flange will
overlap a portion of this adjacent panel 54b and create a
two-sheet-thick framework (see, e.g., FIG. 23A). Thus, each
peripheral flange portion and a respective panel cup the bend line
of another panel or peripheral flange with a double thickness
framework. The edges and comers of the structures generally carry a
significant load of the structure; thus, the above configuration
allows for additional material thickness in the key load-bearing
portions of the structures. In this manner, an exemplary housing
structure has a skeletal framework along the edges and comers with
increased material thickness and strength without increasing the
total thickness of the entire structure.
[0162] In the exemplary embodiment shown in FIG. 23A, the sheet of
material includes a first peripheral flange portion 53a along a
first of the bend lines overlapping a first panel portion 54a of
the sheet of material, and a second peripheral flange 53b portion
along a second of the bend lines overlapping a second panel portion
54b of the sheet of material. The peripheral flanges and panels
thus form a framework 56 of additional thickness along the edges of
the housing for additional support. In an exemplary embodiment, a
framework two-sheets-thick runs along a periphery of the
three-dimensional structure and thus defines load-bearing
framework.
[0163] Referring back to FIG. 21H to FIG. 21L, the inner structure
may include one or more support flanges 58 extending outward from a
periphery thereof which are configured to engage with the housing.
The inner structure is placed within the housing in a wrapping
arrangement, as shown in FIG. 21L to FIG. 21P and FIG. 23A to FIG.
24. Each support flange extends towards a respective bend line 42
of the housing. In the case where inner structure 33 includes bend
lines, the support flange extends from an inner structure towards
framework 56 of housing 39.
[0164] Turning to FIGS. 21-23, the inner structure includes an
inner skeletal structure 60 formed along the periphery of the inner
structure. The inner skeletal structure is formed by the
combination of inner edges 61, inner structure flanges 58, and the
corners of the inner structure. The inner structure edges and
flanges are joined together along the periphery of the inner
structure at corners or vertexes. In an exemplary inner structure,
the flanges overlap each other. Each flange extends from a
respective inner structure edge towards a bend line of the housing.
Depending on the particular overlap configuration, the overlapping
flanges are fastened to each other, the inner structure, or the
panels of the housing. The flange thus braces inner skeletal
structure 60 against movement. In this manner, the inner structure
is supported by the flanges and vice versa in a "matchbox"
fashion.
[0165] Additionally, when the inner structure is positioned inside
the housing, the inner skeletal structure and housing may mutually
reinforce each other. Referring to FIG. 23A, a first end of each
flange 58 extends into a crease or crook 63 formed by a respective
bend line of the housing. An opposite end of each flange extends
diagonally from the bend line to a corner or edge of the inner
structure such that the bend in the housing is supported by the
inner structure through the flanges. In one embodiment, at least
two of the plurality of flanges extend from opposite sides of the
inner structure such that they are diametrically opposed. In an
exemplary embodiment, at least one flange is substantially
straight. In this manner, the housing and inner structure are
locked such that movement of sides 44 and bend lines 42 of the
housing imposes a compressive force on respective flanges 58 and
inner structure 33.
[0166] Referring back to FIG. 13, the bent sheet may be matchboxed
inside the housing in similar manner. As will be understood by the
above description, the configuration of the inner structure
flanges, and housing may be modified depending on the application.
The inner structure may have any number of edges depending on the
three-dimensional structure to be formed. The number and
configuration of the flanges may be modified. For example, the
inner structure may have a bulbous or curvilinear portion on the
inside of a bend line or edge of the housing. In this instance, a
flange may be configured such that it circumnavigates and
substantially conforms to the surface of the inner structure and
extends to the housing bend line. In another example, the flange
may not extend exactly from inner structure edge to housing bend
line. Instead, the flange may be configured to fasten to a portion
of each respective structure adjacent to or even remote from the
respective edges. Such a configuration may be desirable when
another component is to be placed in the comers or edges or some
other design limitation requires the flange mounting point to be
moved.
[0167] Referring back to FIGS. 21-23, in one embodiment, each
support flange includes a fastening structure 65 on an outer edge
67 thereof to fasten the flange to the housing thereby securing the
inner structure to the housing and maintaining engagement between
the flange and respective bend line (see, e.g., FIG. 27). The
fastening structure of each inner structure support flange
cooperates with a respective positioning structure of housing 39 to
support inner structure 33 within the housing.
[0168] In one embodiment, the fastening structure has a tab and
slot configuration. Fastening structure 65 includes a tab 68 and a
respective slot or aperture 70 along a respective bend line 42 or
crook 63 of the housing. Preferably, fastening structure 65 is
monolithically formed with the respective sheets of material, as is
the case with an exemplary embodiment. During or subsequent to
folding, the tab may be inserted into the aperture thereby engaging
a respective support flange of the inner structure to a portion of
the housing. As can be seen in the figures, a plurality of
fastening structures are provided to engage each lateral corner of
the inner structure with a respective corner of the housing
spatially affixing the inner structure to the housing.
[0169] In this embodiment, each support flange is fastened to the
housing without a discrete fastening structure. Instead, flange 58
locks into crook 63 of the bend line during assembly of the
three-dimensional structure as tab 68 engages with corresponding
aperture 70. Alternatively, the flange may not extend at all into
the crook of the respective bend line and/or may include an
intermediate structure to engage with the housing.
[0170] The flange may be fastened to or formed with one of the
housing or the inner structure as described above. Alternatively,
the flange may be freely placed between the inner structure and
housing. For example, one of the inner structure or housing may
employ an alignment structure to align the flange during the
bending of the housing. Once the housing is formed, the flange may
be held in place in the crook of the respective bend line.
[0171] Other fastening structures may be also be utilized
including, but not limited to, those described in the
above-mentioned '440 application. Such fastening structures
include, but are not limited to, tie mounts, snaps, screws, and the
like.
[0172] Further, the structure, dimensions, and configurations of
the flanges may vary depending on the application. In one
embodiment, at least one flange extends from the inner structure to
the housing at an acute angle from a plane defined by an inner side
72 of inner structure 33. In one embodiment, at least one flange
extends at substantially 45 degrees from the plane. Other
configurations include, but are not limited to, dimensioning and
shaping flange 58 for a particular application. For example, the
flange may have a length determined to provide a stop for movement
of the bend line of the housing or may be configured to provide a
spring force or "give" to the overall three-dimensional structure.
Because each flange effectively guides or restricts movement of a
respective bend line, the flange may be configured in various
manners to control the overall rigidity and movement of
three-dimensional structure 30. Moreover, more than one flange, in
particular those on opposite comers of the inner structure, may be
configured to work together to influence and control physical
characteristics of the three-dimensional structure.
[0173] When housing 39 is wrapped around inner structure 33, the
inner structure imparts strength and rigidity to the housing and
vice versa. In one embodiment, the housing is a loosely-formed
structure with minimal strength independently. The inner structure
and flanges impart strength to the housing structure and overall
three-dimensional structure. In particular, the flange secures and
supports a respective bend line of the housing. In one embodiment,
neither the housing nor the inner structure have significant
strength independent of one another. One will appreciate that inner
structure 33, flanges 58, and housing 39 can be arranged in various
ways to increase the rigidity and strength of the resulting
three-dimensional structure. In an exemplary embodiment, the inner
structure and flanges form a type of cross-bracing within the
housing whereby the inner structure forming the oven box mutually
reinforces the oven housing.
[0174] Similar to the housing, inner structure 33 may be formed
from at least one inner sheet of material 35b including an inner
bend line 74b. In one embodiment, support flange 58 is
monolithically formed with the at least one inner sheet and the
inner bend line defines a border between at least one of the
support flanges and inner side 72. As shown in FIG. 22, the flange
is thus formed by overlapping panels on the sheet of material
during folding of the inner structure. The inner bend lines define
a border between the inner side and the support flanges.
[0175] In one embodiment, the housing sheet of material 40 and at
least one of the support flanges are monolithically formed. In one
embodiment, one of the housing and inner structure sheets of
material includes a lip portion 75. In the case where the lip
extends from the housing, bend line 42 of the sheet of material
defines a border between a side panel 54 and the lip portion. The
lip portion extends towards the inner structure in a direction
substantially parallel to the flange portion. In one embodiment,
the inner structure is formed from at least two sheets of material,
one of which includes a bend line. The lip portion extends from the
bend line such that it aids in locating an end of the flange to the
edge or bend line of the inner structure. The lip portion may be
fastened to at least one of support flanges 58 using a fastener.
Alternatively, the lip portion may fasten to the respective flange
without discrete fasteners. The lip portion is configured to
provide additional support to three- dimensional structure 30 and
strengthen fastening of the flanges 58 between the inner structure
and housing. The lip also serves as a mounting point for the
flanges.
[0176] The housing may be configured for a variety of applications.
The housing in the exemplary embodiment is configured to act as an
oven housing. As such, the housing is configured for mounting a
modular control panel 77 thereto. The housing further includes at
least one aperture 79 providing a guide path for electrical wiring
and mounting points for an oven door. The housing may be configured
in other ways as will be understood by one skilled in the art
whether forming an appliance or any other three-dimensional
structure. Similar configurations for electrical wiring and the
like are described in the above-mentioned '440 application. As will
be described below, application-specific configurations may be made
at any stage in the process of forming the three-dimensional
structure from the preparation of the sheet of material to the
finishing process after the sheets of material are folded.
[0177] Suitable materials for the housing and/or inner structure
include, but are not limited to metals, plastics, and other
materials. In one embodiment, the inner structure and/or housing
are formed from a sheet of material that is relatively
incompressible and rigid. Thus, conventional paper and paperboard
products are not considered incompressible. In an exemplary
embodiment, the housing and inner structure are stainless steel.
Similar materials may be used for the flanges. A variety of
materials may be used depending on whether the application
necessitates strength, rigidity, chemical inertness, corrosion
resistance, and the like.
[0178] An exemplary method of manufacture of a three-dimensional
structure in accordance with various aspects of the present
invention can now be described. Referring to FIG. 21A to FIG. 21P,
an assembly system is shown in accordance with the present
invention. The component parts of the oven may be manufactured at
an otherwise conventional first station or forming area including
metal- forming equipment. In particular, sheet of material 40 may
be prepared with monolithic positioning structures and fastening
structures in accordance with the above description. As noted
above, the positioning structures may be formed with processes
similar to those described in the above-mentioned '450 patent and
with reference to FIG. 17 above.
[0179] Additionally, other basic parts, whether plastic, natural
materials, or otherwise, may also be prepared in the forming area.
In an exemplary embodiment, the oven structure body is composed
primarily of steel sheets prepared for bending. The forming station
therefore includes machining equipment to cut multiple sheets and
prepare a plurality of bend-inducing structures. For example, a CNC
machine may be used to prepare the bend-inducing structures. The
outer dimensions of the sheet of material are also important and
may be prepared with similar equipment. The sides 72 of the inner
structure may also be prepared in this station or at another
location. One will appreciate that such steps may be prepared on
one or more stations.
[0180] The forming station may be remotely located from the area in
which the rest of the manufacturing process is performed. In
particular, the sheet of material forming the housing, whether a
single sheet or multiple sheets configured to be joined together,
may be formed at one location and transported to another location
in-the-flat. In one embodiment, the positioning structures of each
sheet are configured to receive positioning structures in adjacent
sheets of material whereby the sheet of material may stacked flat
with the adjacent sheet of material. Thus, when the sheets of
material are stacked on top of each other, positioning structures
in one sheet nest in the positioning structures of adjacent sheets.
This allows for a reduction in packing size when shipping the
sheets of material in the flat for folding at a remote
location.
[0181] Referring to FIG. 21A to FIG. 21P, the housing may be formed
from a single sheet of material or multiple sheets of material
thereafter joined together. In an exemplary embodiment, the housing
is formed from a two-dimensional sheet of material 40 formed from
three separately-formed sections 40'.
[0182] A first section 40a is placed on workbench 32, and
peripheral flanges 53 are folded up around the edges. The first
section includes what will become a first side panel 54a and bottom
81 of the housing.
[0183] Next, a second section 40b is laid on the workbench in an
area adjacent to the first panel. The second section includes what
will become a second side panel 54b and top 82 of the housing. The
peripheral flanges of the second panel are then folded into
position.
[0184] Finally, a third section 40c is laid on the workbench. The
third section overlaps a portion of the first section. In an
exemplary embodiment, the peripheral flanges on the first and third
sections are laid over each other and folded to form a mounting
point for flange 58 (see, e.g., FIG. 21G). In particular, the two
sections may be joined together to form an edge flange portion 84.
The other peripheral flanges on the third section are then folded
up. These steps are repeated until all the sheets of material are
positioned on the workbench with the peripheral flanges folded.
[0185] After the sections of the sheet of material are in place and
prepared, they are joined together by fastener structures. A
variety of structures may be utilized. In an exemplary embodiment,
the fastener structures are similar to those described above
including, but not limited to, tab-and-slot fasteners, screws,
tongue-and-groove fasteners, and the like. Fastening structures
also include welding, adhesives, and the like. In an exemplary
embodiment, rivets are used to further secure the panels together
into a single sheet of material see, e.g., FIG. 21G).
[0186] Once the housing sheet of material 40 is prepared, the inner
structure may be assembled. Referring to FIG. 21H to FIG. 21M, the
inner structure is assembled on the housing. A first side portion
72a of the inner structure is fastened to sheet of material 40. The
side portion includes flange 58 at a far edge which is fastened to
the lip of the housing. (see, e.g., FIG. 21H). As shown in FIG.
21I, the side portion is then folded up to a position perpendicular
to the sheet of material, and in particular, the bottom
portion.
[0187] Next, the other side portions 72b and 72c are affixed to the
sheet of material and the first side portion. The three sides form
a cavity of the inner structure, which will become the over box in
an exemplary embodiment. Thereafter, a top side 72d is positioned
on top of the side portions and fastened thereto. In an exemplary
embodiment, the top side includes three flanges 58' which overlap
flanges 58'' on each of the side portions 72a, 72b, and 72c. Thus,
the flanges have double-thickness. As can be seen in the drawings,
the flanges extend from a periphery of the inner structure along
the edges from corner-to-corner. The increased-thickness flanges
and comers of the inner structure form inner skeletal structure
60.
[0188] After the inner structure walls are formed as described, a
front face 86 is affixed to the inner structure. The front face
provides mounting points for various components. In an exemplary
embodiment, the face includes mounting points for the oven door. A
control plate 88 is further provided for mounting of a control or
display module 89. The front face may also be configured to
increase the stiffness of the inner structure. As will be
understood by one skilled in the art, the front face of an
exemplary embodiment forms a wide frame that serves to increase the
stability of the inner structure. The strengthened flanges,
attachment configuration to the housing, and front face all provide
for a robust and high-strength inner structure.
[0189] The inner structure assembly may be performed at the same
location or another location remote from the housing assembly area.
In an exemplary embodiment, the inner structure is formed by a
plurality of panel portions or sides 72 joined together. In an
exemplary embodiment, the inner structure includes an overlapping
structure 91, such as winged flanges, along the periphery or edges
which form a type of skeletal structure (see, e.g., FIG. 23A).
Because of the overlapping material, this skeletal structure has
increased rigidity and strength. In the alternative, the inner
structure may be formed by conventional methods such as welding
sheets of material. In one embodiment, the inner structure is
formed from a two-dimensional sheet of material similar to the
housing.
[0190] In other embodiments, the overlapping structure 91 may be
fastened together with discrete fasteners (see, e.g., FIG. 23B), or
be a unitary sheet over upon itself (see, e.g., FIG. 23C, FIG.
23D). Also, the angle at which the overlapping structure may vary,
see, e.g., FIG. 23C).
[0191] Also, tabs 73 may be provided at the extremity of flanges 58
which are adapted to extend into and engage apertures 73' in the
housing. Such configuration allows the for-and-aft position of the
inner structure to be affixed relative to the housing (see, e.g.,
FIG. 23B).
[0192] Flanges 58 may also be formed before transporting the
prepared components and sheets. The flanges may be formed at the
forming station or at another location. The flanges may also be
monolithically formed with the inner structure or housing. After
the inner structure is positioned on the housing panels, the
flanges are fastened to the inner structure. Each flange is
fastened such that it extends from inner structure 33 to a
respective bend line of the housing. In an exemplary embodiment,
each flange extends from an inner edge of the inner structure into
the crease formed by the bend line of the housing.
[0193] A plurality of edge flange portions 84 may also be provided
on the housing as described above to strengthen the flange
structures. The edge flange portion is a portion of material that
extends in substantially the same direction as a respective flange
58 and resides on an opposite end of the respective flange from lip
75. The edge flange portions perform a similar function as the
lips.
[0194] Similar to the lips and inner structure flanges, the edge
flange portions may be monolithically formed with the housing or
separately formed and fastened. In one embodiment where the edge
flanges are monolithically formed with sheet of material 40, the
sheet has additional bend lines and panels to form the edge flange
portions in an accordion-like fashion. A side of the housing is
bent along a bend line. Next, a first side of an edge flange
portion is folded and then a second side of the same edge flange
portion is folded back along and overlaps the first side. In this
manner, the edge flange portions have a thickness equal to two
sheets and lend additional strength to the housing and the end of
the attached flange. If the edge flange portions are defined by
bend lines with displacements, the bend-controlling displacements
defining a bend line of the first edge flange portion may be
configured to nest within the displacements defining a bend line of
the second edge flange portion. Flanges 58 and lips 75 may also be
formed in the same manner such that the entire oven box and housing
may be formed from a few sheets of material.
[0195] Referring to FIG. 21A to FIG. 21P, a second station 93 is
provided to facilitate bending the sheets of material into
three-dimensions. In one embodiment, the bend station includes
workbench 32. After preparing the sheets of material in the forming
area, the sheet intended to form the housing is placed on the
workbench and the three-dimensional structure is formed by bending
the sheet.
[0196] Second section 40b is folded about a first bend line and
then about a second bend line until the second section wraps about
the back of the inner structure (see, e.g., FIGS. 21M-21N). Once
folded around the inner structure, the peripheral flanges wrap
around edges of the inner structure such that the peripheral
flanges overlap a portion of the inner structure sides. In an
exemplary embodiment, as the sheet of material is folded, both of
the bend lines engage the edges of the inner structure.
Specifically, the bend lines engage the ends of flanges 58. Next,
the other sections of the sheet of material are folded around the
inner structure in a similar manner until the housing is formed. In
this manner, the housing is formed around the inner structure to
form a rigid three-dimensional structure.
[0197] Further, in an exemplary embodiment, the housing and inner
structure are formed and configured such that each flange extends
from a bend of the housing to an adjacent edge of the inner
structure. A flange extends from each edge of the inner structure
such that, when viewed in a direction orthogonal to the sides of
the structure, flanges on opposite edges extend in the same
direction, and in particular, through a diagonal of the inner
structure from border-to-border (see, e.g., FIG. 26).
[0198] As best seen in FIG. 28, workbench 32 may be configured to
promote bending of the sheets of material into three-dimensional
structures and assembly of the finished product. In an exemplary
embodiment, the workbench includes hinged flaps corresponding to
faces of the structure. The bend lines of the hinges correspond to
the bend lines in the housing such that when the flap is rotated
the sheet of material is precisely folded along the bend line. The
flap further provides the user additional leverage during bending
and minimizes contact between the workpiece and workbench. This
protects the user's hands from being scratched or cut by the
workpiece and can also reduce smudges and dirt on the workpiece
from the user's hands. The workbench may also be configured similar
to that described in U.S. Patent Publication No. 2006/0053857 to
Durney (which is hereby incorporated in its entirety by reference)
for most flexible manufacturing and precise bending of the sheets
of material.
[0199] Further, workbench 32 may be configured for flat-shipping
and assembly in remote location much like the three-dimensional
structure. In an exemplary embodiment, the workbench is formed from
flat pieces of material that are joined together at the assembly
site. The individual pieces may be fastened with known fasteners or
can be pre-joined with hinges or the like to allow folding into the
sturdy, three-dimensional shape shown in the figure. Configurations
other than those described may be used depending on the
application.
[0200] The sheet of material and inner structure are placed and
aligned on the workbench. The inner structure formed in the first
station is positioned on the sheet of material such that fastening
structure 65 engages or aligns with positioning structure 46. The
sheet of material is then bent along the bend lines into the
three-dimensional housing. The inner structure remains positioned
therein such that the housing is wrapped around the inner
structure. The housing may then be coupled to retain it in the bent
position. The housing may be coupled by fasteners and the like
formed integrally with the sheet or separately formed.
[0201] In the bent position, the fastening structure supports the
inner structure relative to the outer housing structure. The
flanges may be configured as braces for both the inner structure
and housing such that the two structures mutually support each
other. For example, in an exemplary embodiment, the flanges are
configured to act as cross beams with the inner structure inside
the housing. In turn, the flanges also support and hold the
position of the inner structure edges.
[0202] During the bending process, other components may be added to
the structure. For example, the oven heating element may be added
before or after sheet of material 40 is folded. The door for the
oven may also be added at this station after the bending process is
completed.
[0203] In one embodiment, the edges of the housing are formed with
more than a two-sheet-thick framework. In this embodiment, a first
peripheral flange portion overlaps a portion of a second panel
portion sheet and the second peripheral flange portion overlaps a
portion of the first panel portion. As seen in FIG. 21M, a first
bend defining the first peripheral flange is immediately adjacent
and parallel to a second bend line defining the second peripheral
flange. This results in a two-sheet-thick framework formed by the
overlap of the first and second peripheral flange portions along a
periphery of the three-dimensional structure. Further, the flange
portions form a three or more sheet thick framework when folded
over respective panel portions in this manner. This may be
compounded with three, four, and more peripheral flanges and
portions of the sheet of material.
[0204] From bending station 93, the structure moves to a
fit-and-finishing station 95. In this finishing station, the
structure is converted from a bare-bones structure to a final and
complete product, in this case an oven. In an exemplary embodiment,
a variety of subassemblies are affixed to the oven body. Such
subassemblies include electrical wiring, control panels, heating
subassemblies, and the like. If the oven includes an optional stove
top, a preassembled stovetop assembly may be fastened to the top of
the oven body in this station. Likewise, if the door has not been
fastened to the structure yet, it may be fastened at the bending
station. As will be understood by one skilled in the art, several
other functions may be performed at the finishing station or
bending station including, but not limited to, installing wiring
and tubing, adding decorative panels, adding trim and decorative
plates, and the like. These functions may also be done at earlier
points in the manufacturing process.
[0205] With reference to FIG. 21K, it is noted that many components
may be installed within the interior of the oven cavity at this
stage. And with reference to FIG. 21L, many components may be
installed to the exterior of the oven cavity at this stage of
assembly. One will appreciate that the assembly sequence allows the
installation of various components and subassemblies during various
stages of overall assembly. Moreover, one will appreciate that many
fasteners, components and/or subassemblies may be stored under the
table and/or on shelves thereon and are thus readily accessible to
the assemblers. With reference to FIG. 4P, one will also appreciate
that many components and/or subassemblies may be added to the
assembly by pre-attachment. For example, a control panel
subassembly may be added to the assembly.
[0206] The three-dimensional structure may also be formed from a
sheet of material in accordance with the present invention such
that that many of the typical finishing process are not necessary.
For example, nameplates may be replaced by stamping items directly
into the sheet of material in the forming station. Paint may also
be applied to the sheet of material after forming instead of
painting the finished three-dimensional structure at the end of the
manufacturing process. In many cases, such flexibility allows for
opportunities to reduce manufacturing costs and increase
efficiency.
[0207] In another exemplary embodiment of the present invention,
inner structure 33a is similar to inner structure 33 described
above but includes is formed of two sheets of material instead of
five, as shown in FIG. 29A through FIG. 29D. Like reference
numerals have been used to describe like components of inner
structure 33 and inner structure 33a. In this embodiment, four
inner sides 72a are monolithically formed from a single sheet of
material and interconnected by flanges 58a which are configured to
fold back upon themselves (see, e.g., FIG. 29A). One will
appreciate that the geometric layout of interconnected structure 93
is particularly well suited for nesting and shipping
in-the-flat.
[0208] This embodiment is particularly well suited for enameling
"in-the-flat", that is, a layer of enamel 97 may be applied to
interconnected structure 98 while the structure is substantially
two-dimensional and before the structure has been folded. In this
embodiment, the layer of enamel may be applied to the entire
structure including along and on the "troughs" 99 by dipping,
coating or other suitable means. Also, the enamel may be baked or
cured "in-the-flat". Upon folding, the only enamel exposed directly
to folding would be directly within the troughs and, as such, if
the enameled layer failed (e.g., cracking, breaking, etc.) the area
of failure would be within the overlapping portion of flange 58a,
isolated from the oven cavity and thus out-of-sight. The
overlapping portion may also be modified in accordance with the
above description and as shown in FIG. 13.
[0209] In various embodiments, the positioning structures are
formed with aesthetic factors in consideration. In one embodiment,
the positioning structures in the sheet of material forming the
housing are all formed on one side of the bend line such that they
form a smooth edge when the sheet is bent. Such configurations and
modifications are similar to those described in the above-mentioned
'216 application and '426 patent.
[0210] After the finishing station, the assembly system may also
include one or more inspection sites and other quality
control/quality assurance (QA/QC) processes. In an exemplary
embodiment, the assembly system includes an inspection station (not
shown) subsequent to the finishing station.
[0211] Several processes may be performed at various stations or
off-line as understood from the foregoing discussion. For example,
painting, construction of subassemblies, installing wiring and
functional equipment, and similar processes may be done at any
number of stations. Alternatively, many of the components may be
fully prepared at another location and added to the structure
somewhere on the assembly line.
[0212] As will be understood by one in the art, the assembly system
may be configured in many alternative ways. The three-dimensional
structure and method of the present invention allow great
flexibility in the assembly system. In particular, because the use
of tools, skilled labor, and heavy equipment is greatly minimized,
the manufacturing system can be configured in ways not possible
with conventional methods. For example, the bending station and
forming station may be separate and distinct from each other.
Additionally, most, if not all, of the assembly system described
may be moved out of the factory. In fact, in an exemplary
embodiment, workbench 32 and likewise bending station 93 are
portable.
[0213] Additionally, the exact assembly processes performed to
prepare the housing and inner structure depends on the
three-dimensional structure design as much as manufacturing
constraints. In an exemplary embodiment, the article to be
manufactured is an oven with a square housing and square inner
structure. Other articles of manufacture may have different design
shapes and configurations requiring changing the order and types of
process to be performed in keeping with the spirit of the
above-described method of manufacture.
[0214] The structure and method described has several advantages
over conventional structures. The structure and method described
allows for precision folding into accurate three-dimensional
structures.
[0215] Further, structures and methods in accordance with the
present invention can have superior strength relative to
conventional three-dimensional structures, including those formed
from two- dimensional sheets of material. For example, the inner
structure and housing can be configured so as to mutually reinforce
each other and provide added protection against buckling,
collapsing, and wobbling of the resulting structure. Moreover,
additional support can be located in selected regions of the
structure, for example, along the edges and comers. The structure
of the present invention can further provide additional material
thickness along the edges of the housing such that a rigid skeletal
structure is formed. In this manner, the three-dimensional
structure can have superior strength without unnecessary material
usage. The structure framework can also have increased resistance
to denting and failure.
[0216] By contrast to the structures and method of the present
invention, conventional assembly processes are more complex and
material-intensive. For example, conventional appliances are
typically formed by welding thick, heavy-gauge sheets. The sheets
must be thick to ensure that the sheets conform to a desired
posture for placement in fixtures prior to welding. The sheet and
process of the present invention allows for simple assembly of at
least semi-independent pieces. Each of the pieces can be easily
modified and adjusted. Fixturing problems are reduced or eliminated
by the ability to form positioning information in the sheet using
the principles described. Further, the components can be more
easily mixed and matched with other components. For example, an
entirely different appliance series can be manufactured by simply
changing the width of the material coil, cutting a different shape,
adjusting the timing of the stamping process, and/or adding fewer
or more panels in different positions.
[0217] As discussed above, application of treatments, finishing and
other functions are generally performed with better results and at
reduced costs when using sheets in-the-flat in comparison to
complex three-dimensional structures. The method of the present
invention also reduces capital costs (e.g. tool costs and fewer
unique parts), increases flexibility and modularity, and reduces
product planning and roll-out times among other benefits. Likewise,
energy usage may be decreased in part based on the greater
simplicity of the process and reduced use of heavy tools and
machinery.
[0218] Furthermore, it has been found that the use of relatively
thinner sheet material reduces heat flow from the heated
compartments. In comparison, conventional appliances typically
require heavy stock material for structural strength. Thus, heated
compartments not only use less material in accordance with the
invention, they also may have better performance characteristics.
In cases where increased heat transfer is desirable, apertures and
other features may be added to increase the flow of heat. In other
words, the thickness of the material to form the structure does not
need to be dictated by the strength requirements of the structure.
Rather, the structure may be customized for improved performance
with less wasted material.
[0219] Additionally, other aspects of the structure may be more
easily modified for various performance parameters in comparison to
conventional structures. For example, the overlap structure
described above has been found to reduce heat loss from heated
compartments. The amount and configuration of the overlap can be
adjusted to reduce the sealing of heat in the compartment.
[0220] For convenience in explanation and accurate definition in
the appended claims, the terms "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.
[0221] In many respects the modifications of the various figures
resemble those of preceding modifications and the same reference
numerals followed by subscripts "a", "b", "c", and "d" designate
corresponding parts.
[0222] 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.
* * * * *