U.S. patent application number 12/372493 was filed with the patent office on 2009-08-20 for system for low-force roll folding and methods thereof.
This patent application is currently assigned to Industrial Origami, Inc.. Invention is credited to Michael S. Binion, Max W. Durney.
Application Number | 20090205387 12/372493 |
Document ID | / |
Family ID | 40953849 |
Filed Date | 2009-08-20 |
United States Patent
Application |
20090205387 |
Kind Code |
A1 |
Durney; Max W. ; et
al. |
August 20, 2009 |
SYSTEM FOR LOW-FORCE ROLL FOLDING AND METHODS THEREOF
Abstract
A system for low-force roll folding effects bending of a
two-dimensional sheet material having one or more predetermined
fold lines into three-dimensional article. The system may include a
sheet material with bend-facilitating structure extending along a
length one or more of the predetermined fold lines, a stand of
rollers configured to effect bending of the sheet metal along the
bend-facilitating structure, and a driver to move the stand of
folding rollers relative to the sheet material along the length of
one or more of the predetermined fold lines to effect bending of
the sheet material along the bend-facilitating structure. A method
for low-force roll folding is also disclosed.
Inventors: |
Durney; Max W.; (San
Francisco, CA) ; Binion; Michael S.; (Cary,
NC) |
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: |
40953849 |
Appl. No.: |
12/372493 |
Filed: |
February 17, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61029322 |
Feb 16, 2008 |
|
|
|
Current U.S.
Class: |
72/178 ;
72/379.2 |
Current CPC
Class: |
B21D 11/08 20130101;
B21D 5/083 20130101; B21D 5/08 20130101 |
Class at
Publication: |
72/178 ;
72/379.2 |
International
Class: |
B21D 5/08 20060101
B21D005/08; B21D 31/00 20060101 B21D031/00 |
Claims
1. A method for low-force roll folding of a two-dimensional sheet
material having one or more predetermined fold lines into a
three-dimensional article, said method comprising: providing a
sheet material with bend-facilitating structure extending along a
length of one or more of said predetermined fold lines; providing a
stand of folding rollers configured to effect bending of said sheet
metal along said bend-facilitating structure; and moving said stand
of folding rollers relative to the sheet material along said length
of one or more of said predetermined fold lines to effect bending
of the sheet material along said bend-facilitating structure.
2. A method for low-force roll folding according to claim 1, said
method further comprising: driving the sheet material through said
stand of folding rollers.
3. A method for low-force roll folding according to claim 1, said
method further comprising: driving the sheet material through a
plurality of stands of folding rollers in order to effect a series
of incremental cross-sectional profiles upon the sheet
material.
4. A method for low-force roll folding according to claim 1, said
method further comprising: providing said sheet material with
bend-facilitating structure along a length of diverging
predetermined fold lines.
5. A method for low-force roll folding according to claim 1, said
method further comprising: providing said sheet material with
bend-facilitating structure along a non-linear length of
predetermined fold lines.
6. A method for low-force roll folding according to claim 1,
wherein said folding rollers are substantially cylindrical and roll
along the sheet material adjacent to but removed from said fold
lines.
7. A method for low-force roll folding according to claim 1,
further comprising: adjusting the rotational axes of said folding
rollers relative to one another in order to accommodate spring back
along said predetermined fold lines.
8. A method for low-force roll folding according to claim 1,
further comprising: manually rolling said stand of folding rollers
along said length of said predetermined fold lines.
9. A system for low-force roll folding of a two-dimensional sheet
material having one or more predetermined fold lines into
three-dimensional article, said system comprising: a sheet material
with bend-facilitating structure extending along a length one or
more of said predetermined fold lines; a stand of rollers
configured to effect bending of said sheet metal along said
bend-facilitating structure; and a driver to move said stand of
folding rollers relative to the sheet material along said length of
one or more of said predetermined fold lines to effect bending of
the sheet material along said bend-facilitating structure.
10. A system for low-force roll folding according to claim 9,
further comprising: a plurality of stands of folding rollers, each
stand configured to effect and incremental cross-sectional profile
upon the sheet material.
11. A system for low-force roll folding according to claim 9,
wherein said sheet material includes bend-facilitating structure
along a link of diverging predetermined fold lines.
12. A system for low-force roll folding according to claim 9,
wherein said sheet material includes bend-facilitating structure
along a nonlinear length predetermined fold lines.
13. A system for low-force roll folding according to claim 9,
wherein said folding rollers are substantially cylindrical and roll
line the sheet material adjacent to but removed from said fold
lines.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/029,322 filed Feb. 16, 2008, entitled SYSTEM FOR
LOW-FORCE ROLL FOLDING AND METHODS THEREOF, the entire contents of
which is incorporated herein for all purposes by this
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates, in general, to systems for low-force
roll folding, and more particularly to devices which may be used
for roll folding of sheets having bend-facilitating fold lines, and
methods for their use.
[0004] 2. Description of Related Art
[0005] Roll forming is a continuous bending operation in which a
two-dimensional sheet of material, for example, sheet metal is
passed through a series of rollers, each performing an incremental
amount of bending, until a particular cross-sectional profile of a
three-dimensional product or item is produced. A "flower pattern"
represents each incremental cross-sectional profile from flat
two-dimensional sheet metal to ultimate cross-sectional profile of
the three-dimensional product. Roll forming is generally used to
produce objects formed of sheet metal having straight,
longitudinal, and parallel bends.
[0006] A "stand" or set of rollers is required to produce each
incremental cross-sectional profile as well as the ultimate
cross-sectional profile of the product. Each stand includes
cooperating contoured rollers which impart incremental bending upon
the sheet metal as it passes through the stand, preferably without
changing the thickness of the material. One will appreciate that
roll forming machines are generally quite expensive due to the high
cost of fabricating the closely tolerant sets of rollers of each
stand for each incremental cross-sectional profile.
[0007] U.S. Pat. No. 2,127,618 to Reimenschneider illustrates an
exemplary automobile side rail produced by roll forming. Japanese
Patent Application No. 11-188426 illustrates an exemplary channel
member also produced by roll forming. Exemplars of machines
currently used for roll forming are described by U.S. Pat. No.
7,275,403 to Meyer and U.S. Pat. No. 7,243,519 to Chuang.
[0008] Again, one will appreciate that such roll forming machines
are generally quite expensive due to the high cost of fabricating
sets of rollers for each stand. Each set of rollers generally
require the use of hardened steels and other metals that are highly
machined with close tolerances to a respective incremental
cross-sectional profile.
[0009] In light of the foregoing, it would be beneficial to have a
forming system which overcomes the above and other disadvantages of
known apparatuses for bending sheet materials.
BRIEF SUMMARY OF THE INVENTION
[0010] One aspect of the present invention may be directed to a
method for low-force roll folding of a two-dimensional sheet
material having one or more predetermined fold lines into a
three-dimensional article. The method includes one or more of the
steps of providing a sheet material with bend-facilitating
structure extending along a length of one or more of the
predetermined fold lines, providing a stand of folding rollers
configured to effect bending of the sheet metal along the
bend-facilitating structure, and moving the stand of folding
rollers relative to the sheet material along the length of one or
more of the predetermined fold lines to effect bending of the sheet
material along the bend-facilitating structure.
[0011] The method may further include driving the sheet material
through the stand of folding rollers. The method may further
include driving the sheet material through a plurality of stands of
folding rollers in order to effect a series of incremental
cross-sectional profiles upon the sheet material. The method may
further include providing the sheet material with bend-facilitating
structure along a length of diverging predetermined fold lines. The
method may further include providing the sheet material with
bend-facilitating structure along a non-linear length of
predetermined fold lines. The folding rollers may be substantially
cylindrical and roll along the sheet material adjacent to but
removed from the fold lines. The method may further include
adjusting the rotational axes of the folding rollers relative to
one another in order to accommodate spring back along the
predetermined fold lines. The method may further include manually
rolling the stand of folding rollers along the length of the
predetermined fold lines.
[0012] Another aspect of the present invention is directed to a
system for low-force roll folding of a two-dimensional sheet
material having one or more predetermined fold lines into
three-dimensional article. Preferably, the system includes a sheet
material with bend-facilitating structure extending along a length
one or more of the predetermined fold lines, a stand of rollers
configured to effect bending of the sheet metal along the
bend-facilitating structure, and a driver to move the stand of
folding rollers relative to the sheet material along the length of
one or more of the predetermined fold lines to effect bending of
the sheet material along the bend-facilitating structure.
[0013] The system may further include a plurality of stands of
folding rollers, each stand configured to effect and incremental
cross-sectional profile upon the sheet material. The sheet material
may include bend-facilitating structure along a link of diverging
predetermined fold lines. The sheet material may include
bend-facilitating structure along a nonlinear length predetermined
fold lines. The folding rollers may be substantially cylindrical
and roll line the sheet material adjacent to but removed from the
fold lines.
[0014] The methods and apparatuses of the present invention(s) have
other features and advantages which will be apparent from or are
set forth in more detail in the accompanying drawings, which are
incorporated herein, and the following Detailed Description of the
Invention, which together serve to explain certain principles of
the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1a is an isometric view of an exemplary apparatus for
low-force roll folding a three-dimensional article from a
two-dimensional sheet material in accordance with various aspects
of the present invention. FIG. 1b is a schematic view of the
initial cross-sectional profile of the two-dimensional sheet
material. FIG. 1c is a schematic view of the final cross-sectional
profile of the three-dimensional article. FIG. 1d is a plan view of
the two-dimensional sheet material of FIG. 1b.
[0016] FIG. 2a is a plan view of another two-dimensional sheet
material prepared for low-force roll folding in accordance with
various aspects of the present invention. FIG. 2b is a perspective
view of a three-dimensional article formed with two-dimensional
sheet materials similar to that shown in FIG. 2a.
[0017] FIG. 3a is a schematic view of other incremental
cross-sectional profiles as a two-dimensional sheet material (top)
is roll folded into a three-dimensional article (bottom) in
accordance with various aspects of the present invention. FIG. 3b
is a schematic view of the incremental cross-sectional profiles of
FIG. 3a passing through respective sets of fold rollers.
[0018] FIG. 4a is a schematic view of other incremental
cross-sectional profiles as a two-dimensional sheet material (top)
is roll folded into a three-dimensional article (bottom) in
accordance with various aspects of the present invention. FIG. 4b
is a schematic view of the incremental cross-sectional profiles of
FIG. 4a passing through respective sets of rollers. FIG. 4c is a
schematic view of the incremental cross-sectional profiles of FIG.
4a passing through another respective set of rollers similar to
those shown in FIG. 4b.
[0019] FIG. 5a is a schematic view of the incremental
cross-sectional profiles of FIG. 4a passing through another
respective set of rollers similar to those shown in FIG. 4b. FIG.
5b is an enlarged cross-sectional view of a final set of rollers
shown in FIG. 5a, said final set of rollers configured to produce a
cross-sectional profile, shown in FIG. 5c to accommodate
spring-back resulting in the final cross-sectional profile of FIG.
5d. FIG. 5e is an enlarged detail of the rollers of FIG. 5b. FIG.
5f is a schematic side view of the rollers of FIG. 5b illustrating
adjustment of the upper roller in phantom.
[0020] FIG. 6a is a schematic view of incremental cross-sectional
profiles of another two-dimensional sheet material (top) passing
through respective sets of rollers to form a three-dimensional
article (bottom) in accordance with various aspects of the present
invention. FIG. 6b is an enlarged set of folding rollers shown in
FIG. 6a.
[0021] FIG. 7a is an isometric view of another exemplary apparatus
for low-force roll folding a three-dimensional article from a
two-dimensional sheet material in accordance with various aspects
of the present invention. FIG. 7b is an enlarged detail of the
apparatus of FIG. 7a
[0022] FIG. 8 is a plan view of another two-dimensional sheet
material similar to that shown in FIG. 7a, but prepared for
low-force roll folding along non-parallel and diverging fold lines
in accordance with various aspects of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] 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.
[0024] Turning now to the drawings, wherein like components are
designated by like reference numerals throughout the various
figures, attention is directed to FIG. 1a, which illustrates an
exemplary roll folding system generally designated by the numeral
30 that may be used to fold a two-dimensional sheet material 32
(see FIG. 1b and FIG. 1d) into three-dimensional article 33 (see
FIG. 1c). The roll folding system is designed to be used with
ductile sheet materials having engineered fold lines 35 which
facilitate bending along predetermined fold lines. As the sheet
material is guided through the machine along a predetermined path
of travel, its cross-sectional profile is gradually transformed
from a flat sheet into a three-dimensional article having a desired
cross-sectional profile.
[0025] In contrast to conventional roll forming machines, which
require a carefully crafted set of rollers for each stand
conforming with an incremental cross-sectional profile, the roll
folding system of the present invention may utilize simple roller
wheels, which need not conform with any particular cross-sectional
profiles. Accordingly, the roll folding system of the present
invention greatly reduces the capital costs of roll folding
equipment because it does not require costly machining of rollers
precisely conforming to cross-sectional profiles.
[0026] The roll folding systems in accordance with the present
invention are particularly suited for bending two-dimensional sheet
materials having engineered fold lines which utilize various fold
geometries and configurations including, but not limited to, those
disclosed by U.S. Pat. No. 6,481,259, U.S. Pat. No. 6,877,349 ,
U.S. Patent Application Publication No. US 2006/0021413 A1, U.S.
Pat. No. 7,152,449, U.S. Pat. No. 7,032,426, U.S. Pat. No.
7,152,450, U.S. Patent Application Publication No. US 2005/0005670
A1, U.S. Pat. No. 7,263,869, U.S. Pat. No. 7,222,511, U.S. Patent
Application Publication No. US 2005/0257589 A1, U.S. Patent
Application Publication No. US 2006/0213245 A1, U.S. Pat. No.
7,296,455, U.S. Patent Application Publication No. US 2006/0130551
A1, U.S. Provisional Patent Application No. 60/911,910, U.S.
Provisional Patent Application No. 60/974,466, U.S. Provisional
Patent Application No. 60/974,468, and U.S. patent application Ser.
No. 11/925,195, the entire contents of which patents and patent
applications are incorporated herein by this reference.
[0027] The roll folding systems of the present invention is
designed to take advantage of various aspects of manufacturing with
engineered fold lines. For example, accurate machine tool
tolerances are relatively less critical because the location of
desired fold lines are engineered into the sheets of material.
Accordingly, the roll folding systems of the present invention can,
but need not, take the form of a high-efficiency light-duty machine
which may be capable hundreds of thousands and/or millions of
cycles due to relatively minimal wear and tear. Special materials,
expensive and time-consuming machining, hardening, heat treatments,
and/or other costly processes may be reduced or avoided because the
need for precise machine tool tolerances is reduced. Instead, the
tolerances are built into the sheet of material whereby a less
expensive and lighter-duty roll folding may be utilized to fold a
two-dimensional sheet of material into its final shape, or in some
cases one or more intermediate shapes. As such, the present roll
folding systems may be constructed with milder steel, laser cut
parts and other relatively inexpensive components such as those
including mild steels, plastics, composites and/or other materials
typically considered to be too soft to be built for metal forming
equipment, as well as die cast and other relatively less precise
componentry. Of course, the foregoing does not necessarily preclude
heavy-duty construction using hardened steels. Rather, it allows
enhanced flexibility depending on factors such as duty cycle,
economy, weight, and the like.
[0028] One will appreciate, however, that the present roll folding
systems are also suited for bending other types of ductile sheet
materials about a fold line including, but not limited to, sheet
metal prepared with the above-mentioned engineered fold lines,
predetermined fold lines defined by scoring and/or other suitable
means.
[0029] One will appreciate that a number three-dimensional products
may be formed by the roll folding of the present invention which
include both relatively narrow flanges and relatively wide flanges.
For example, the three-dimensional products may include, but are
not limited to, various enclosure components, electronic chassis
components, automotive components, appliance components, transport
components, construction components, HVAC components, aerospace
components, and the like.
[0030] Returning to FIG. 1a, an exemplary roll folding system 30
generally includes a machine chassis 37 configured to support and
position various sub-assemblies of the roll folding system. For
example, upper receiving drive rollers 39 are rotatably supported
by the machine chassis in an otherwise conventional manner and
driven by a suitable drive means. Upper exiting drive rollers 40
are similarly mounted and driven on the machine chassis. Lower
receiving and exiting drive rollers 39', 40' are also provided in a
similar fashion. The drive rollers are configured to receive and
propel sheet material 32 through the roll folding system as the
roll folding system folds the sheet material into three-dimensional
article 33.
[0031] One or more guide rollers 42 may be provided to generally
support and guide the sheet material as it passes through the roll
folding system.
[0032] A number of "stands" 44 or sets of folding rollers 46 are
also provided to impart the folding force upon the sheet material.
The folding rollers may be spring loaded to apply a relatively
uniform force against the sheet material as the sheet material
passes by the folding rollers. The folding rollers are configured
and positioned to roll along continuous surfaces 47 of the sheet
material substantially parallel to or along respective fold lines
in order to impart folding force upon the sheet material as the
sheet material passes through the respective set of folding
rollers.
[0033] As noted above, sheet material 32 includes preformed
engineered fold lines and thus requires less force to effect
bending along the fold lines. Furthermore, as the preformed
engineered fold lines self identify precisely where the sheet
material will bend and in particular where a deformation will
occur, the folding rollers need only approximately position the
continuous surfaces to effect bending.
[0034] Furthermore, since the sheet material includes engineered
fold lines 35, the amount of force necessary to effect bending of
the sheet material is greatly reduced. In contrast to conventional
roll forming machines, which require a carefully crafted set of
hardened and/or relatively hard rollers for each stand of rollers
conforming with an incremental cross-sectional profile, the roll
folding system of the present invention may utilize simple
off-the-shelf roller wheels, which need not conform with any
particular cross-sectional profiles. For example, the roller wheels
may be formed of urethane, rubber, or other suitable materials that
are applicable to relatively low force environments. For example,
Delrin.RTM. skids may provide an alternative to the rollers for
applying force against the sheet material as it passes by each
stand. Accordingly, the roll folding system of the present
invention greatly reduces the capital costs associated with
conventional roll forming equipment because it does not require the
machining of rollers precisely conforming to cross-sectional
profiles.
[0035] One will appreciate that the light-duty nature of the
present roll folding system may facilitate roll folding of
pre-painted sheet materials wherein the rollers and/or skids would
effect little scuffing and/or scrubbing along the surface of the
sheet material as it passes through the stands. Also, one will
appreciate that relatively large-radii roller wheels may be
utilized, and may facilitate loading of, or receiving of the sheet
material into and through each stand.
[0036] In the illustrated embodiment, roll folding system 30
includes an upper series 49 and a lower series 51 of stands 44, in
which the two-dimensional sheet material 32 is fed to left-to-right
into roll folding system 30 and through the upper series of stands
to form an intermediate article 53, which intermediate article may
again be fed right-to-left into the roll folding system through the
lower series of stands to form the final three-dimensional article
33. The roll folding system is preferably configured to guide the
intermediate article from the upper series to the lower series of
stands by conventional means, for example, allowing the
intermediate article to drop or otherwise move down in the
direction of arrow D. The "out-and-return" configuration of the
roll folding system is particularly advantageous in that a single
operator may operate the roll folding system from a single position
(e.g., position P). One will appreciate, however, that a single
series of stands may be provided in which the sheet material moves
outwardly in a single direction.
[0037] In the illustrated embodiment, the upper series is provided
with four stands 44, that is four sets of rollers corresponding
with four incremental cross-sectional profiles, and the lower
series is provided with three stands 44' or three sets of rollers
corresponding with two additional incremental cross-sectional
profiles and the final cross-sectional profile of three-dimensional
article 33. One will appreciate, however, that one, two, three or
more stands may be provided to effect the desired amount of
bending.
[0038] In contrast to conventional roll forming technology, the
roll folding system of the present invention may also be used to
form three-dimensional articles having nonuniform cross-sectional
profiles. For example, FIG. 2a illustrates a sheet of material
having fold lines 35a that are not parallel but instead converge
toward one another. Such a configuration of fold lines may be used
to produce articles of varying cross-sectional width dimensions
such as the horn-shaped article 54 shown in FIG. 2b. As is shown in
FIG. 2a, the fold lines on either side may be parallel to one
another (see, e.g., fold lines 35a) or may converge toward one
another (see, e.g., fold lines 35a').
[0039] As shown in FIG. 1a, roll folding system 30 may be provided
with one or more tuning knobs 56 to adjust the of each stand 44 by
suitable means. One will also appreciate that a tuning knob may be
provided for each subset of stand rollers in order to independently
adjust the subset of rollers on each lateral side of the stand.
[0040] The roll folding system of the present invention is
particularly useful for folding sheet materials into a wide variety
of three-dimensional articles. For example, with reference to FIG.
3a and FIG. 3b, roll folding system 30 may be used to fold sheet
material 32b in to a three-dimensional article 33b in the form of a
channel-shaped closed box beam. In the illustrated embodiment,
eight stands 44b of rollers are utilized to flare each side of
sheet material 32b upwardly and inwardly to form a closed box beam
58, as shown in FIG. 3b. The uppermost stand gently flares the
outermost edge of sheet material 32b upwardly, while the next two
stands continue to flare the outermost edge upwardly and began to
flare inwardly while flaring inner sidewalls upwardly. The next
stand begins to guide the outermost edge inwardly, while the
remaining stands further guide the outermost edge and sidewalls to
close the box beam. As can be seen in this schematic series, the
rollers of each stand may be uniformly sized wheels which are
configured to roll upon the flat surfaces of sheet material 32b
between fold lines 35b.
[0041] One will appreciate that the orientation of folding rollers
may very widely depending upon the desired cross-sectional profile.
For example and with reference to FIG. 4a, the roll folding system
of the present invention may be utilized to create a double channel
beam 60. One will further appreciate, that a number of
configurations may be utilized to affect folding of a particular
desired cross-sectional profile, as can be seen in FIG. 4b and FIG.
4c. For example, each stand 44c of folding rollers 46c may be
rotatably mounted on parallel axes, as shown in FIG. 4b.
Alternatively, each stand 44d may include folding rollers 46d
rotatably mounted on orthogonal axes. One will appreciate that
limiting rotational axes to either horizontal or
perpendicular/vertical axes simplifies machine design. Also, by
positioning the wheels substantially perpendicular to the surface
of the sheet material, one may limit the amount of scrubbing or
scuffing of the folding rollers upon the sheet material.
[0042] In still a further embodiment of the present invention,
contoured folding rollers 61 may be utilized to impart folding
forces upon the sheet material, as shown in FIG. 5a, in which a
two-dimensional sheet material is also roll folded into a
three-dimensional article 33e (bottom). With reference to FIG. 5b
and FIG. 5e, the contoured folding rollers may be configured with a
cooperating recess 63 and protrusion 65 in order to over bend sheet
material 32e (see FIG. 5c) in order to accommodate spring-back
resulting in a desired cross-sectional profile (see FIG. 5d). One
will appreciate that other configurations may be utilized to effect
over-bending including the positioning of folding rollers. In this
embodiment, the contoured folding rollers are rotatably mounted on
parallel axes and, as such, may be easily adjusted relative to one
another. For example and as shown in FIG. 5f, one of the contoured
rollers may be adjusted "within plane" such that the axis of one
roller 61 may be slid back-and-forth relative to the axis of a
cooperating roller 61 ' in order to adjust the distance between
recess 63 and protrusion 65. In the illustrated embodiment, roller
61.5 may be slid back and forth within a horizontal plane to adjust
the amount of over-bending, that is, the amount of bending beyond a
desired angle in order to accommodate spring back. One will
appreciate that the rollers may be configured such that they are
adjustable by sliding or otherwise adjusted along an inclined plane
or along a vertical plane instead of a horizontal direction.
[0043] FIG. 6a is a schematic view of a series of incremental
cross-sectional profiles of yet another two-dimensional sheet
material passing through respective sets of rollers to form a
three-dimensional article 33f (bottom) in accordance with various
aspects of the present invention. In this embodiment, folding
rollers 46f are fixed relative to one another in a roller mount 67
but positioned in such a manner that the rollers follow along fold
lines 35f, 35f, 35f'. With such configuration, the folding rollers
impart folding forces upon sheet material 32f along the fold lines
and, as such, the configuration tends to follow the fold lines in
the sheet material due to the geometric constraints created by the
position of the fold lines. In one embodiment, the roller mount may
be in the form of a hand tool having a grip 68 in which case, an
operator may manually sweep a first roller mount along the length
of the sheet material to impart the first incremental
cross-sectional profile thereon, and follow by sweeping other
roller mounts to impart the subsequent incremental cross-sectional
profiles thereon, and ultimately, the final cross-sectional profile
thereon.
[0044] In another exemplary embodiment of the present invention,
roll folding system 30g is similar to roll folding system 30g
described above but it incorporates movable roller mounts in order
to fold a two-dimensional sheet material 32g into a
three-dimensional article 33g having compound curves as shown in
FIG. 7. Like reference numerals have been used to describe like
components of roll folding system 30 and roll folding system
30g.
[0045] In this embodiment, each stand 44g includes opposing roller
mounts 67g slidably supported by a machine chassis 37g such that
folding rollers 46g are allowed to move laterally in order to
effect bending and follow the lateral profiles of sheet material
32g Each roller mount is allowed to move up and down in order to
follow the basic curvature of the sheet material as the sheet
material is bent along fold lines 35g, as shown in FIG. 7a.
Accordingly, the roller mounts 67g and the respective stand folding
rollers 46g are limited to two degrees of freedom. The folding
rollers float in the sense that they may move up-and-down and
in-and-out, but they are fixed relative to the longitudinal length
of machine chassis 37g. As such, respective sets of folding rollers
may be provided to effect each incremental cross-sectional profile
as the two-dimensional sheet of material 32g passes through roll
folding system 30g. As the orientation of rollers mounted on each
roller mount is fixed relative to one another, and because an upper
roller and at a lower roller is aligned with respective inside
corners or valleys of the incremental cross-sectional profiles, the
set of rollers will closely follow along the path of the fold
lines. One will appreciate that the rollers may be configured such
that their orientation may vary in order to accommodate fold lines
that converge or diverge from one another such as those shown in
FIG. 8. Preferably springs or other suitable biasing means are
utilized to bias the roller mounts back to an initial position to
facilitate receipt of the sheet material between the respective
folding rollers.
[0046] One will appreciate that the roll folding system of the
present invention may be utilized in combination with other
conventional metalworking stations or processes. For example, the
present roll folding systems may be utilized with various
configurations that punch and cut off parts during otherwise
conventional continuous operations, such as cutting a part to
length when supplying coils are used to supply the sheet metal
"blanks" to the roll folding system. Further, various
configurations of stations may be utilized to add features such as
holes, notches, embossments, and/or shear forms by punching,
stamping, and or other known processes found in conventional roll
forming lines. For example, fastening structures 70 (see, e.g.,
FIG. 2a and FIG. 2b) may take the form of spring clips of the type
disclosed by U.S. Patent Application Publication No. US
2006/0277965 A1, and/or other integral fastening structure, which
structure may be stamped directly into the sheet metal either
before or after the sheet metal passes through the roll folding
system.
[0047] 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
exemplary embodiments with reference to the positions of such
features as displayed in the figures.
[0048] In many respects various modified features of the various
figures resemble those of preceding features and the same reference
numerals followed by subscripts "a", "b", "c", "d", "e", "f" and
"g" designate corresponding parts.
[0049] 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.
* * * * *