U.S. patent application number 14/084583 was filed with the patent office on 2014-10-30 for method for forming three-dimensional support structure.
This patent application is currently assigned to TESSELLATED GROUP, LLC. The applicant listed for this patent is TESSELLATED GROUP, LLC. Invention is credited to Gregory W. GALE.
Application Number | 20140323283 14/084583 |
Document ID | / |
Family ID | 38962600 |
Filed Date | 2014-10-30 |
United States Patent
Application |
20140323283 |
Kind Code |
A1 |
GALE; Gregory W. |
October 30, 2014 |
METHOD FOR FORMING THREE-DIMENSIONAL SUPPORT STRUCTURE
Abstract
A three-dimensional support structure is provided and includes a
single sheet of material that is folded into a repeating pattern of
cells. Each of the cells is formed by first and second spaced-apart
endwalls and first and second sloped sidewalls spanning between the
endwalls. Each endwall comprises two plies of material while each
sidewall comprises a single ply of material. The first and second
sidewalls are adjoined at a folded edge. The cells are aligned such
that the first endwall of one cell from the repeating pattern abuts
the second endwall of an adjacent cell of the repeating pattern to
form a four-ply wall of the material. A first liner may be attached
to a first side of the folded material and a second liner may be
attached to a second side of the folded material.
Inventors: |
GALE; Gregory W.; (Napa,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TESSELLATED GROUP, LLC |
Napa |
CA |
US |
|
|
Assignee: |
TESSELLATED GROUP, LLC
Napa
CA
|
Family ID: |
38962600 |
Appl. No.: |
14/084583 |
Filed: |
November 19, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13487107 |
Jun 1, 2012 |
8585565 |
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14084583 |
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|
12794513 |
Jun 4, 2010 |
8192341 |
|
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13487107 |
|
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|
11459550 |
Jul 24, 2006 |
7762938 |
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12794513 |
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Current U.S.
Class: |
493/405 |
Current CPC
Class: |
Y10T 428/24702 20150115;
Y10T 428/24215 20150115; Y10T 428/24669 20150115; Y10T 428/24711
20150115; Y10T 428/24628 20150115; E04C 2/3405 20130101; Y10T
428/2419 20150115; Y10T 428/24719 20150115; Y10T 428/24149
20150115; Y10T 428/24264 20150115; Y10S 493/966 20130101; Y10T
428/24727 20150115; Y10T 428/24694 20150115; Y10T 428/24686
20150115; E04C 2002/3438 20130101; Y10T 428/24661 20150115; B31F
1/0009 20130101; E04C 2/08 20130101; B65D 65/406 20130101; Y10T
428/24645 20150115; Y10T 428/24678 20150115; Y10T 428/12417
20150115; E04C 2002/3444 20130101; B32B 3/12 20130101 |
Class at
Publication: |
493/405 |
International
Class: |
B31F 1/00 20060101
B31F001/00 |
Claims
1-21. (canceled)
22. A method for creating a three-dimensional support structure
having opposite first and second surfaces, comprising providing a
single sheet of foldable material having a first crease path that
is linear when the sheet of material is unfolded and a plurality of
first, second and third chevrons spaced apart along the first
crease path and extending parallel to each other when the sheet of
material is unfolded wherein each chevron includes first and second
chevron legs that intersect each other at the first crease path and
wherein the first crease path has a first path segment extending
between the first chevron and the second chevron and a second path
segment extending between the second chevron and the third chevron,
folding the sheet of foldable material along the second chevron and
along the second path segment in a first direction and along the
first path segment in a second direction opposite to the first
direction so that each second chevron forms a ridge disposed in the
first surface of the support structure.
23. The method of claim 22, further comprising compressing the
sheet of foldable material so that each first chevron leg and
second chevron leg moves towards the first crease path so as to
form a four ply wall in the sheet of foldable material.
24. The method of claim 22, wherein the compressing step includes
compressing the sheet of foldable material so that the first and
second chevron legs of each chevron extend substantially parallel
to each other.
25. The method of claim 24, wherein the compressing step includes
compressing the sheet of foldable material so that the first and
second chevron legs of each chevron extend substantially parallel
to the first crease path.
26. The method of claim 22, wherein each of the first and second
chevron legs of the second chevron has an end and wherein the sheet
of foldable material includes a line segment extending from the end
of each of the first and second chevron legs of the second chevron
and wherein the folding step includes folding the sheet of foldable
material along the line segments in the first direction so that the
line segments form part of the ridge disposed in the first surface
of the support structure.
27. The method of claim 26, wherein each of the first and second
chevron legs of the first and third chevrons has an end and wherein
the sheet of foldable material includes a line segment extending
from the end of each of the first and second chevron legs of the
first and third chevrons and wherein the folding step includes
folding the sheet of foldable material along the first and second
chevron legs of the first and third chevrons and respective line
segments in the second direction so that the first and second
chevron legs of the first and third chevrons and respective line
segments form a ridge disposed in the second surface of the support
structure.
28. The method of claim 26, wherein the line segments are collinear
when the sheet of material is unfolded.
29. The method of claim 22, wherein the first and second chevron
legs of the second chevron are equal in length.
30. The method of claim 29, wherein the first and second chevron
legs of the first and third chevrons are equal in length.
31. The method of claim 22, wherein the first and second chevron
legs of the first, second and third chevrons are equal in
length.
32. The method of claim 22, wherein each first chevron leg of the
first, second and third second chevrons has an end and wherein the
sheet of foldable material includes a first additional first crease
path extending between the ends of the first chevron legs and
wherein each second chevron leg of the first, second and third
second chevrons has an end and wherein the sheet of foldable
material includes a second additional first crease path extending
between the ends of the second chevron legs.
33. The method of claim 32, wherein the first additional first
crease path and the second additional first crease path each extend
parallel to the first crease path when the sheet of material is
unfolded.
34. The method of claim 32, wherein the first additional first
crease path and the second additional first crease path each
includes an additional first path segment extending between the
first chevron and the second chevron and an additional second path
segment extending between the second chevron and the third chevron,
and wherein the folding step includes folding the sheet of foldable
material along each additional first path segment in the first
direction and along each additional second path segment in the
second direction.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation application of Ser. No.
13/487,107 filed Jun. 1, 2012, now U.S. Pat. No. 8,585,565, which
is a continuation application of Ser. No. 12/794,513 filed Jun. 4,
2010, now U.S. Pat. No. 8,192,341, which is a continuation
application of Ser. No. 11/459,550 filed Jul. 24, 2006, now U.S.
Pat. No. 7,762,938, the entire content of each of which is
incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] The present invention relates to structural products. More
specifically, the present invention relates to three-dimensional
support structures.
BACKGROUND OF THE INVENTION
[0003] Various sandwich-type structures currently exist that are
used in numerous industries as components of products. These
structures suffer from many drawbacks in strength, rigidity,
weight, and durability.
[0004] For example, at the present time, structures for use in
packaging typically use corrugated board, to form, for example,
corrugated boxes. Corrugated board is a sandwich of one or more
liner sheets adhered to a fluted, inner-medium. Combinations of
liners and flute configurations are used to generate variations of
corrugated board. The weights of material used to form the liners
and medium can be adjusted to achieve desired bursting and stacking
strength. However, many disadvantages to corrugated board exist.
For example, corrugated board has a load bearing capacity along
only a single axis (the y-axis). Additionally, to increase the
width of the corrugated structure, yet retain structural stability,
a multi-wall corrugated board format is often used. Typically a
one, two, or three wall format corrugated board is used depending
upon the width needed. Delamination of attached liners adhered to
the flutes is also a problem. Namely, the flutes comprise flexible
contact points resulting in an uneven application of an adhesive
between the flute and the liner. Likewise, the uneven application
and flexible contact points can lead to uneven surfaces for
printing inks.
[0005] Corrugated board is also prone to warping during
manufacture, which is a prominent issue within the industry.
Moreover, the mechanical function of corrugated board and the
limitations of existing machinery (such as corrugators) allow for
only a narrow range of board types. Another disadvantage of
corrugated board is that its preparation requires the application
of steam in order to form the curved flutes. The use of steam
involves the consumption of water as well as the requirement to
manage the waste water within the corrugator system. Drying of the
"steamed" corrugated board is also required. Drying of the steamed
medium paper occurs within the forming rolls that provide the flute
profiles. These rolls are sometimes heated to approximately 700
F..degree. and in essence are pressing/ironing the fluted shape
into the medium. As a result additional energy, time, and expense
is incurred in the preparation of a product that is not very
durable.
[0006] Various three-dimensional metal and plastic, and other
composite material structures also exist. For example, structures,
such as fuselages, wings, bulkheads, floor panels, construction
panels, refrigerators, ceiling tiles, intermodal containers, and
seismic walls are often formed by corrugated metal or plastic
sandwich structures or hexacomb products. Unfortunately, such
structures have significant weight or mass associated with the
structure, and typically involve a multi-piece core which requires
welding or soldering, or other adhesives for assembly. Moreover,
current metal and plastic structures often flex or curve along the
x-axis, making it difficult to form a rigid structure. These
structures are also prone to create anticlastic curvature. As a
result, these structures are often costly, contain numerous
components, do not have sufficient rigidity, and are often
heavy.
[0007] In view of the foregoing, there is a need in the art for a
three-dimensional support structure that will overcome the
foregoing deficiencies.
BRIEF SUMMARY OF THE INVENTION
[0008] An improved three-dimensional support structure is provided
and includes a single sheet of material that is folded into a
repeating pattern of cells. Each of the cells is formed by first
and second spaced-apart endwalls and first and second sloped
sidewalls spanning between the endwalls. Each endwall comprises two
plies of material while each sidewall comprises a single ply of
material. The first and second sidewalls are adjoined at a folded
edge. The cells are aligned such that the first endwall of one cell
from the repeating pattern abuts the second endwall of an adjacent
cell of the repeating pattern to form a four-ply wall of the
material. A first liner may be attached to a first side of the
folded material and a second liner may be attached to a second side
of the folded material.
[0009] Other aspects, features and details of the present invention
can be more completely understood by reference to the following
detailed description in conjunction with the drawings, and from the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will now be described, by way of example, with
reference to the attached drawings, of which:
[0011] FIG. 1 is a perspective view of a structure, partially cut
away, incorporating the structure of the present invention.
[0012] FIG. 2 is a cross-sectional, perspective view, partially cut
away, of the structure of FIG. 1 taken along the line 2-2 of FIG.
1.
[0013] FIG. 3 is a cross-sectional, perspective view, partially cut
away, of the structure of FIG. 1 taken along the line 3-3 of FIG.
2.
[0014] FIG. 4 is a perspective view of the structure incorporated
into the structure of FIG. 1 taken along the line 4-4 of FIG.
1.
[0015] FIG. 5 is a perspective view of the structure incorporated
into the structure of FIG. 1 taken along the line 5-5 of FIG.
1.
[0016] FIG. 6 is a plan view of an unfolded sheet of material as
creased to form the structure of FIG. 4.
[0017] FIG. 7 is a perspective view of the sheet of material of
FIG. 6 partially folded to form the structure of FIGS. 4 and 5.
[0018] FIG. 8 is a perspective view of a portion of the sheet of
material of FIG. 6 in its partially folded state.
[0019] FIG. 9 is a perspective view of a portion of the sheet of
material of FIG. 6 in a fully folded state to form a portion of the
structure of FIG. 4 shown by the dashed area 9-9 of FIG. 4.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] The present invention is embodied in a three-dimensional
support structure. As will be seen by the disclosure and drawings,
the structure set forth herein is structurally superior to existing
products, such as container board, or corrugated board, and current
sandwich-type metal and plastic structures. The structure set forth
herein also requires less material, and eliminates significant
amounts of process energies currently required for
manufacturing.
[0021] In a preferred embodiment, the three-dimensional support
structure of the present invention is for use in the manufacture
and composition of packaging materials and other support materials,
including but not limited to fuselages, wings, bulkheads, floor
panels, construction panels, refrigerators, ceiling tiles,
intermodal containers, and seismic walls. However, it is
appreciated that the structure disclosed herein has other
applications where its advantages may be applied.
[0022] The three-dimensional support structure 10 disclosed herein
comprises a medium or material 12 folded to form a durable
structure. In a preferred embodiment, the tessellated medium 12
comprises flexible member, including but not limited to, paper,
metal, plastic, composite, or material of similar composition. The
material may be of varying grade and thickness, as is currently
commercially available, and is based upon user preferences.
[0023] FIG. 1 demonstrates a view of a material, the structure 10,
of the present invention. The structure 10, in its fully assembled
state, comprises a folded, tessellated medium 12 and optionally one
or more liners 14 attached thereto.
[0024] As can be seen from FIGS. 1-5, the structure 10 comprises a
folded, tessellated medium 12 folded in multiple directions to form
vertical structures in three planar orientations, namely, the x-,
the y- and the z-axis. Preferably, positioned and attached to the
folded medium 12 is at least one liner 14. Preferably, the liner 14
is attached to a first side or surface 16 of the folded medium 12.
A liner 14 may also be attached to the second side or surface 18 of
the folded medium 12. Preferably, a plurality of liners 14 are
attached to the folded medium 12. More preferably, the medium 12 is
sandwiched between a pair of liners 14. The liner 14 on the second
surface 18 is positioned in a plane parallel to the liner 14
positioned on the first surface 16. Additional liners 14 may also
be attached in various locations on the various planes and
structures of the folded medium 12, depending upon the user's
desire, without departing from the overall scope of the present
invention.
[0025] The liner 14 is made from any suitable material 17, such as
a flexible membrane of paper, metal, plastic or composites, and may
be of a material and form commonly available for the relevant
application. The liner 14 is preferably planar, and may be of any
dimension. Preferably, the liner 14 corresponds in size to the
width and length (the x- and y-axis) of the folded medium 12, but
variations on the size of the liner 14 do not depart from the
overall scope of the present invention.
[0026] As discussed, the medium 12 is formed from a single sheet of
material 19 that is folded into a repeating pattern of cells 20
(see FIGS. 4 and 5). Each of the cells 20 is formed by, and
comprises first 22 and second 24 spaced-apart endwalls and first 26
and second 28 sloped sidewalls spanning between the endwalls. Each
of the endwalls 22, 24 comprises two plies of the material 12 and
each of the sidewalls 26, 28 comprises a single ply of the material
12. The first 26 and second 28 sidewalls are adjoined at a folded
edge 30. The cells 20 are further aligned so that the first endwall
22 of one cell 20 from the repeating pattern abuts the second
endwall 24 of an adjacent cell 20 from the repeating pattern to
form a four-ply wall 32 of the material 12. Each of the repeating
cells 20 form opposite first 16 and second 18 surfaces having a
recess or valley 46 therein. Accordingly, the folded medium 12
forms one or more wall structures 32, or rails, for support of the
liner 14, and preferably forms a rigid support. The top 34 of the
rails or four-ply wall 32 as well as the top edges of 30 support
the liner 14 thereon.
[0027] Each two-ply portion 36 of the material 12 of each of the
first 22 and second 24 endwalls joins at a top fold 38. Two
adjacent top folds 38 comprise the top of the rail, or four-ply
wall 32, that is part of the first surface 16 to which a liner 14
may be attached and part of the second surface 18 to which a liner
14 may be attached. In addition, the first surface 16 (and/or
second surface 18) serves as a platform for supporting an adhesive,
or provides a surface for welding or soldering, that secures the
liner 14 to the surface. Accordingly, the two adjacent two-ply
folds 36 form part of a support rail 32, the top 34 of which
extends along the first surface 16 and along the second surface 18.
Each substantially continuous four-ply wall 32 is formed from a
plurality of longitudinally disposed, four-ply wall segments 40
(see FIGS. 4 and 9). As indicated, these four-ply wall segments 40
are formed by the folding of the medium 12, resulting in the
repeating pattern of cells 20, each cell 20 formed in part by a
two-ply wall segment 42, and a side wall 26, 28 of each adjacent
pair of cells 20 forming the four-ply wall segment 40. The pattern
results in the formation of at least one, but preferably a
plurality of, parallel extending "double" ridges or rails 32 which
are four-plies thick from the folding of the single-ply medium 12.
As can be seen in FIG. 4 and FIG. 5, the plurality of substantially
continuous four-ply walls 32 extend parallel to each other.
[0028] Each of the two-ply wall segments 42 is formed from material
12 having a fold 44 extending longitudinally along the two-ply wall
segment 42, as shown in FIG. 5. As can be seen from a comparison of
FIGS. 6 and 7 with FIGS. 4 and 5, as the material folds at the
two-ply wall folds 44, these two-ply wall segments 42 are formed
and further positioned adjacent to additional two-ply wall segments
42 to form the cells 20 and four-ply wall segments 40 described
herein.
[0029] The pattern of repeating cells 20 forms a structure 10
having a plurality of columns, or four-ply walls 32, and recesses
46 formed from the plurality of cells. Namely, the single sheet of
material 19 forms the substantially continuous four-ply wall 32 of
the material, described above, between each adjacent pair of
columns and recesses. Each recess is formed, in part, by the
spaced-apart four-ply wall segments 40.
[0030] In addition to the four-ply wall structure 32, the cells 20
formed comprise a repeating pattern of ascending facets or sloped
sidewalls 28 and descending facets or sloped sidewalls 26 (see
FIGS. 1-5). The combination of each adjacent ascending facet or
sloped sidewall 28 and descending facet or sloped sidewall 26 forms
an apex, or peak 30, and a valley or recess 46. Specifically, a
recess or valley 46 is formed by facets 26 and 28 and a pair of
adjacent four-ply wall segments 40 or two-ply wall segments 42.
Likewise, the peak 30 is formed by facets 26, 28 and at a peak fold
88. Adjoining facets 26 and 28 meet at the top at a ridge or peak
30, the peak fold 88, and at the bottom or base of the valley 46,
the valley fold 90. The peaks or ridges 30 and valleys 46 are
perpendicular to the four-ply wall structure 32. Accordingly, the
architecture of the folded medium 12 is comprised of a repeating
pattern of facets 26, 28 that are angled to follow a contoured
path.
[0031] To form the structure 10 set forth in FIGS. 1-5, the
material 12 must be folded from a substantially flat, planar state
(see FIG. 6). The tessellated medium 12 herein changes in three
directions as it is folded from its planar, unfolded state, as
shown in FIG. 6, into the form shown in FIGS. 4 & 5.
Specifically, the medium 12 increases in height (the z-axis), while
decreasing in both length (the x-axis) and in width (the
y-axis).
[0032] In further detail, referring to FIG. 4, three structural
planes of a folded tessellated medium 12 exist, including the
x-axis, the y-axis and the z-axis. Once the tessellated medium 12
folds into its designated form, the vertical walls 32 extend in the
y-axis. These walls are the four-ply thick walls 32 that
effectively create a continuous rail. This four-ply structure 32,
which is rigid, provides substantial strength to the
three-dimensional support structure 10. Specifically, a vertical
fold 44 as provided, due to the four-ply wall structure, is not a
flexible contact point and is thus quite strong. Preferably, a
plurality of rows of parallel ridges 34 formed by the top of the
wall structure 32 are created. As can be seen in FIGS. 4 and 5,
these top 34 of rails 32 exist on two of the two major surfaces 16,
18 of the folded material. Likewise, the medium 12, in its folded
state, also comprises cells 20 on two major surfaces 16, 18 of the
folded medium 12.
[0033] The folded medium 12 provides a unique platform for
application of an adhesive, or for welding or soldering.
Specifically, the rows of four-ply structures 32, 40 provide
superior adhesion surfaces. For example, an adhesive, such as corn
starch and other adhesives commonly used for packaging structures
currently commercially available, is applied between the top
portion 34 of the four-ply wall structure 32 and the liner 14, and
secures the liner 14 in position on the folded tessellated medium
12. Likewise, the top portion 34 of the four-ply wall structure 32
and the liner 14 may be welded, soldered, or otherwise fused
together by means commonly used to attach two materials, such as
plastic or metal, together. Namely, when the tessellated forms are
folded, the plurality of parallel ridges 34 that are created
provide adhesion or welding or soldering surfaces. When adhesive is
used, the adhesive is preferably applied to the apex of the folds
44 for attaching the liner 14. Moreover, four-plies of material
provide a platform for receiving and retaining an adhesive,
increasing, and preferably doubling, the surface for adhesive
application, thereby minimizing delamination issues. The same
location would also be used for welding or soldering. Additionally,
small pockets 48 are formed between the parallel two-ply rails 42
that make up the four-ply rail structure 34 to capture additional
adhesive.
[0034] The cells 20 on each of the two major surfaces 16, 18 of the
medium 12 also add certain advantages. For instance, when one or
more liners 14 are bonded to the surface or surfaces 16, 18, the
cells 20 are closed, sealing air within each cell. As a result,
these cells 20 provide superior insulation qualities for thermal
applications, such as may be used in the food industry or, for
example, pizza boxes.
[0035] FIG. 6 shows a plan view of an unfolded tessellated medium
12, which when folded, forms the structure of FIGS. 1-5. As
indicated, the medium 12 herein is folded, rather than curved. To
accommodate same, creases or scores exist where the folding is to
take place. The unfolded tessellated medium 12 preferably contains
a repeating pattern of scores or creases that comprise the "fold
lines" of the tessellated medium 12. In broad terms, the contour
path for the tessellated medium is comprised of a sheet of material
19 having a plurality of first crease paths 59, 61 extending
parallel to each other and a plurality of second crease paths 60,
68 extending parallel to each other and intersecting the first
crease paths 59, 61. Each first crease path 59, 61 is formed from a
plurality of first path segments 63. Each second crease path 60, 68
is formed from a repeating pattern of first and second chevron legs
50, 52 and a straight line or leg 56 extending from a free end 65
of one of the first and second chevron legs 50, 52. The two legs or
lines of the chevron are equal in length and typically angled
120.degree.. The straight line extends from either line end. The
third line may be of any length. Each second crease path 60 is
foldable in an opposite direction from the adjacent second crease
path 68. This results in the formation of an alternating pattern of
ridges or peaks 30 and valleys 46 as the sheet of material 19 is
folded. Each of the first crease paths 59, 61 are straight lines
extending between the ridges 30 and valleys 46 of adjacent second
crease paths 60, 68 to form a pattern of facets 80, 82, 84 on the
first surface 49 of the sheet of material 19. The sheet of material
19 is foldable along the first and second crease paths 59, 61, 60,
68 to form a three dimensional support structure 10. The three
dimensional support structure 10 extends in a plane, partially
shown in dotted lines in FIG. 5 and identified therein by letters
A'-A'', characterized by a repeating pattern of normal walls, or
end walls 22, 24, formed by the facets 80, 82 between the chevron
50, 52 and inclined walls 26, 28 formed by the facets 84 between
the straight lines or third legs 56. The normal walls 22, 24 extend
perpendicular to the plane A'-A''. The inclined walls 26, 28 are
inclined relative to the plane A'-A''.
[0036] The normal walls 22, 24 comprise a wall 32 having four plies
of the sheet of material 19. A liner 14 may be attached to the
three dimensional support structure 10 at the top 34 of the
four-ply wall 32.
[0037] The scoring pattern of the planar structure discussed above
is explained in further detail hereinbelow. For purposes of
discussion only, the fold lines of the medium 12 will described as
"legs", however, any designation would be acceptable for the
purposes provided.
[0038] Referring to FIGS. 6-9, in a preferred embodiment, the
material 12 comprises a first leg 50 and a second leg 52 forming
the first chevron. The first leg 50 and second leg 52 are
preferably of equivalent length. A first angle 54 exists between
the first leg 50 and the second leg 52. The angle 54 preferably
comprises an angle of 120.degree.. A third leg 56 extends from the
second leg 52, and as shown in the Figures is of a greater length
than the first and second legs, but may be of any length to
accommodate manufacturing preferences. The third leg 56 extends
from the second leg 52 at a second angle 58 of 150.degree.. The
series of first 50, second 52, and third 56 legs comprises the
structure that forms a repeating pattern of the medium 12 described
above.
[0039] The third leg 56 of the first pattern 60 60a of the second
crease path 60 is connected to the first leg 50 of the adjacent or
second pattern 62 of the second crease path 60 along the y-axis,
the third leg 56 of the second pattern 62 is connected to the first
leg 50 of the adjacent or third pattern 64 of the second crease
path 60 along the y-axis, and so forth. A third angle 66, which is
between the third leg 56 of the first pattern 6060a and the first
leg 50 of the adjacent or second pattern 62, comprises an angle of
150.degree. opposite the second angle 58.
[0040] Connecting the repeating adjacent pattern of the second
crease path 60 to a parallel repeating pattern of the second crease
path 68 in the x-axis is a plurality of additional legs. Namely, a
fourth leg 70 extends at a fourth angle 72 of 60.degree. from the
first leg 50 to connect the first leg 50 of the first pattern 60a
of the second crease path 60 with a corresponding first leg 50 of
an adjacent parallel pattern 60a of the second crease path 68 in
the x-axis. A fifth leg 74 extends from the apex of the second
angle 54 on the first pattern 60a of the second crease path 60 to
the apex of the second angle 54 of the adjacent parallel pattern
60a of the second crease path 68 in the x-axis. A sixth leg 76
extends at a fifth angle 78 of 90.degree. from the third leg 56 on
the first pattern 60a of the second crease path 60 to the
corresponding point on the third leg 56 of the adjacent parallel
pattern 60a of the second crease path 68 in the x-axis. As with the
foregoing, this combination forms a repeating pattern.
[0041] The combination of these adjacent and parallel repeating
patterns of legs in the x- and y-axis, and their corresponding
angles, form the architecture of the tessellated medium 12.
Accordingly, as shown in FIG. 8, the first leg 50 of the first
pattern 60 60a of the second crease path 60 and the first leg 50 of
a second, parallel pattern 60a of the second crease path 68 in the
x-axis are linked by the fourth leg 70 and the fifth leg 74,
defining a first facet 80. Likewise, the second leg 52 of the first
pattern 6060a of the second crease path 60 and the second leg 52 of
the second, parallel pattern 60a of the second crease path 68 in
the x-axis are linked by the fifth leg 74 and the sixth leg 76,
defining a second facet 82. The third legs 56 of corresponding
parallel patterns 60a of the second crease paths 60, 68 in the
x-axis are linked by the sixth leg 76 and a fourth leg 70 of an
adjacent pattern 62, defining a third facet 84. These three facets
80, 82, 84 repeat in both the y-axis (repeating in series as 80,
82, 84) and in the x-axis (repeating as the identical facet) (see
FIG. 6).
[0042] Any number of repeating facets 80, 82, 84 may be used to
form the material comprising the three-dimensional support
structure 10. Preferably, the size of the three-dimensional support
structure is defined by the number of facets, the size of the
facets, or the legs creating the facet, and the desired size of the
structure to be created by the folded tessellated medium.
[0043] As described, the scores, or legs, of the tessellated medium
12 serve to assist in folding the medium 12 into the structure
shown in FIGS. 1-5. As the medium 12 is folded (see FIG. 7), the
scores cooperate to form a series of peaks 30 and valleys 46 in the
medium 12 ultimately resulting in the repeating pattern of cells 20
described herein and shown in FIGS. 3 & 4. For purposes of
description herein, the folds that form peaks, generally, will be
described as "peak" folds 88, while the folds that form valleys,
generally, will be described as "valley" folds 90. However, these
designations are merely provided for purposes of description
herein, and other designations would be acceptable for the purposes
provided.
[0044] In each repeating pattern 60a of the second crease path 60,
the score line of the subsequent, adjacent parallel pattern 60a of
the second crease path 68 is oriented to fold in the opposite
direction to the pattern 60a of the second crease path 60. This
results in an alternating pattern of ridges or peaks 30 and valleys
46. As shown in FIG. 7, the score lines of the fourth leg 70, the
fifth leg 74 and the sixth leg 76 form straight lines extending
between the peak folds 88 of the ridges 30 and the valley folds 90
of the valleys 46 of the adjacent patterns 60a of the second crease
paths 60, 68 to form a pattern of facets 80, 82, 84 on the first
surface 49 of the medium 12. For example, the fourth leg 70 may be
scored to form a valley fold 90. The fifth leg 74 (which defines
the second facet 82, as described above) is scored to form a peak
fold 88. The sixth leg 76 (which defines the third facet 84, as
described above), like the fourth leg 70, is the scored to form a
valley fold 90. As a result, a peak or apex is created between the
facets 80, 82, 84. In the adjacent parallel pattern 60a of the
second crease path 68 to the first pattern 60a of the second crease
path 60 along the x-axis, these score lines are oriented for
folding in the opposite direction to those set forth in the
previously described pattern.
[0045] Similarly, the legs of sequential parallel patterns 60a of
the second crease paths 60 and 68, and in particular, each of the
first 50, second 52, and third 56 legs, in sequential patterns
along the x-axis, are oppositely scored so that each leg 50, 52, 56
in the pattern of the second crease path 60 folds in a direction
opposite to the identical leg in the parallel pattern of the second
crease path 68. In other words, with the exception of the outer
edge 86 or end of the pattern, the first leg 50 of the pattern 60a
of the second crease path 60 comprises a valley fold 90, while the
first leg 50 of the pattern 60a of the second crease path 68
comprises a peak fold 88. The first leg 50 of the pattern 60a of
second crease path 92 forms a valley fold 90. As a result, a peak
is created, the apex of which is the first leg 50 of the pattern
60a of second crease path 68. The first 50, second 52 and third 56
legs of the parallel pattern, along the y-axis, maintain the same
fold orientation throughout the repeating pattern 60, 62, 64. Only
the legs in the parallel patterns along the x-axis alternate in
fold orientation. Thus, the repeating adjacent pattern of first 50,
second 52, and third 56 legs along the y-axis may all comprise an
peak fold 88, or alternatively, may all comprise a valley fold 90
orientation.
[0046] In addition to the varying fold orientations, as the medium
12 is folded, the first angle 54 narrows, resulting in slopes or
facets 80, 82 of increasing steepness. The fold may be continued
until the first angle 54 reaches approximately 0.degree. (the angle
being limited by the width of the material used). Upon reaching
this approximately 0.degree. angle, the faces of the first 80 and
second 82 facets formed between a first repeating pattern 60a of
the second crease path 60 and first repeating pattern 60a of the
second crease path 68 are in substantial contact with one another
(see FIG. 9). At the same time, the first 80 and second 82 facets
formed between the parallel pattern 60a of the second crease path
68 and parallel pattern 60a of an additional crease path,
identified by 92, in the x-axis fold to face away from one another.
The first 80 and second 82 facets of immediately parallel repeating
patterns in the x-axis form the four-ply wall structure 32
described herein. Namely, the first facet 80 between first parallel
patterns 60a of crease paths 60 and 68 and the first facet 80
between first parallel patterns 60a of crease path 68 and crease
path 92 form a first two-ply wall segment 42, while the second
facet 82 between first parallel patterns 60a of crease paths 60 and
68 and the second facet 82 between first parallel patterns 60a of
crease paths 68 and 92 form a second two-ply wall segment 42. The
first two-ply wall segment 42 is formed by a peak fold 88 of the
medium 12 at the first leg 50. The second two-ply wall segment 42
is formed by a peak fold 88 of the medium 12 at the second leg 52.
The combination of the first two-ply wall segment 42 and the second
two-ply wall segment 42, in the folded state with the first angle
54 at approximately 0.degree. forms the four-ply wall segment
40.
[0047] As alluded to above, during folding of the medium 12, the
angles between facets on the crease paths 60, 68 of parallel
repeating patterns 60a, in the x-axis also change. Namely, as the
material is folded, the angle increases or decreases in degrees at
the first leg 50, the second leg 52, and the third leg 56.
Referring to FIG. 7, the angle 94 defined at the first leg 50 by
the first facets 80 of the parallel patterns 60a in the x-axis (as
well as the angle 96 defined at the second leg 52 by the second
facets 82 of parallel patterns 60a) changes from 180.degree. (in
the medium's completely unfolded state (FIG. 6)) to nearly
0.degree. (in the completely folded state of the structure (FIG.
4)). The angle 94, 96 in the folded state is limited only by the
width of the medium 12. The angle 98 defined at the third leg 56 by
the third facets 84 of the parallel patterns 60a changes from
180.degree. (in a completely unfolded state) to an angle of
approximately 60.degree.. Based upon the alternation between the
valley 90 and peak folds 88, this angle 98, likewise, alternates in
orientation, resulting in a series of peaks 30 and valleys 46.
These peaks 30 and valleys 46 are positioned between parallel
four-ply wall structures 32.
[0048] While specific dimensions and patterns are set forth
hereinabove, the dimensions and angles can be adjusted for specific
applications without departing from the overall scope of the
present invention. Moreover, examples of particular adjacent and/or
parallel patterns have been given herein. These examples may be
applied to other locations on the medium 12, such as a third or
fourth of fifth pattern, and so forth. Likewise, orientations of
the various patterns may be reversed from the specific discussion
hereinabove without departing from the scope of the present
invention.
[0049] The three-dimensional support structure of a preferred
embodiment comprises a medium 12 that is formed with a combination
of folds rather than being shaped into flutes as, for example, is
common with corrugated board. Furthermore, the medium 12 or
material of the preferred embodiment comprises a tessellated medium
12 having an architecture that allows the weights of liners 14 and
medium 12 or material to be reduced while achieving the same, or
better performance, than comparably rated products. In addition, a
weight reduction further results from a decrease in the volume of
material used to prepare a structure, such as a package, or similar
product, using the structure of the embodiments disclosed. For
example, due to the unique architecture of the three-dimensional
support structure, applications involving a metal medium 12, can be
used to form a strong, rigid support structure even with extreme
material thicknesses, such as a minimal thickness between
0.125-0.25 inch, which greatly reduces weight and material costs,
and is a significant advantage over currently available products.
The architecture of the multi-planar structure, as shown in FIGS. 4
& 5, created by the folding of the material or medium 12 allows
the height of the folded structure 10, and thus the thickness, to
be varied to a dimension greater than that available in current
products, such as corrugated board, without loss of structural
stability. The structure 10, can be formed of any height, for
example up to 1.5 inches, with a single sheet while retaining the
same structural stability. The height is varied by altering the
dimensions of the score lines. Preferably, a thickness of up to 1.5
inches for specialty applications, such as pallets can be created
from a single sheet of material. In comparison, corrugated board in
a single wall format cannot exceed 1/4inch in height as it becomes
structurally unstable. Furthermore, corrugated board's maximum
height of 0.5 inch can only be achieved with a triple-wall
configuration.
[0050] Advantageously, the four-ply walls 32 of the
three-dimensional structure 10 prevent flexing a curvature along
the x-axis. Likewise, these four-ply walls permit curvature along
the y-axis without anticlastic curvature in metal and plastic
applications.
[0051] In addition to the capability described above, as a result
of the multi-dimensional folded architecture, which creates
significant structural stability and firm or rigid contacts at the
various rails 34, the three-dimensional support structure 10
comprises significant strength and enhanced performance over
currently available products, and permits the use of lighter weight
material for the medium 12. For instance, the structure 10
disclosed herein (FIG. 1) when used for packaging, due to its rigid
multi-planar structure, features ECT (Edge Crush Test) performance
both laterally and longitudinally. By comparison, corrugated board
can perform in only a single dimension. The dual ECT format of the
three-dimensional support structure 10 results in stronger
container board boxes.
[0052] While the three-dimensional support structure 10 may be
stronger than currently available products, additional strength can
be added to the folded structure. Specifically, the structure 10
disclosed herein can be varied in strength by three different
methods, namely, by changing the length of the facets 80, 82, 84,
by changing the medium thickness, and/or by altering the weight of
the liner 14 and medium 12 materials. In comparison, the strength
of products, such as plastic, metal, or corrugated board can only
be adjusted by varying the weight of the liner and medium.
Moreover, the structure 10 disclosed, of a single wall format (i.e.
a liner-medium-liner format), can outperform double wall formats,
such as corrugated board (i.e. liner-medium-liner-medium-liner
format). As a result, the structure of the preferred embodiment
uses less material (or paper in a board-type structure) than
traditional double wall corrugated board. This reduction is also
reflected in product weight loss, and in space saving for both
storage and transport.
[0053] In addition, the grid platform (shown in FIGS. 4 & 5)
created by the folded medium 12 provides a foundation to support a
printed substrate for boxes, such as a liner 14. The grid platform
prevents the substrate from becoming slack, as corrugated is prone
to do because multiple contact points exist.
[0054] Using the three-dimensional support structure described
herein, a device or package may be formed. Specifically, a device
or package or their components may be formed having multiple walls,
such as a box or a divider, wherein a plurality of structures 10
are integrally connected to form a single package or device. The
integral connection of a plurality of structures of the present
invention may occur through bonding, such as by adhesive or by
other means, such as welding or soldering. Likewise, a single sheet
of the structure 10 may be folded into the desired shape.
[0055] Manufacturing the three-dimensional support structure 10 of
the preferred embodiment has several significant advantages over,
for example corrugated board. For instance, the structure does not
require steam for purposes of shaping the medium because it is
folded rather than shaped. Likewise, the structure does not need to
be heated for purposes of formation and drying. The structure does
not comprise multiple components that need to be adhered or welded
together. Moreover, application of an adhesive, such as corn starch
or other adhesive substrate, can be completed at a reduced
temperature.
[0056] Accordingly, the foregoing description and drawings disclose
a three-dimensional support structure that achieves equal or
greater performance to standard materials, with materials of lesser
weights. The structure comprises a medium 12 that is folded to form
a repeating pattern of cells 20 and parallel four-ply rails 34, to
which a liner 14 is adhesively attached, welded, or soldered.
[0057] Although various representative embodiments of this
invention have been described above with a certain degree of
particularity, those skilled in the art could make numerous
alterations to the disclosed embodiments without departing from the
spirit or scope of the inventive subject matter set forth in the
specification and claims. All directional references (e.g., upper,
lower, upward, downward, left, right, leftward, rightward, top,
bottom, above, below, vertical, horizontal, clockwise,
counterclockwise, x-axis, y-axis, and z-axis) are only used for
identification purposes to aid the reader's understanding of the
embodiments of the present invention, and do not create
limitations, particularly as to the position, orientation, or use
of the invention unless specifically set forth in the claims.
Joinder references (e.g., attached, coupled, connected) are to be
construed broadly and may include intermediate members between a
connection of elements and relative movement between elements. As
such, joinder references do not necessarily infer that two elements
are directly connected and in fixed relation to each other.
[0058] In some instances, components are descried with reference to
"ends" having a particular characteristic and/or being connected
with another part. However, those skilled in the art will recognize
that the present invention is not limited to components which
terminate immediately beyond their points of connection with other
parts. Thus, the term "end" should be interpreted broadly, in a
manner that includes areas adjacent, rearward, forward of, or
otherwise near the terminus of a particular element, link,
component, part, member. In methodologies directly or indirectly
set forth herein, various steps and operations are described in one
possible order of operation, but those skilled in the art will
recognize that steps and operations may be rearranged, replaced, or
eliminated without necessarily departing from the spirit and scope
of the present invention. It is intended that all matter contained
in the above description or shown in the accompanying drawings
shall be interpreted as illustrative only and not limiting. Changes
in detail or structure may be made without departing from the
spirit of the invention as defined in the appended claims.
[0059] Although the present invention has been described with
reference to preferred embodiments, persons skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *