U.S. patent application number 14/528678 was filed with the patent office on 2015-05-07 for system and method for structure design.
The applicant listed for this patent is Liberty Diversified International, Inc.. Invention is credited to JUSTIN BERKEN, JONAS HAUPTMAN, PAUL JAMES, KHANH NGUYEN, WALTER ZESK.
Application Number | 20150121772 14/528678 |
Document ID | / |
Family ID | 53005172 |
Filed Date | 2015-05-07 |
United States Patent
Application |
20150121772 |
Kind Code |
A1 |
BERKEN; JUSTIN ; et
al. |
May 7, 2015 |
SYSTEM AND METHOD FOR STRUCTURE DESIGN
Abstract
An architectural structure having a curved surface that includes
a plurality of folded boxes is provided. Each of the plurality of
folded boxes comprising a front box portion and including a front
subsurface joined with a plurality of first sides along a plurality
of first folds. The curved surface is formed on at least one of the
front subsurfaces of at least one of the plurality of folded boxes.
The curved surface extends continuously across more than one of the
plurality of folded boxes and includes at least one doubly-curved
portion extending across at least one of the plurality of folded
boxes.
Inventors: |
BERKEN; JUSTIN;
(Minneapolis, MN) ; NGUYEN; KHANH; (Chanhassen,
MN) ; ZESK; WALTER; (Providence, RI) ;
HAUPTMAN; JONAS; (Saint Louis Park, MN) ; JAMES;
PAUL; (Edina, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Liberty Diversified International, Inc. |
New Hope |
MN |
US |
|
|
Family ID: |
53005172 |
Appl. No.: |
14/528678 |
Filed: |
October 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14518276 |
Oct 20, 2014 |
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14528678 |
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|
12975917 |
Dec 22, 2010 |
8959845 |
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14518276 |
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62040588 |
Aug 22, 2014 |
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61898012 |
Oct 31, 2013 |
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61293508 |
Jan 8, 2010 |
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61289936 |
Dec 23, 2009 |
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Current U.S.
Class: |
52/28 ;
52/81.1 |
Current CPC
Class: |
E04B 1/34331 20130101;
E04B 9/32 20130101; E04B 9/0414 20130101; E04F 13/0871 20130101;
E04F 13/12 20130101; E04B 1/34352 20130101; E04B 1/3211 20130101;
E04B 2001/8442 20130101; E04B 2/7453 20130101; E04B 2001/327
20130101; E04C 2/328 20130101; E04B 2/7405 20130101; E04H 3/00
20130101; E04B 1/32 20130101; E04B 9/34 20130101; E04B 9/0457
20130101; A47B 47/00 20130101; E04B 1/34384 20130101; E04B 9/0435
20130101; E04B 9/18 20130101 |
Class at
Publication: |
52/28 ;
52/81.1 |
International
Class: |
E04B 1/343 20060101
E04B001/343; E04B 9/32 20060101 E04B009/32; E04B 9/04 20060101
E04B009/04; E04B 9/18 20060101 E04B009/18 |
Claims
1. An architectural structure having a curved surface, the
architectural structure comprising: a plurality of folded boxes,
each of the plurality of folded boxes comprising a front box
portion; each of the front box portions comprising a front
subsurface joined with a plurality of first sides along a plurality
of first folds; wherein the curved surface is formed on at least
one of the front subsurfaces of at least one of the plurality of
folded boxes; wherein the curved surface extends continuously
across more than one of the plurality of folded boxes; wherein the
curved surface includes at least one doubly-curved portion
extending across at least one of the plurality of folded boxes
comprising a first curved portion along a first axis and a second
curved portion along a second axis, wherein the first curved
portion is different than the second curved portion; wherein at
least one of the plurality of folded boxes is a different size than
another of the plurality of folded boxes; and wherein the plurality
of folded boxes are attached to one another with a first attachment
member selected from the group consisting of magnets, fasteners and
adhesives.
2. The architectural structure of claim 1, further comprising a
base assembly that includes mobility structures for the
architectural structure; wherein the mobility structures are
selected from the group consisting of wheels, casters, rollers, and
slides; and wherein the assembly includes a base that attaches to
the mobile structures and the architectural structure so the
architectural structure is movable from one location to
another.
3. The architectural structure of claim 1, further comprising a
lighting structure located opposite the front subsurface of each of
the front box portions; wherein the lighting system includes a
light attached to at least one of the front box portions facing the
front subsurface of that front box portion; wherein a panel
attaches to at least one of the front box portions; and wherein the
panel includes a plurality of access openings to secure the light
on the panel and accommodate a power cord.
4. The architectural structure of claim 1, wherein at least one of
the front box portions is coupled to a line to suspend the
architectural structure from a ceiling structure.
5. The architectural structure of claim 1, further comprising a
graphical image applied to the cured surface of the architectural
structure; and wherein the graphical image is not substantially
visibly distorted in comparison to a comparable graphical image not
applied on the curved surface.
6. The architectural structure of claim 1, wherein the front
subsurface of at least one of the plurality of folded boxes
includes a lensed subsurface.
7. The architectural structure of claim 1, wherein at least one of
the plurality of folded boxes includes the front box portion and a
rear box portion coupled together by a hinge; and wherein the front
subsurface of at least one of the plurality of boxes is
tessellated.
8. The architectural structure of claim 1, wherein at least one
folded box of a plurality of boxes includes a trimless edge; and
wherein at least one of the folded boxes of the plurality of boxes
has a pinwheel folding scheme.
9. The architectural structure of claim 1, wherein at least one
folded box of the plurality of boxes includes a front subsurface
being triangularly shaped; wherein the plurality of folded boxes
form a non-grid based pattern on the curved surface of the
structure; and wherein the architectural structure has clustered
region boundaries to accommodate easier sorting non-grid
tessellated folded boxes of the plurality of boxes.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Utility
application Ser. No. 14/518,276, filed Oct. 20, 2014, entitled
"System and Method for Structure Design" which is a divisional of
U.S. Utility application Ser. No. 12/975,917, filed Dec. 22, 2010,
entitled "System and Method for Structure Design" which claims
priority to U.S. Provisional Application Ser. No. 61/293,508, filed
Jan. 8, 2010, entitled "System and Method for Structure Design" and
U.S. Provisional Application Ser. No. 61/289,936, filed Dec. 23,
2009, entitled "System and Method for Structure Design." This
application also claims priority to U.S. Provisional Application
Ser. No. 62/040,588, filed Aug. 22, 2014, entitled "System and
Method for Structure Design--3" and U.S. Provisional Application
Ser. No. 61/898,012, filed Oct. 31, 2013, entitled "System and
Method for Structure Design--2," all of which are hereby
incorporated by reference in their entirety.
TECHNICAL FIELD AND SUMMARY
[0002] The present disclosure is directed to self-supporting
structural bodies that can have complex curved surfaces wherein
each structural body is made up of smaller sub-bodies.
[0003] Structures, such as tradeshow displays, cubical partitions,
room walls, and even ceilings are typically flat planar surfaces.
They generally have plywood or gypsum drywall panels attached to
wood or metal wall studs or frames, flat wall surfaces are
conducive to hanging pictures, shelves, marketing materials, etc.,
but they lack intrinsic visual expression. Doubly curved walls, on
the other hand, are more dynamic, expressive and modulate the
experience of architectural space. They are uncommon, however, due
to the high degree of geometric complexity and the extreme
technical challenges that arise in fabrication and installation.
This complexity arises from the fact that a doubly curved surface
has curvature in two axes and, therefore, cannot be unrolled flat.
For this reason, doubly curved architectural surface occurs either
as an expensive custom installation, or is simplified down to one
arc or "S" curve. Typically, these walls are constructed by placing
either wood or metal studs or tubes in an arc, curve (for example a
French curve or an ellipse vs. only a radial curve) or, at best, an
"S" curve pattern and covering with bent drywall. If a more complex
curved surface (such as a spherical or other double curved
surfaces) is desired, a custom curved or highly mitered (faceted)
frame is made to support curved panels placed over top. It is made
through forming which is sometimes comprised of bent laminated
panels made over molds for composite materials like wooden veneer
layers or fiberglass and resin or thermal forming in thermal
plastic materials. Other curved walls, such as landscaping walls,
can be made by stacking identically-sized bricks, pavers or blocks
in a curved pattern. But these too are often arcs or "S" curves and
if they represent a more complex shape, they only approximate it
with a shingled or fractured affect with some required
noncontiguous edges between units, as well as generally also
needing a frame.
[0004] In contrast, an illustrative embodiment of this present
disclosure includes doubly curved structures and methods of making
the same without requiring specially made frames or the like. These
structures may accommodate variable Gaussian curvature and may be
used as curved walls, barriers, ceilings, columns, or other
structures. Not limited to simple arcs, "S" curves, or shingled
approximations of forms, these structures can easily and accurately
approximate doubly curved surfaces including saddle shaped or
hyperbolic, spherical, conical, folded, or twisted surfaces, or
other Gaussian curvature. In this illustrative embodiment,
individually sized geometrically unique boxes are stacked or
assembled to form the structure. Indeed, almost any doubly curved
surface can now be closely approximated if not exactly formed (or
perceptively identically formed) into a physical self-supporting
structure. Put another way, partitions, displays, walls, and
countless other structures are no longer limited to a simple flat
wall shape or a single-axis curved shape that rely heavily on slow,
labor intensive and, therefore, expensive frames.
[0005] Spherical, twisted, multi-directional waves or other complex
curved shapes can be achieved by assembling the plurality of
individually sized boxes in a specifically arranged order. Each box
in the assembly has unique geometry specific to its location in the
assembly. It is this continuously variable geometry that enables
the construction system to accurately approximate doubly curved
surfaces. Each box is stackable and attach to each other via
magnets, fasteners, etc., so no support structure, skeleton, or
frame is necessary. In an illustrative embodiment, all boxes that
form the structure are made from a flat sheet blank of material. No
specially molded cubes or blocks are required. Once the needed box
sizes are calculated, the flat sheet blanks are cut and scored into
the individual sizes and folded into boxes. By numbering or
affixing the boxes with some indicia to indicate positioning, they
can be assembled to make the structure. Rare earth magnets or other
fasteners attach to the sides of each box to connect one to
another. By assembling the boxes in this prearranged order, the
resulting structure will be that of the designed shape.
[0006] Another illustrative embodiment of the present disclosure
provides a digitally assisted design and specification method which
a user employs to modify a base surface to create a
three-dimensional design parametrically divides the design into
individual box elements; and export two-dimensional representations
of the individual box elements for rapid manufacture by robot and
assembly into a physical manifestation of the three-dimensional
design.
[0007] The above and other illustrative embodiments may further
provide: parametrically dividing the design which includes dividing
the three-dimensional design into a grid of contiguous panels,
wherein each panel is defined by a series of shared 1-degree edge
curves; the panels comprising triangular mesh surfaces; mapping
graphics onto the box elements while maintaining alignment on
non-planar assemblies of the three-dimensional design; the box
elements being 3, 4, 5 or n sided; the panels being defined by sets
of edge curves extruded or lofted to create sidewalls mated to each
panel face; each sidewall being contiguous with a neighboring
sidewall precisely offset to account for the installation specific
material thickness; each edge of each face of each box abut an
adjacent edge of a neighboring box except for edges located along
the outer periphery of the design; two-dimensional representations
being labeled to facilitate sorting and assembly of the
three-dimensional design; comprising forming each box element as a
two-dimensional panel; and the panel being formed of corrugated
plastic, sheet metal, or paper-based board.
[0008] Another illustrative embodiment of the present disclosure
provides a system comprising a graphic design tool, a box element
module, and a panel module. The graphic design tool modifies a base
surface to create a three-dimensional design. The box element
module parametrically divides the design into individual box
elements. The panel module provides two-dimensional panel
representations of the individual box elements that are capable of
being manufactured and assembled into a physical manifestation of
the three-dimensional design.
[0009] The above and other illustrative embodiments may further
provide: the box element module dividing the three-dimensional
design into a grid of contiguous panels wherein each panel is
defined by a series of shared 1-degree edge curves; the panels
being comprised of triangular mesh surfaces; the panel module
mapping graphics onto the box elements while maintaining alignment
on non-planar assemblies of the three-dimensional design; the box
elements being 3, 4, 5 or n sided; the panels being defined by sets
of edge curves extruded (or lofted) to create sidewalls mated to
each panel face; each sidewall being co-planar and contiguous to a
neighboring sidewall; each non peripheral box sidewall having an
edge that mates with a corresponding edge of a neighboring box
element; the two-dimensional representations being labeled to
facilitate sorting and assembly of the three-dimensional design;
forming each box element as a two-dimensional panel; and the panel
being formed of corrugated plastic.
[0010] Another illustrative embodiment of the present disclosure
includes a method of making a structure. The method comprises:
determining a base surface having a shape formed from at least two
curves one of which not parallel to the other; subdividing the
surface into a plurality of boxes wherein each box is uniquely
shaped based on the shape of the base surface so assembling the
boxes will form the structure that at least closely approximates
the shape of the base surface, wherein each box includes a front
surface and an at least one side, wherein at least two boxes each
have their surface and side be non-orthogonal to each other and at
least one face of one of the two boxes is a curved surface, and
wherein each box has a corner edge located between the face and
each side, wherein each box that is configured to be located
adjacent to another box has its corner edge mate the corner edge of
the another box; determining an order the plurality of boxes will
be assembled in to create the structure; affixing an indicia on
each of the plurality of boxes to indicate the position of each box
with respect to each other to form the structure that at least
closely approximates the shape of the base surface; forming each of
the plurality of boxes by a scoring and cutting a flat sheet
material; constructing each box by folding each box, wherein each
box includes a magnet on at least one side which is configured to
attract to and connect to a magnet attached to an adjacent box;
assembling the structure by placing each box in order according to
the indicia on each of the plurality of boxes so each box is
located in the position with respect to each other to make the
structure that at least closely approximates the shape of the base
surface; and attaching each box to one another by placing the
magnets from each box next to each other; and aligning each corner
edge from each side of each of the plurality of boxes with each
corner edge from each abutting side of each adjacently placed
box.
[0011] Another illustrative embodiment provides an architectural
structure having a curved surface. The architectural structure
comprises: a plurality of folded boxes, each of the plurality of
folded boxes comprising a front box portion; each of the front box
portions comprising a front subsurface joined with a plurality of
first sides along a plurality of first folds; wherein the curved
surface is formed on at least one of the front subsurfaces of at
least one of the plurality of folded boxes; wherein the curved
surface extends continuously across more than one of the plurality
of folded boxes; wherein the curved surface includes at least one
doubly-curved portion extending across at least one of the
plurality of folded boxes comprising a first curved portion along a
first axis and a second curved portion along a second axis, wherein
the first curved portion is different than the second curved
portion; wherein at least one of the plurality of folded boxes is a
different size than another of the plurality of folded boxes; and
wherein the plurality of folded boxes are attached to one another
with a first attachment member selected from the group consisting
of magnets, fasteners and adhesives.
[0012] In the above and other illustrative embodiments, the
architectural structure may further include: a base assembly that
includes mobility structures for the architectural structure; the
mobility structures are selected from the group consisting of
wheels, casters, rollers, and slides; and the assembly includes a
base that attaches to the mobile structures and the architectural
structure so the architectural structure is movable from one
location to another; a lighting structure located opposite the
front subsurface of each of the front box portions; the lighting
system includes a light attached to at least one of the front box
portions facing the front subsurface of that front box portion; a
panel attaches to at least one of the front box portions; and the
panel includes a plurality of access openings to secure the light
on the panel and accommodate a power cord; at least one of the
front box portions is coupled to a line to suspend the
architectural structure from a ceiling structure; a graphical image
applied to the cured surface of the architectural structure; and
wherein the graphical image is not substantially visibly distorted
in comparison to a comparable graphical image not applied on the
curved surface; the front subsurface of at least one of the
plurality of folded boxes includes a lensed subsurface; at least
one of the plurality of folded boxes includes the front box portion
and a rear box portion coupled together by a hinge; and wherein the
front subsurface of at least one of the plurality of boxes is
tessellated; at least one folded box of a plurality of boxes
includes a trimless edge; and wherein at least one of the folded
boxes of the plurality of boxes has a pinwheel folding scheme; at
least one folded box of the plurality of boxes includes a front
subsurface being triangularly shaped; wherein the plurality of
folded boxes form a non-grid based pattern on the curved surface of
the structure; and wherein the architectural structure has
clustered region boundaries to accommodate easier sorting non-grid
tessellated folded boxes of the plurality of boxes.
[0013] Additional features and advantages of the structure assembly
and method of making same will become apparent to those skilled in
the art upon consideration of the following detailed description of
the illustrated embodiment exemplifying the best mode of carrying
out the structure assembly and method of making same as presently
perceived.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The present disclosure will be described hereafter with
reference to the attached drawings which are given as non-limiting
examples only, in which:
[0015] FIG. 1 is a perspective view of a freestanding, partially
spherical-shaped structure;
[0016] FIG. 2 is a perspective, partially exploded view of the
freestanding partially spherical-shaped structure of FIG. 1;
[0017] FIG. 3 is a perspective view of box portions that make up
the freestanding partially spherical-shaped structure and an
unfolded box portion;
[0018] FIG. 4 is another illustrative embodiment of the present
disclosure depicting a self-structuring and suspended ceiling
structure;
[0019] FIG. 5 is a perspective, partially exploded view of the
ceiling structure of FIG. 4 depicting how the ceiling structure is
composed of individual boxes;
[0020] FIG. 6 is a perspective exploded view of first and second
box portions of the ceiling structure of FIG. 4, along with one of
those boxes shown in an unfolded blank condition;
[0021] FIG. 7 is a perspective view of a wall mounted structure
having a multi-curved surface;
[0022] FIG. 8 is a perspective, partially exploded view of the wall
mounted structure of FIG. 7 depicting individual boxes that compose
the wall structure;
[0023] FIG. 9 is a perspective view of one set of the box portions
from the wall mounted structures of FIGS. 7 and 8, and a
perspective view of one of those boxes in an unfolded blank
condition;
[0024] FIG. 10 is a perspective view of four box assemblies that
make up a portion of a freestanding structure;
[0025] FIG. 11 is a perspective, exploded view of the box
assemblies of FIG. 10;
[0026] FIG. 12 is another view of the box assemblies of FIGS. 10
and 11, but further exploded to separate the inner and outer box
portions;
[0027] FIGS. 13A-C show the box assemblies of FIGS. 10-12, where
FIG. 13A shows the same exploded view from FIG. 12 except with one
of the box assemblies removed, FIG. 13B shows the removed box
assembly of FIG. 13A in a further exploded view identifying the two
box portions, and FIG. 13C shows the same box portions of FIG. 13B
in unfolded blank form;
[0028] FIGS. 14A-G are perspective views of a single box portion
showing a progression from their unfolded cut blank form in FIG.
14A to a completely folded box portion form in FIG. 14G, with the
other views demonstrating how the box portion is folded;
[0029] FIG. 15 is an upward-looking perspective view of an interior
ceiling of a theater space that includes a suspended structure
overhead;
[0030] FIGS. 16A-E are side perspective views of the outline of a
portion of the theater of FIG. 15 showing a progression from an
empty space where the structure is to be located, through the
design of the base surface of the structure, to the eventual
formation of the individual boxes that connect to each other to
form the structure;
[0031] FIGS. 17A-C are perspective views of a partially formed
structure with base surface demonstrating how the structure is
made;
[0032] FIG. 18 includes views depicting how a building box is
formed from a base surface;
[0033] FIGS. 19A and B depict how the base surface of a structure
can be changed even when defined by individual boxes;
[0034] FIGS. 20A and B are each plan and perspective views of the
structure of FIGS. 19A and B that demonstrate how it can be further
modified even while defined by individual boxes;
[0035] FIGS. 21A and B are perspective views of the structure from
FIGS. 19 and 20 demonstrating how computationally derived control
points can further manipulate the base surface to change the size
and shape of the structure;
[0036] FIGS. 22A-D are perspective views of the structure from
FIGS. 19A and B where the structure's density and aspect ratio
along with the tiling strategy or configuration may be changed;
[0037] FIG. 23 includes perspective, plan, section detail, project
matrix, solid and mesh model, and center of gravity views of the
structure of FIGS. 19-22;
[0038] FIG. 24 shows different types of box configurations that can
be used on structures such as that of FIGS. 19-23;
[0039] FIG. 25 shows various views of folded and unfolded box
configurations;
[0040] FIGS. 26A and B show an unfolded box surface pattern that is
translated into line work to be cut into a blank and folded into a
box;
[0041] FIGS. 27A-I are various views demonstrating how to construct
a partially spherical enclosure;
[0042] FIGS. 28A-G demonstrate an additional embodiment of a
structure and how it is assembled;
[0043] FIGS. 29A-G show another illustrative embodiment of a
structure attached to a wall;
[0044] FIGS. 30A-C are front, perspective, and top views of a
freestanding column structure;
[0045] FIGS. 31A-E are various views of the column of FIG. 30 along
with individual box components in folded and unfolded form;
[0046] FIGS. 32A-D are perspective, front, side, and top views of a
diamond ceiling structure;
[0047] FIGS. 33A-D are perspective, front, side, and top views of a
Voronoi wall fixed to a wall surface;
[0048] FIGS. 34A-D are perspective, front, side, and top views of a
freestanding dome structure;
[0049] FIGS. 35A-D are perspective, front, side, and top views of a
framed wall-to-ceiling transition structure;
[0050] FIGS. 36A-D are perspective, front, side, and top views of a
suspended cuspy ceiling;
[0051] FIGS. 37A-D are perspective, front, side, and top views of a
variable quad wall affixed to a conventional wall;
[0052] FIGS. 38A-D are perspective, front, side, and top views of a
freestanding multi-curved wall;
[0053] FIGS. 39A-D are perspective, front, side, and top views of a
pleated freestanding wall;
[0054] FIGS. 40A-D are perspective, front, side, and top views of a
rolled box wall fastened to another wall;
[0055] FIGS. 41A-K are various perspective views demonstrating how
a box, as a subcomponent of a structure, can be twisted to better
approximate the shape of the structure's intended base surface;
[0056] FIG. 42 includes views of a portion of a structure and
individual box portions to demonstrate a method of labeling the box
portions to indicate number, orientation, and location of that box
with respect to other boxes;
[0057] FIGS. 43A and B are perspective partial cutaway and exploded
views of box portions that demonstrate how acoustics and lighting
can be incorporated therein;
[0058] FIGS. 44A and B include perspective and partial cutaway
views of a box portion with lens layers inserted therein for visual
lensing affect;
[0059] FIG. 45 is a partially exploded view of stacked box portions
to demonstrate raceways for lights, power, data wiring, and
ventilation;
[0060] FIGS. 46A and B include perspective and various front views
of a surface comprised of boxes that create an optical effect of
relief and depth;
[0061] FIGS. 47A-D demonstrate another illustrative embodiment of a
suspension system for a ceiling-mounted structure;
[0062] FIGS. 48A-E show a variety of design strategies for the
boxes used on a particular structure;
[0063] FIGS. 49A-D show another illustrative embodiment of a
structure;
[0064] FIGS. 50A and B show another illustrative embodiment of a
structure and boxes that are able to connect to one another without
requiring accessory hardware;
[0065] FIGS. 51A-H show another illustrative embodiment of a
structure, as well as how the box component is formed;
[0066] FIG. 52 shows a progression view of roll fold quick box
portions from flat blank to final assembled box form;
[0067] FIG. 53 shows progression views of a box portion from blank
to folded configuration that employ a back frame for inside the box
portion;
[0068] FIGS. 54A-E include progression views of an integral
double-back flange box from flat blank form to final box portion
form;
[0069] FIGS. 55A-G are progression and detail views of an offset
box tab assembly system for use on a box from the flat blank
condition to folded box portion condition;
[0070] FIGS. 56A-F are progression and detail perspective views of
a mushroom tab box system from flat blank condition to assembled
box condition;
[0071] FIGS. 57A-E are perspective progression views, detail, and
pattern views of an intra box face joining mechanical tenon system
for use with a folding box;
[0072] FIGS. 58A-F are perspective progression views of folding a
cuspy box from the flat blank condition to assembled box
condition;
[0073] FIGS. 59A and B are progression perspective views of a
zigzag box from flat blank condition to folded box condition;
[0074] FIG. 60 is a perspective progression views of a Voronoi
sleeve box from flat blank condition to folded box condition;
[0075] FIG. 61 is progression perspective views of a ruled surface
relief box from flat blank condition to folded box condition;
[0076] FIG. 62 is a perspective view of an illustrative shelf
system that can be integrated into a wall structure system;
[0077] FIG. 63 is another perspective view of a wall structure that
includes shelving and a fenestration;
[0078] FIGS. 64A-E are various views of a structural wall made in
different ways including the methods described herein and by
conventional bricks or blocks;
[0079] FIG. 65 is a perspective view of an illustrative embodiment
of a mobile wall structure;
[0080] FIG. 66 is a perspective view of an underside of a mobile
base portion;
[0081] FIG. 67 is a perspective view of another illustrative
embodiment of a mobile wall structure;
[0082] FIG. 68 is a partially exploded perspective view of the
mobile wall structure of FIG. 67;
[0083] FIG. 69 is a perspective view of a base portion of the
mobile wall structure;
[0084] FIG. 70 is a detail view of mobile wall structure shown in
FIG. 69;
[0085] FIG. 71 is a top view of an unfolded box portion from the
mobile wall of FIG. 70;
[0086] FIG. 72 is a top view of a base portion of a mobile wall
structure;
[0087] FIG. 73 is a perspective view of a box structure suspended
from a ceiling;
[0088] FIG. 74 is a perspective view of a structure suspended from
a ceiling including lighting and power features;
[0089] FIG. 75 is a top view of a box structure according to
aspects of this disclosure including lighting features;
[0090] FIG. 76 shows a portion of a column with a box removed
showing power and lighting cables attached thereto;
[0091] FIG. 77 is a detail view of a lighting assembly
structure;
[0092] FIGS. 78A and B are perspective views of a lighting assembly
for use on boxed wall structure and a portion of the wall structure
according to the present disclosures;
[0093] FIG. 79 is a two-dimensional image to be applied on a
tessellation map;
[0094] FIG. 80 is a perspective view of a tessellated surface with
a print applied thereto;
[0095] FIG. 81 is a top view of an unfolded box according to the
present disclosure;
[0096] FIGS. 82A-C show another two-dimensional image that is
applied to a structure along with a single box portion to a single
box according to the present disclosure;
[0097] FIGS. 83A-C show another view of an image that is then
applied to the curved face according to embodiments the present
disclosure along with an unfolded box portion;
[0098] FIG. 84 is a perspective view of a magnetic snap grid
module;
[0099] FIG. 85 is a side-sectional schematic view of a snap grid
module;
[0100] FIGS. 86A and B are perspective views depicting how a snap
grid module attaches to a ceiling structure;
[0101] FIGS. 87A-D show a box print file and subsurface lensing on
boxes to create backlighting effects on boxes according to
embodiments of the present disclosure;
[0102] FIGS. 88A-B show perspective views of an individual box and
a corresponding wall structure that include briefcase modules;
[0103] FIG. 89 is a perspective view of an illustrative embodiment
of a folded briefcase module;
[0104] FIG. 90 is a top view of an unfolded briefcase module;
[0105] FIGS. 91A-C show various embodiments of structures according
to embodiments of the present disclosure including tessellated
subsurfaces;
[0106] FIGS. 92A-C are various perspective views of a box according
to embodiments of the present disclosure with a tessellated
subsurface;
[0107] FIGS. 93A-C are various perspective views of a box according
to embodiments of the present disclosure with a tessellated
subsurface;
[0108] FIGS. 94A-C are various perspective views of a box according
to embodiments of the present disclosure with a tessellated
subsurface;
[0109] FIGS. 95A-B show a perspective view of a structure with a
box portion having a trimless edge;
[0110] FIGS. 96A-C show a perspective view of a structure as a box
portion having a trimless edge;
[0111] FIGS. 97A-B show a perspective view of a structure as a box
portion having a trimless edge;
[0112] FIG. 98 is a top view of another illustrative embodiment of
a box design according to embodiments of the present disclosure,
including a pinwheel fold scheme;
[0113] FIG. 99 is a perspective view of a folded box portion
according to embodiments of the present disclosure;
[0114] FIG. 100 is a perspective view of the unfolded box shown in
FIG. 99, constituting the first step of the assembly of same;
[0115] FIGS. 101A and B are perspective and detailed perspective
views of assembling the box shown in FIG. 99 including folding
corner flanges;
[0116] FIGS. 102A and B are perspective and detailed perspective
detail views of the box from FIG. 99 further showing folding
flanges and attaching with screws;
[0117] FIGS. 103A and B further show the assembling of the box
shown in FIG. 99 including folding additional flanges and securing
them to the box with a fastener;
[0118] FIG. 104 is a perspective view of a finished folded box of
FIG. 99 with any unsecured flanges secured with a fastener;
[0119] FIG. 105 shows a wall structure made of triangular
subsurfaces according to embodiments of the present disclosure;
[0120] FIGS. 106A-D are various top views of the wall structure of
FIG. 101, including selected unfolded box portions;
[0121] FIG. 107 is a plan view of the wall structure shown in FIG.
101;
[0122] FIGS. 108A and B are views of a cut triangular subsurface
flat blank employed to make the wall structure of FIG. 101;
[0123] FIG. 109 is a perspective view of a flat blank used to form
a box portion of the structure of FIG. 105; and
[0124] FIG. 110 is a top view of the unfolded blank of FIG.
105.
[0125] The exemplification set out herein illustrates embodiments
of the structures and methods of making the same, and such
exemplification is not to be construed as limiting the scope of the
structures and methods of making the same in any manner.
DETAILED DESCRIPTION OF THE DRAWINGS
[0126] A perspective view of a partially spherical freestanding
structure 2 is shown in FIG. 1. Structure 22 illustratively sits on
floor 4 of a dwelling or building that may include a wall 6 and
ceiling 8. This embodiment stands freely without assistance from
wall 6 or ceiling 8, however. Structure 22 only needs to rest on
floor surface 4. An outline of a person 10 is included to show an
illustrative scale for structure 2. It is appreciated that
structure 22 may vary in size from relatively small, to relatively
large.
[0127] Structure 22 is curved in multiple directions and on
multiple axes. Structure 22 also has an outer surface 12 and an
inner surface 14. Both the outer and inner surfaces 12 and 14 are
formed entirely of box faces, such as outer face 16 and inner face
18 of inner and outer box portions 20 and 22, respectively. Each
inner and outer box portion in addition to portions 20 and 22 are
uniquely sized and shaped to form a small portion of the entire
surface so that when all of the boxes are assembled in a predefined
order, they form the desired predefined surface shape and
structure. The letter/number system A-1-A-3, B-1, B-3 and C-2-C-3,
is useful to ensure all the boxes are attached to each other in
proper order. It is appreciated that this indicia does not have to
be so prominently apparent on the boxes. It is further appreciated
that this or other organizational indicia may appear on the sides
of the boxes or any other less conspicuous location that obscures
it from view when the structure is assembled, if that is the
desired effect. It is still further appreciated from this view that
structure 22 is only made up of these box portions. There are no
skeletal or other support frames on studs needed to construct this
complex-shaped structure.
[0128] In an illustrative embodiment, each box portion has a
four-edged surface, like surfaces 12 or 14. Each box is uniquely
sized and combined with other boxes to make up the surface of
structure 22 as a whole. This means that each box surface, while
having straight line edge curves, can still be assembled with other
boxes to create a complex curved surface not achievable in this way
by traditional stud framing or uni-sized block construction. In
this illustrative embodiment, outside and inside box portions 20
and 22, respectively, are employed because the outside and inside
surfaces 12 and 14 are not always the same and may be significantly
different. For example, one side may be topographic (or doubly
curved), while the other side may be planar (or singly curved)
against a wall. The thickness of the box itself forces the inside
surface 14 to be slightly different than outer surface 12. This
arrangement also allows some independent control of the surface
shape of both the inner or outer surface.
[0129] Another perspective view of structure 22 is shown in FIG. 2.
This view shows how structure 22 is constructed entirely of boxes,
such as boxes 24, 26, 28, 30, 32 and 34. Each of the boxes 24
through 34 in this illustrative embodiment is made up of outer and
inner box portions, such as portions 20 and 22, except that each
box is individually sized to create its portion of the entire
surface. These boxes are then stacked one on top of another.
Because of the way the boxes are formed, as discussed further
herein, when assembled in proper order they create the desired
curved surfaces of structure 22. For example in this case, unlike a
traditional shipping box where all angles of the sides are
generally orthogonal to each other, the sides of the boxes of this
disclosure are not necessarily orthogonal to each other. Sides 36
and 38 of box 24 are formed to achieve a non-orthogonal angle with
respect to face 40, so that when combined with the other boxes,
such as box 32, they form a curved surface.
[0130] The perspective view in FIG. 3 shows box 24 split up into
its outer box portion 42 and inner box portion 44. As demonstrated
by this illustrative embodiment, each box portion can be a
different size if needed so all the boxes form the overall desired
shape; in this case, the partially spherical form of structure 2.
This view also shows how face 40 is a planar face when unfolded. It
is appreciated that in other embodiments, depending on how the box
is ultimately cut, scored, and assembled, the box face may be
twisted to further approximate or match a needed portion of a
complex base surface. (See, also, FIG. 41.) Also shown in this view
is an unfolded blank version of box portion 42. As will be
discussed further herein, each box has a surface, such as surface
40, that is individually sized to be part of the overall desired
surface of structure 22. In addition, sidewalls, such as walls 38,
46, 48 and 50, are cut and scored illustratively along lines 52,
54, 56 and 58, respectively, so the blank can be folded into the
box, as shown in this and FIGS. 13 and 14. Illustrative joints 60,
62, 64 and 66 attach one box portion side to another. For example,
joints 60 and 62 which extend from side 46 attach to sides 38 and
48, respectively, when sides 38, 46 and 48 are folded along score
lines 52, 54 and 56, respectively. The joint may be a tab cut of
the box material or can be added separately. The joints may also be
mechanically fastened, glued, or attached to the sides by some
other similar type means. Properly attaching the joints to adjacent
sides also ensures that those sides will be at the appropriate
angle with respect to their adjacent surface. As previously
discussed, unlike a conventional box the angle of the sides of
these boxes with respect to the face are not necessarily
orthogonal. They may be acute or obtuse with respect to the face
depending on the ultimate shape of the surface and the box's
location within that surface.
[0131] A perspective view of another illustrative embodiment of
these structures includes a suspended ceiling structure 80 shown in
FIG. 4. Structure 80 is suspended from ceiling 8 via wires 82. In
this illustrative embodiment, only enough wires are used to suspend
the structure in the desired position. Additional structures or
other wires are not needed to support each box that makes up
structure 80 (but may be in alternative embodiments as shown in
FIG. 47). It is appreciated in this view how structure 80, despite
being made from a collection of straight edged twisted plane boxes,
can form overall curved contours curves along both X and Y axes as
shown.
[0132] The view of FIG. 5, is similar to that of FIG. 2, is
structure 80 in partially exploded form having some of its
component boxes separated therefrom. Boxes 84, 86, 88, 90, 92, 94,
96, 98, and 100 are each illustratively made from two box portions.
Box 84, for example, includes box portions 102 and 104. In
addition, each face of boxes 84 through 100 is individually sized,
so when assembled in proper order with all of the other boxes, they
form the surfaces 106 and 108 of structure 80. Likewise, the sides
of the boxes are individually configured, as discussed with respect
to the boxes shown in FIGS. 2 and 3. When assembling the boxes,
however, the final shape will be that of structure 80 shown in FIG.
4. It is appreciated that this individualized box folding process
may create a wide variety of structures having almost limitless
complex form. A limiting factor in this regard is a designer's
imagination.
[0133] Similar to FIG. 3, the perspective view of box 84 further
exploded into its box portions 102 and 104 in FIG. 6 show how the
boxes can be assembled to create structure 80. Each box portion 102
and 104 may have its own unique box surface, such as surfaces 110
and 112, to serve as a component of the overall shape of surfaces
106, 108, respectively. And like box portions 42 and 44 of
structure 2, each box portion 102 and 104 is made from a flat
blank, such as the blank form of box portion 104 that is cut,
scored and then folded into a box. As shown, sides 114, 116, 118,
and 120 are cut out and surface 110 defined by score lines 122,
124, 126, and 128, respectively. This defines the size of the
surface as well.
[0134] Joints 130, 132, 134, and 136, are formed and configured to
attach to adjacent sidewalls to form the folded box portion. As
previously discussed, it is appreciated that the joints are
configured to ensure the sides are located at the proper angle with
respect to the corresponding surface. As also discussed, that angle
is not necessarily orthogonal. It is conceivable, based on a
particular desired surface shape that some boxes may have
orthogonal sides with respect to their surfaces, but as these
illustrative embodiments demonstrate, it is not a requirement and
it is this flexibility that allows such a variety of surface shapes
to be constructed. It is further appreciated that the joints can be
attached to corresponding sides via magnets, fasteners, adhesives,
or the like.
[0135] A perspective view of another illustrative embodiment of a
structure 150 mounted onto wall 6 is shown in FIG. 7. This further
illustrates the versatility in shape and application of these
structures. Structure 150, despite being mounted onto wall 6, still
includes a plurality of curves in the Y and Z directions as shown.
Like structures 2 and 80 shown in FIGS. 1 and 4, respectively,
structure 150 is made up of individual boxes of unique size that
when assembled in proper order, forms surface 152. The assembly
order system shown for structure 150 is the same as that shown with
respect to structures 2 and 80.
[0136] Using individually sized and shaped boxes, but boxes
nonetheless, attached to each other without a frame or support
structure, but in proper order may create radically varied surface
forms. The boxes can be attached to each other via magnets or other
structures, as discussed further herein. It is appreciated that the
teachings of this disclosure are not limited to the specific
surface forms or structures shown herein. Indeed, these examples
demonstrate how many variably-shaped structures can be made.
[0137] Similar to FIGS. 2 and 5, FIG. 8 shows structure 150 in
partially exploded view to demonstrate how individual boxes 154,
156, 158, 160, 162, and 164 are connectable to form structure 150
and create surface 152. This view in particular shows how box 154
is very much different in shape than box 160 or box 158 for that
matter. Again, this is not simply stacking identically-shaped boxes
on top of one another. Each box is its own size and is a small
contributor to the overall surface shape of the structure. As shown
in this view, assembling boxes in order of A1, A2, A3, and so on,
over boxes B1, B2, over Box C1 and so on, builds the final
structure. It is appreciated that although not shown, the
letter/numbering system starting with A1, A2 . . . is extended to
all of the boxes. In addition, the location of the indicia is
illustrative only. In other embodiments, box assembly sequence
indicia can be located on the sides, back, or other discreet
locations that may not even be visible when the final structure is
assembled. Surface 166 of box 154 is real estate that may be used
for such applications as advertising, murals, light, lenses,
mirrors, etc. that might be applied to the entire structure 152 in
a manner that runs across several or all of faces. It is also
appreciated that these surfaces may be useful in the same and even
more ways as conventional wall surfaces.
[0138] Perspective views of box 154 split into front and rear
portions 168 and 170, respectively, are shown in FIG. 9. In
addition, an unfolded blank version of box portion 168 is shown.
This view depicts how sides 172, 174, 176, and 178 of box portion
168 and sides 180, 182, 184, and 186 of box 170 can all be
different and have varied thicknesses depending on the boxes'
location in the overall structure. Box portion 168, shown in blank
form, depicts how sides 172, 174, 176, and 178 are formed and may
vary the thickness of box 168 when folded. The same is true with
sides 180-186 of box 170 and all the other boxes of the structure
for that matter. Like the blanks shown in FIGS. 3 and 6, blank 168
is cut and scored to form sides 172, 174, 176, and 178.
[0139] Perspective detailed views in FIGS. 10-14 show boxes in
various forms of assembly from unfolded blank form to fully
assembled. It is the folding, assembling, and stacking these boxes
that form the final structure. As seen in these views, as well as
the others, there are no additional frames or skeletons needed to
support the shape of the structure.
[0140] The perspective view of structure 200 in FIG. 10 includes a
structure surface 202 composed of subsurfaces 204, 206, 208, and
210 of boxes 212, 214, 216, and 218, respectively. Curves along
axis Y is formed as part of surface 202. In order to assemble a
structure that includes such curves, each box is specially formed
as a small part of that surface. As shown in this view, each box is
labeled so during assembly each box will have a predetermined
location. For example, box 212 includes the indicia "A-c0-r0." In
this embodiment, "A" indicates the outer surface, "c" is the column
and "r" is the row. So box portion 220 is positioned on the outward
side, in the 0 column and the 0 row. The next box portion 222 of
box 214 is also shown in column 0, but is now in row 1, as
indicated. Similarly, the other box portions 226 and 228 are
located outwardly with box portion 226 now in column 1 while still
in row 0. Lastly, box portion 228 is located in column 1, row 1.
Knowing where each box portion is to be positioned with respect to
the other box portions is what ensures the final surface of the
structure is assembled properly. As previously discussed, each box
surface size and sidewall angle is specific to its predetermined
location within the scheme of the overall surface. In an
illustrative embodiment, when designing a structure with a
particular surface contour, there are often both inner and outer
surfaces. Because many structures contemplated in this application
have a thickness, the inner surface will be slightly different than
the outer surface. In certain embodiments the surfaces may be the
same, but in others very different. Accordingly for these
embodiments, each box may be made up of two box portions, a single
box portion in other embodiments, essentially inner and outer
hemispheres, such that each box portion may connect together to
form a box. Each box portion may also have different dimensions,
particularly thickness. Box portions 230, 232, 234, and 236 all
support the inner surface (not shown) of structure 200.
[0141] An exploded view of structure 200 is shown in FIG. 11. In
this view each box 212 through 218 is separated from each other.
Illustratively, each box portion 220-228 and 230-236 join together
as shown. Hemispherical lines 238, 240, 242, and 244 are the seams
located between the box portions. It is appreciated that in these
illustrative embodiments the box portions are not necessarily
partially spherical. Each box portion is given this term to
indicate how two box portions are combined form the single box. In
order to connect the boxes together, each box portion includes
attachment points, such as points 246, 248, 250, 252, 254, 256,
258, 270, 272, 274, 276, and 278. These attachment points, which
are visible on boxes 212-218, may be magnets that attract
corresponding magnets on other boxes to attach them together.
Alternatively, the points may be through-holes that accept
fasteners, such as bolts or screws; an adhesive that stick to
adjacent boxes; or other like attachment structure so that each of
the boxes will connect and secure to each other. It is appreciated
that this securement may be temporary or permanent, depending on
the need of the structure. These attachment points may also assist
in aligning boxes together to ensure they assemble to the desired
structure.
[0142] A perspective, further exploded view of structure 200 is
shown in FIG. 12. Here each box portion is separated. For example,
box 212 is separated into box portions 220 and 230. The same is the
case with box portions 222 and 232 of box 214, portions 226 and 236
of box portion 218, and portions 228 and 230 of box 216. This view
further demonstrates how hemispherical box portions may attach to
each other. With respect to box 212, for example, each box portion,
such as box portion 230, includes flanges 280, 282, 284, and 286
that extend from sides 288, 290, 292, and 294, respectively. These
flanges are configured to face corresponding flanges on the opposed
box portion, such as flanges (not shown) on box portion 220.
Magnets 296, 298, 300, 302, 304, 306, 308, are likewise,
illustratively configured to attract to and thus attach to
corresponding magnets (not shown) on the flanges of box portion
220. It is further appreciated that in alternative embodiments, the
attachment means may include fasteners such as bolts or screws,
adhesives, or they may be alignment holes to receive other
attachment, structures, or mechanisms. As can be appreciated from
FIG. 12, the same process may be applied to box portions 222/232,
226/236, and 228/230 as well.
[0143] An illustrative method of forming and assembling each box
portion is shown in FIGS. 13B-C. The view in FIG. 13A is similar to
that of FIG. 12 with each of boxes 212 to 214 and 218 in exploded
view separating portions 220/230, 222/232, and 226/236 from each
other. Box portions 228/230 of box 216 are shown in FIG. 13B. In
this illustrative embodiment, each box portion 228 and 230 (as well
as all the box portions for that matter) begin life as a cut blank,
as shown in FIG. 13C. Portions 228 and 230, in blank form, are made
from a sheet of material such as plastic, paper, or sheet metal,
for example. Box portion 228 in blank form includes face 310 with
sides 312, 314, 316, and 318 extending therefrom defined by score
lines 320, 322, 324, 326. Extending from sides 312, 314, 316, and
318 are flanges 328, 330, 332, and 334, respectively, defined by
score lines 336, 338, 340, and 342, respectively. Indicia 344 may
be affixed to one of the sides to indicate assembly order as
previously discussed. Joints 346, 348, 350, and 352 are cut and
scored to attach adjacent sides together, such as sides 312 and
314, for example. It is appreciated that the joints may attach to
adjacent sides via mechanical means, such as fasteners, adhesives,
welding, etc.
[0144] A perspective progression view of creating box portion 328
from a flat sheet blank is shown in FIGS. 14A-G. The view of FIG.
14A is the same as FIG. 13C where a flat sheet version of box
portion 328 has been cut and scored. In this illustrative
embodiment, flanges 328, 330, 332, and 344 are folded upwards.
Similarly, portions of lap joints 346, 348, 350, and 352 are folded
upward as shown. Then sides 314 and 318 are folded upward as well.
This causes flanges 330 and 334 to be essentially positioned
parallel to surface 310. This not only begins to form the shape of
the box, but positions the flanges so they will be located opposite
flanges from the opposed box portion thereby forming a complete
box. Next, lap joints 346, 348, 350 and 352 are folded over
adjacent their corresponding sides as shown so they may attach to
both adjacent sidewalls and adjacent flanges, as shown in FIG. 14D.
The view in FIG. 14E continues folding flanges 346, 348, 350 and
352 over to receive sides 312 and 316. In FIG. 14F, sides 312 and
316 are folded upward so both sides may attach to their adjacent
lap joints, such as joints 346 and 352 with respect to side 312 and
joints 348 and 350 with respect to side 316. Once all the lap
joints have attached to the sides via means previously discussed, a
finished box portion 328 is formed as shown in FIG. 14G.
[0145] An upward looking perspective view of a theater interior
space 400 with a suspended structure 402 located overhead is shown
in FIG. 15. This embodiment demonstrates another application for
these structures. In this case, structure 402 is suspended between
two ends 404 and 406 of space 400 illustratively under roof, below
a floor above or below a ceiling. The view of FIG. 15 only shows
end 404, but a second end 406 is represented in the line drawings
of FIGS. 16A-E. Nevertheless, the view in FIG. 15 depicts another
illustrative utility of these self-supporting structures. Though
structure 402 is attached to building 400 at ends 404 and 406,
there is no independent framing or skeleton needed to support the
shape of the individual boxes that make up structure 402. It is
also evident from this view how surface 408 of structure 402 can be
arched or curved in multiple directions.
[0146] FIGS. 16A-E are side perspective views of an outline 410
portion of space 400 and a progression of how structure 402 is
designed. Building outline 410 is shown in FIG. 16A. Outline 410
includes ends 404 and 406, as well as open space 412 to establish
the location and boundaries for the yet to be created structure
402. It is appreciated that sight dimensions or CAD data from this
outline may be used to establish the boundaries. Curves 418 and 422
are derived from boundaries 406 and 404 respectively. Curves 416,
420, and 424 are specified by designer of 402. Base surface 414 is
created from curves 416, 418, 420, 422, and 424. It is appreciated,
however, that the number and design of curves of the base surface
can almost be limitless. As depicted in FIG. 16C, curves 426-432
are generated to show the contour lines of the curves. The base
surface is the starting and end point of the structure. On one
hand, the base surface is the desired surface shape of the final
structure; while on the other hand, it is the starting point for
creating that structure. The computer system based design system
generates the boxes for the final installation from the surface
automatically and the boxes can, therefore, be previewed in
realtime as the base surface is manipulated. This process creates
an ease in design because the focus always is on the final
structure's intended look. The view in FIG. 16D shows a grid of
curves 434 whose quantity and location are specified by the
designer for aesthetic or functional reasons or both. A grid of
points 435 lying on surface 414 is derived by the intersections of
all lines in grid 434 and the end points of lines in 434 (which are
also illustratively the intersection of 434 with lines 416, 418,
420, and 422). By connecting the points in 435 with straight line
segments in the same pattern as the curves in 434, a group of
quadrilateral polygon faces is formed. These faces are converted
into box-like volumes to form the final structure shown in FIG.
16E. In this view, base surface 414 may form hexagonal tiles 437,
quad tiles 439, or diamond tiles 441, for example.
[0147] It is appreciated that with the boxes defined, as shown in
FIG. 16E, each box can be subdivided to form the two box portions
(top and bottom in this case). Each of these box portions is then
translated into a two-dimensional outline which serves as the cut
and score line template used to cut the flat sheet blanks, such as
that shown in FIG. 13C. Indeed, FIGS. 13C-A depict the next step of
this process. Once the box portion templates are established and
the sheet blank is cut and scored, as shown in FIG. 13C, the blank
may be folded into box portions, as shown in FIG. 13B, according to
the process shown in FIGS. 14A-G. The box portions may then be
connected and assembled with the other box portions, as shown in
FIG. 13A, to form the structure.
[0148] FIGS. 17A-C are perspective views of another illustrative
embodiment of a structure 464. FIG. 17A shows a complete structure
with only one box 470 in exploded view. FIG. 17B is a partially
formed structure 464 that includes base surface 466. And FIG. 17C
shows the original base surface 466. As previously discussed, base
surface 466 is the starting point for designing 464, and can be
modified throughout the design process. To design and make the
boxes that comprise 464, a computer program sub-divides the base
surface 466 into sub-regions using a chosen tiling strategy, such
as quad (illustrated), vari-quad, diamond, Voronoi and hexagonal.
The resulting surface sub-regions are then converted into
individual boxes, each with unique geometry and location that is
dependent on the characteristics of the corresponding surface
sub-region. Because each box, such as box 470, is unique, as
determined by the shape of the base surface, each box is assembled
in unique location and orientation to form the structure. It is
appreciated that each box is uniquely shaped, such as box 470 as
compared to box 472. All the different boxes that make up structure
464 are assembled in the same manner. This is in contrast to using
same-shaped boxes. Having all the boxes be the same size does not
offer the flexibility to make complex curves with boxes whose
front-face edges abut edges of neighboring boxes. This is one of
several distinctions between prior art designed in the present
disclosure.
[0149] Now the question becomes, if a base surface is to be
converted into a grid of boxes and that base surface can be any
myriad of bends, curves, shapes, etc., how does that base surface
translate into a grid of three-dimensional boxes? To accomplish
this, as depicted in FIG. 18, the base surface undergoes an
illustrative series of transformations. Once the base surface, such
as base surface 474 is created with all the curves and angles,
etc., it is divided into discreet tile regions, such as tiles 476,
478, 480, 482, 484, 486, 488, 490, and 492 based on the specific
tiling logic chosen by the designer. Again, the tiling logic or
strategy means the type of surface shape each box will have,
whether it is quad, variable-quad, diamond, Voronoi, or hexagonal
(and many more). In the case of tiles 476-492, each is generally
square or rectangularly-shaped (quad) defining nine discreet
regions. This number may be more or less depending on the size and
configuration of the base surface and the will of the designer. It
is appreciated at this step that both the density and aspect ratio
of the tile is adjustable (or other shape characteristics depending
on the particular nature of the tiling strategy). The density is
the number of tiles in a given space and aspect ratio is the change
in length and width of the tile itself. In illustrative
embodiments, the density and aspect ratio can be continuously
adjusted at any time throughout the design process of the structure
prior to cutting the flat sheet material. Once the tiles on base
surface 474 are established, it is offset in opposed directions 494
and 496 to form two additional surfaces, each having a unique
relationship to the original base surface 474 (parallel offset,
variable distance offset, or even different contour) per the
specification of designer. In this view, a front surface 498 and
rear surface 500 are formed extending parallel to base surface 474.
In addition, each tile 476-492 extends to surfaces 498 and 500. As
shown in this view, tiles 502 and 504 are located on surfaces 498
and 500, respectively, and are highlighted herein for demonstrative
purposes. The offset of surfaces 498 and 500 from base surface 474
also establishes the thickness of the boxes that will be created.
In this case, tile 502 represents the front face of a box, while
tile 504 represents the rear face. Like density and aspect ratio,
this depth or box thickness can be variable and, thus, adjusted
throughout the design process. With the front and rear tiles 502
and 504 established, they can be connected by surfaces to create
the box that is part of the final structure. As shown herein, a box
506 has a front 508 from tile 502 and rear face 510 from tile 504.
The shape of the sidewalls and angle with respect to the front and
rear surfaces will be contingent and variably based on the local
curvature of the base surface at that particular location. As the
curve and location changes, so too will the angle and shape of
those surfaces. This process is repeated for every tile created on
the base surface until that entire surface has been translated into
individual boxes.
[0150] Despite converting surface tiles into three-dimensional
boxes, the shape of the structure may still be modified. The
perspective views of structure 464 in FIGS. 19A and B demonstrate
how it is modifiable by slider function 512 (alternatively integer
input). In the illustrative embodiment, slider 514, shown in a
starting position in FIG. 19A, can be slid in direction 516 to
extend structure 464 in direction 518. It is contemplated that a
computer program can generate numeric inputs that drive the
definition of the base surface and, thus, proportions of the tiles
as established in FIG. 18 to change the shape of the boxes as shown
(as well as quantity of boxes if predetermined min-max threshholds
are exceeded.
[0151] Another way of modifying structure 464 is shown in FIGS. 20A
and B. In this example, plan views 520 and 522 include curve 524
that defines the bottom edge of the base surface 466 in FIG. 17C
that defines structure 464 located to the right. Control points
526, 528, 530, 532, and 534 are attached to curve 524. Moving the
control points will move the shape of the curve surface 524. For
example, moving control point 534 from location in FIG. 20A in
direction 536 to new location 537 in FIG. 20B moves curve 524 and
ultimately structure 464 as shown. Accordingly, by moving control
points 526-534, the user can make precise adjustments to curve 524
in this two-dimensional view. Alternately, the user can make
similar adjustments to other two-dimension curves (plan, elevation,
and/or section views) in order to change shape of 464.
[0152] Similar control points may also be used in three-dimensional
space to adjust the shape and size of structure 464. As shown in
FIGS. 21A and B, the same base surface, although not shown in this
view but represented by reference number 466 in FIGS. 17A-C, can be
adjusted to change the shape of structure 464. Control points 536,
538, 540, 542, 544, 546, 548, 550, 552, 554, 556, 558, and 560
(additional control points not shown may be employed as well) are
each individually movable to move a corresponding portion of
structure 464. As demonstratively shown in FIG. 21B, control points
540, 546, 552, and 558 are moved in direction 562 to move the shape
of 464 in the same direction to create a deeper curve than that
shown in FIG. 21A.
[0153] In addition to changing the geometry of surface 466 of
structure 464 as previously discussed, a designer can also adjust
the tiling solution, density, and aspect ratio. As previously
discussed with respect to FIG. 18, by creating a box from surfaces,
in this case parallel (non-parallel in other embodiments) to the
base surface, all of these parameters are adjustable. It is
appreciated in this illustrative embodiment that all of these
parameters are independent of each other and, thus, can be
independently adjusted at any time during development. As shown in
FIGS. 22A-D, varying the density and aspect ratio of structure 464
between FIGS. 22A and B causes a net increase of boxes. By
increasing the number of boxes, however, the cost of manufacture
may also increase. Nevertheless, the precision of the surface will
approximate closer to the original base surface than a surface with
a lower density. The views shown in FIGS. 22A and C also
demonstrate how the type of tiling solution may be changed. FIGS.
22A and B show quad-shaped boxes while FIGS. 22C and D show diamond
shaped boxes. This flexibility allows the designer to have an
expanded pallet of design choices for creating these
structures.
[0154] Another perspective view of structure 464 along with plan
section and detail views of the same, a project matrix analysis,
solid and mesh models, and a center of gravity model of structure
464, are shown in FIG. 23. A designer has ability to see these
kinds of information in real-time as they modify 464 as previously
described. A designer has ability to view structure 464 from
different angles, including the plan and section detail views to
ensure the structure shape is correct. The project matrix view
identified by box 570 calculates useful information, such as part
count, unrolled dimensions, sheet count, fabrication hours, and
total weight (based on known materials) for use while fabricating
structure 464. This information can be used for creating documents,
shop drawings, and architectural drawings, for example. Solid model
572 shows the box version of structure 464. This solid model can be
used to make scaled rapid prototyping models, or be exported for
insertion into compatible CAD modeling and information management
systems. Mesh model 574 can be exported to a rendering application
in order to be rendered to show clients how the final product may
look. The center of gravity view 576 which identifies the center of
gravity 578 may be useful for structural purposes. It is
appreciated that this information may be continually updated as the
structure changes.
[0155] FIG. 24 shows box 470 from FIG. 17A exploded from structure
464. Additionally, it shows how this box can be specifically
constructed in several ways to achieve visual, structural,
performance (i.e. internal lighting or acoustical absorption) or
other operational goals or specifications. These construction
strategies constitute cutting and folding strategies to make
three-dimensional boxes from two-dimensional sheet goods. Box 578
is an example of a box construction strategy consisting of front
part 582 and rear part 580. The rear part 580 nests inside front
part 582 and is connected in several possible ways to create a
self-structuring box portion of 464. The resulting rear face of box
578 in recessed (this is unlike box 584 and 590 in this
illustration). Box 584 is an example of a box construction strategy
comprising front part 588 and rear part 586. The two parts 588 and
685 have "male" tenon members that fit inside the mating box and
connect in several possible ways to create a self-structuring box
portion of 464. Box 590 is an example of a box construction
strategy consisting of front part 594 and rear part 592. The two
parts 594 and 592 have "female" flanges that allow the boxes to be
connected (in several possible ways such as magnets, glue, etc.) to
create a self-structuring portion of structure 464.
[0156] As previously discussed, individual box fold-up strategies
are tied proportionally to the box geometry, enabling it to adapt
as the boxes' geometries stretch and twist into a particular form,
and to adjust for characteristics (including but not limited to
thickness) of sheet material the boxes will be made from.
Constraints can be applied to the proportions of the geometry to
ensure the individual folded boxes will assemble properly and do
not exceed either the dimensional yield capacity of the flat sheet
goods or the structural (or tailoring) capacity of the folded-up
three-dimensional box and overall assembly. FIG. 25 shows
wire-frame geometrical extens of two boxes from structure 464.
These wire frame geometrical extents represent the outer most
boundaries of the boxes, as shown by 506 in FIG. 18. The
geometries' of boxes 610 and 620 are derived proportionally smaller
from these wire frame extents to account for material
characteristics, etc., as described above. In the embodiment shown,
unfolded box portions 602 and 604 have been cut and scored so that
when folded they form box portions 606 and 608 which are brought
together, by means previously discussed, to form box 610. In
another example, cut and scored box flats 612 and 614 are folded
into box portions identified as 616 and 618. Those portions are
then brought together to create box 620. The boxes (like 610 and
620 in structure 464) have geometrical constraints (upper and lower
limits for lengths and included angles for example) that govern the
allowable final size and shape of the boxes. These constraints are
calculated to ensure that what the user is designing can be made to
meet minimum acceptable tailoring and structural tolerances. The
user may not, for instance, specify a box that is too small to be
adequately fabricated to pre-determined quality specifications from
the desired flat sheet material.
[0157] With any box construction fold-up strategy, each box starts
as a flat two-dimensional set of line-work that describe all of the
outer profile cutting geometries, fold type (by scoring, machining,
bending, etc.) and location geometries, as well as connection and
alignment geometries (through holes, blind holes, slots, tabs,
etc.) that are necessary to manufacture and assemble the unfolded
box part from a specified flat sheet material into the final
self-structuring box. FIGS. 26A and B show two box parts unfolded
593 and 595 and their resulting sets of line-work nested onto a
flat sheet good that describe the required motions for a
fabricating tool. This line-work is converted to machine code and
transmitted to a robot (CNC for example) for fabrication.
[0158] FIGS. 27A-I are perspective progression views showing the
assembly of a domed structure made according to the techniques
discussed herein. A completed dome 600 shown in FIG. 27G includes a
top opening 602 and entryway 604. An outline of an illustrative
person 606 is included to demonstrate scale. For this illustrative
embodiment, a base plate 608 is affixed to a ground or floor
surface 610 via fasteners as shown in FIG. 27A. Base plate 608 may
be attached to ground surface 610 via bolts or other fasteners
suitable to attach such structures to a ground surface. It is
appreciated that base plate 608 can be generated while creating the
structure itself using techniques previously discussed. As
discussed previously, the exact geometry of the location and
orientation of the bottom-most sides of the boxes that comprise the
first row of boxes 612-644 is known. In this case, that geometry is
used to define the geometry for the profile and corresponding box
connection points on base plate 608. The base plate may be
fabricated using this geometry in a material and process
appropriate for the specific application (i.e., sheet metal,
plywood, etc.). It is further appreciated that the materials used
to make the base plate can be the same plastic, metal, or paper
used for the structure. Once base plate 608 is fixed to ground
surface 610, it may serve as a template to begin assembling
structure 600. As shown in FIG. 27B, first box 612 starts the
process by being placed onto plate 608 adjacent entryway 604. A
second box 614 is placed on base plate 608 adjacent first box 612.
As this view demonstrates, the face plate serves as a sufficient
guide, so this first row of boxes is set properly. FIG. 27D
continues the process by placing box 616 onto base plate 608
adjacent box 614. FIG. 27E continues this process by placing boxes
618, 620, 622, 624, 626, 628, 630, and 632 next to each other on
base plate 608. Lastly, boxes 632-646 are placed on base plate 608
to complete the bottom row of structure 600. Also shown in this
view is a detailed view of base plate 608 that includes affixment
647 to the floor such as bolts or screws. A plurality of magnets
648 attract corresponding magnets on boxes 612-646 connecting the
boxes to the base plate just as the boxes having magnets thereon
connect to each other, as previously discussed. Repeating this
process by stacking additional rows of boxes on top of this first
row, as indicated by reference numerals 650, 652, 654, the dome
structure 600 is assembled.
[0159] Trim may be attached to the periphery or openings
(fenestrations) in structure 600 such as a jam 656 located around
entryway 604 as shown. Jam 656 may include magnets of the same type
as used on the boxes and face plate 608 so that jam 656 couples
securely to the boxes. Shown in FIG. 27H is a center retaining ring
that trims out opening 602 of structure 600. Ring 658, jam 656 and
the boxes that form structure 600, may be made of the same plastic,
metal, paper, or combination of each and have the same magnets, or
other attachment means, as also previously discussed. A header 660
shown in FIG. 27I may be used to add additional structure in
locations where either tension stresses are calculated to exceed
the structural capabilities of the boxes and their connection
strategy, and/or in the case of an opening like 604, functions as a
header across the top of the opening to support an open span.
Either way, the geometry to fabricate and install the additional
structural members is drawn from appropriate box geometries. It is
appreciated this header may also be made of the same (or different)
material and connection means as the boxes and other trim pieces,
as well as have the same magnets to attach itself to the boxes.
[0160] Another illustrative embodiment of the present disclosure
includes a suspended wall divider structure 670, as specifically
shown in FIGS. 28B, E, and G. The view shown in FIG. 28A discloses
the means to suspend structure 670 off of ground surface 672. An
outline of a person 674 is included to show scale. In this view,
tension rods 676 extend downward from top mount 678 to a bottom
plate 680 which is attached to floor 682. It is appreciated that
tension rod 676 may be a rigid metal rod or cable. A base member
682 attaches to each of tension rod 678 illustratively above ground
surface 672 and bottom plate 680. Base member 682 is the surface
structure 670 sits on to be suspended above ground surface 672. As
shown in this view, a box 684 is placed on top of base member 682
to begin assembling structure 670. The view shown in FIG. 28C
demonstrates how box portions 686 and 688 straddle tension rod 676
and join together to form box 684. The view in FIG. 28D shows top
side 690 of box portion 688 that includes an illustrative cutout
692 for receiving a portion of tension rod 676. Also shown in this
view is magnet 694 that may be used to attach box portions to each
other. By assembling the several boxes in a manner similar to that
previously discussed, structure 670 can be created as shown in FIG.
28E. In that additional embodiment, as indicated in FIG. 28F, a top
tension plate 696 fits on top surface 698 of structure 670 (see
FIG. 28E) to compress the boxes which maximizes their strength and
resists lateral and compressive loading as an individual unit. To
complete this illustrative embodiment, trim panels 700 and 702 are
attached to the end of structure 670, as shown. It is appreciated
that this attachment may be made by means previously discussed,
including magnets.
[0161] An illustrative embodiment of structure 704 is shown in
FIGS. 29A-G. These views demonstrate how wall mounted structure 704
may be assembled and attached, as shown in FIG. 29A. An outline of
an illustrative person 706 is included to show scale. As shown in
FIG. 29B, illustrative boxes 708 and 710 are attached together via
magnets or rivets. The progression view in FIG. 29C demonstrates
how stacking one box on top of another, such as adding boxes 712,
714, and 716 forms a complete column of boxes as indicated by
reference numeral 718. This process is repeated until all of the
columns are assembled. The view shown in FIG. 29D includes wall
surface 720 having batten strip 722 attached thereto via an anchor
or other fastener, or screw. The detail view in FIG. 29A shows the
profile of batten strip 722 attached to wall 720. It has an angled
face 724 to catch a corresponding notch portion 726 formed
illustratively in the top box, such as box 716, of at least a
portion of if not all of the columns. Column 718 may also be hung
onto batten strip 722, as shown in FIG. 29E. Another column 728 is
hung onto batten 722 and placed adjacent column 716, as shown in
FIG. 29F. This process continues with the additional columns
729-744 of structure 704 as shown in FIG. 29G. Trim pieces 746 and
748 may be attached to the end of structure 704 by means previously
discussed to finish the look of structure 704.
[0162] Perspective, front, and top views of freestanding column 800
are shown in the FIGS. 30A-C. Column 800 is another complex-curved
structure that can be assembled via uniquely sized and shaped boxes
by means previously discussed. It is appreciated from these views
how column 800 is made from a plurality of different sized boxes,
such as box 802, in order to create the multi-curved surfaces 804,
808, 810, and 812. This illustrative embodiment of column 800 is
configured to include a center opening 814, as shown in FIG. 18c.
It is possible that opening 814 may receive a structural beam to
support a roof structure or the like. Such beam, however, is not
needed to necessarily support column 800. The view of 18c also
shows an illustrative profile of the box shapes which include a
plurality of L-shaped boxes 816, 818, 820, 822, and quad boxes 824,
826, 828, and 830, respectively.
[0163] Additional views of column 800 are shown in FIGS. 31A-E.
FIG. 31A shows a single corner box 840 removed from column 800. A
perspective view of box 840 is shown in FIG. 31B. The L-shaped
corner box has two front faces one on each side of the corner. The
triangulated panels that make up the digital surface approximation
841 shown in FIG. 31C and the digital unfold pattern 843 shown in
FIG. 31D are a result of the surface approximation method
illustrated in FIG. 41. FIG. 31E shows the unroll pattern 843 with
the soft folds, also described in FIG. 41, removed.
[0164] Another illustrative embodiment of the present disclosure
includes a diamond ceiling structure 880 as shown in FIGS. 32A-D.
The perspective view shown in FIG. 32A depicts a plurality of
open-backed boxes that form the multi-curved structure. Boxes, such
as box 882, are generally diamond shaped, include a face and four
sides, but as shown in FIGS. 32B-D, does not include a back panel.
This can make the overall structure lighter while still offering
the flexibility in complex curve design, like other structures
discussed herein. And just like the other embodiments, these
diamond shaped open back boxes are individually sized in order to
create the complex curves. It is further appreciated that some of
the boxes may have three sides, such as those on the end, like
boxes 884, 886, 888, and 890, for example. This is a result of the
box orientation particular to the diamond pattern applied to the
base surface. Illustratively, the box construction is similar to
that of the prior embodiments and the structure assembled in a
similar way.
[0165] Various views of an illustrative embodiment of a Voronoi
wall adjacent a standard wall is shown in FIGS. 33A-D. The Voronoi
wall 892 shown in FIG. 33a may serve as a decorative architectural
feature, in this case located adjacent a stairway. The
characteristics of this wall include the irregular shapes of the
boxes. Despite their irregular shape, they can be constructed by
means further disclosed herein (see, e.g., FIG. 60). It is
appreciated from the views particularly seen in FIGS. 33C and D
that it is not only the multiple curves that can add uniqueness to
the structure but the varied box shapes as well. In this case, box
896 for example, is shaped substantially different than adjacent
box 898 or even box 900.
[0166] Perspective, front, side, and top views of a freestanding
dome structure 910 are shown in FIGS. 34A-D. An outline of an
illustrative person 912 is located adjacent the views of dome 910
in FIGS. 34B and C to show scale. These views demonstrate another
structure that can be made from uniquely sized boxes, such as box
914 and 916. Because the boxes are configured to match a particular
contour, rather than the contour being limited by single-sized box
construction, such complex structures as shown herein, can be
assembled. It is appreciated that the boxes that make up structure
910 are stacked and attached to each other via magnets or other
fasteners such as those discussed herein.
[0167] A wall to ceiling transition structure 920 is shown in FIGS.
35A-D. Structure 920 demonstrates yet another illustrative
embodiment of the present disclosure that can be made from uniquely
sized boxes, such as box 922 and 924 positioned in a predetermined
order to form the structure shown herein. The outline of an
illustrative person 926 is included in FIG. 35C to show
illustrative scale.
[0168] Perspective, front, side, and top views of a suspended
ceiling with cuspy shaped boxes 930 are shown in FIGS. 36A-C. In
this illustrative embodiment, these boxes have a generally
rectangular footprint, but their faces have multi-paneled facets,
such as is the case with boxes 932 and 934. The sides of the boxes
that connect one another via magnets, bullets, etc., are uniquely
sized and abut each other edge-to-edge the same as prior
embodiments, but the face of each box from this embodiment has a
plurality of facets to add additional dimension and uniqueness to
surface of structure 930. An outline of an illustrative person 936
is shown for scale.
[0169] Another illustrative embodiment includes perspective front,
side, and top views of a variable quad wall, as shown in FIGS.
37A-D. An outline of an illustrative person 941 is located adjacent
wall 940 in FIG. 37C to show scale. Quad wall 940, like the other
embodiments, includes connectable sides that are assembled in
particular order. In this case, however, the faces have
continuously variable skewed four-sided geometry to create the
pattern as shown. In addition, side walls of the boxes are variably
angled to further assist in creating the multiple curves as shown.
Edge-to-edge alignment of the boxes is still achieved, however.
[0170] Perspective, front, side, and top views of structure 950 are
shown in FIGS. 38A-D. This structure can serve well as a partition
or a product display. The outline of an illustrative person 952 is
added to show scale. Curve wall 950 is similar to embodiments
previously discussed.
[0171] Another illustrative embodiment of the present disclosure
includes a pleated freestanding side wall 960 as shown in FIGS.
39A-D. This design, like the others, may employ the concept of the
uniquely shaped boxes, such as boxes 962 and 964 to make the
pleated pattern surface. The outline of a person 966 is shown for
scale. This installation illustrates an inside corner condition
within an installation and subtly skewed seams between boxes for
aesthetics.
[0172] Another illustrative embodiment of the present disclosure
includes a ruled box wall 970 attached to a standard wall 972, as
shown in the perspective, front, side, and top views of FIGS.
40A-D. In this illustrative embodiment, the boxes run like columns
the entire width of the structure to give a particular
architectural affect which is appreciated by comparing FIG. 40B
with FIG. 40D. Again, because each box is individually shaped, the
structure surface can be almost anything to create a unique design
or surface pattern. The technique used to build the ruled boxes
used in this example is illustrated in FIG. 51.
[0173] One of the mechanisms employed to better approximate these
uniquely shaped boxes to the particular curved base surface is to
have the face of the box twist to some degree. The views shown in
FIGS. 41A-K demonstrate how this may be done. Illustratively, base
surface 1000 is translated into structure 1002, both shown in FIG.
41A. Each box, such as box 1004 is uniquely shaped to best
approximate base surface 1000 using techniques previously
discussed. In doing so, instead of every box having a flat face
when assembled, some boxes will be calculated to have a twisted
face, as also shown in FIGS. 41B and C. As demonstrated in FIG.
41B, box 1004 has one of its four corners raised a distance. The
same is the case with respect to box 1004 in FIG. 41C, as indicated
by distance 1006. It is appreciated that these boxes may be
fabricated from materials that can be twisted without permanently
affecting their resiliency or memory. The twist for a particular
face is digitally approximated by breaking the twisted surface down
into triangular facets that are inherently flat, shown in FIGS.
41D-G. These triangular flat faces are digitally unrolled into a
blank (see FIG. 41F). The diagonal edges triangulating each face
are eliminated in the blank before cutting, as illustrated in FIG.
41G. The resulting blank's boundary is cut out of a flexible flat
material and the remaining interior edges are bent, scored, heat
formed or partially routed, removing the material memory and
enabling it to bend sharply as a living hinge. The resulting blank
may be twisted precisely into the original box shape, with sharp
creases along the relieved edges and soft twisted along the removed
diagonal edges. The orientation of the diagonal edges that are
digitally added for surface approximation affect the accuracy of
the approximation. FIG. 41I illustrates how the triangular panels
approximate the twisted face by highlighting sections planes along
each diagonal. At the center of the face the triangulated panels
will be slightly higher or lower than the twisted face. FIGS. 41J
and K illustrate how the distance between the twisted face and the
triangular panel approximation can vary dramatically depending on
which direction the surface is triangulated. The triangular panels
in Fig. j are much closer to the initial twisted surface resulting
in a more accurate approximation. This difference can also be a
manipulated visual effect if primarily convex or concave boxes are
desirable. The view of the blank version of box 1004 shown in FIG.
41F also shows the hard fold lines to create the box. If blank 1004
is made of a relatively soft material, like cellular plastic, hard
fold lines are routed, v-cut, creased, etc., as described above. In
contrast, if these boxes are made of sheet metal, a folding tool is
used to form the hard edge folds, as shown in FIG. 41G. It is
appreciated that when using a cellular plastic the box can be
unfolded and laid flat while the hard fold lines 1020 cannot be
unfolded.
[0174] FIG. 42 shows a structure 1030 that is made up of boxes
1032, 1034, 1036, and 1038. As previously discussed, it is
necessary to know where each box portion and ultimately each box is
positioned in relation to the other boxes in order to assemble the
structure. In this example, box 1036 is shown split up into
separate box portions 1038 and 1040. Each box has indicia on it to
identify its location vis-a-vis the entire structure. For example,
box 1038 includes the indicia "1-1i." This means this box is to be
positioned in row 1, column 1, and is part of the inner hemisphere.
In contrast, box portion 1040 includes the indicia "1-1o" which
indicates row 1, column 1, but part of the outer hemisphere.
Therefore, box portions that form a box will have the same column
and row numbers, but one will have an "i" or an "o." This
convention works for the other boxes as well. For example, box 1034
will have indicia "1-2" with each box portion having either an "i"
or "o." Box 1038 will be labeled "2-1" with either an "i" or "o" on
either box portion. Box 1032 will be labeled "2-2" again with the
"i" or "o" depending on the box portion.
[0175] Partial cutaway-perspective and exploded perspective views
of box 1050 are shown in FIGS. 43A and B. Box 1050 is made up of
box portions 1052 and 1054. These views demonstrate how the empty
space inside each of the boxes can be used for a myriad of
functions, in addition to being components of a structure. In this
case, the boxes are designed to have integrated, acoustical, and
lighting properties. It is appreciated that such boxes may have
either acoustical or lighting properties, in an alternative to
having both. As shown in FIG. 43A, the exterior of box 1050 can be
of a design similar to conventional boxes already discussed herein.
Box portion 1054 may include a fabric-wrapped skin 1056 over a
perforated rigid housing 1058. An acoustic panel 1060 may be
positioned between the two box portions 1052 and 1054 and may
include integrated lighting 1062 on the periphery of acoustic panel
1060. Openings 1064 and 1066 are available to run wires to power
the lighting, speakers, or any other similar device that requires
wiring.
[0176] An exploded view of box 1050 shown in FIG. 43B further
depicts how acoustic and lighting boxes are constructed. In this
case, acoustic fabric 1056 is fitted over top of the perforated box
face. It is appreciated that the holes in the panel can vary
depending on the particular acoustical need. These holes allow
sound waves to pass through and absorb in acoustic panel 1060. In
this illustrative embodiment, an integrated lighting strip, such as
a LED lighting strip 1062 is positioned adjacent the periphery of
acoustic panel 1060. It is appreciated that this type of light as
well as its positioning is illustrative only. Upon examining this
disclosure, one skilled in the art will understand that other
lighting configurations may be employed with these boxes. The
acoustic panel is illustratively fastened to box portion 1052 to
receive and absorb the sound waves. Box portion 1052 also includes
a hollow cavity 1068 configured to receive wires or other
components that are to be hidden behind acoustic panel 1060. The
openings 1064 and 1066 are available to run wires into cavity
1068.
[0177] Front and perspective partial-cutaway views of another
illustrative embodiment of a box 1070 are shown in FIGS. 44A and B.
Box 1070 demonstrates how the boxes can be used to create a variety
of shadow patterns. In this case, box 1070 includes an outer box
1072 which is illustratively a translucent plastic, at least on its
front face 1074. A plurality of darker translucent layers can be
placed inside so that when light from a fixture or ambient light
passes through the box, a particular shadow affect is created. As
shown in the perspective views of FIG. 44B, box 1070 has a
translucent or transparent face 1074. A first panel 1076 having
styles 1078 can be placed adjacent a second panel 1080 having rails
1082. This creates a weave-like effect with dark regions 1084 at
locations where styles 1078 and rails 1082 overlap. Shadow areas
1086 are located where portions of either panel 1076 or 1080 do not
overlap. And then light regions 1088 are located where neither
panel 1076 or 1080 are located.
[0178] A partially exploded view of stacked portions 1090, 1092,
1094, 1096, 1098, 1100, 1102, and 1104 are shown in FIG. 45. These
boxes include cavities 1106 and 1108 and box portions 1090 and
1102, respectively. Openings 1110, 1112, 1114, and 1116 run light,
power/data cabling, air ventilation, or other kind of in-wall type
services. This configuration provides the opportunity and
flexibility of running utilities behind the wall surface, just like
those available to conventional studded drywall walls.
[0179] FIGS. 46A and B are perspective and front views of another
illustrative embodiment of a box 1120. Box 1120 is designed to
create the illusion of relief and depth when illuminated from
behind. Though the front faces of the boxes remain flat, the side
walls of the boxes are twisted or sloped making it appear as though
the front surface created by the boxes is curvy or twisted. In the
example illustrated, the entire box appears to bulge towards the
viewer, an effect that is dramatically enhanced by the translucency
of the boxes allowing the view to see shadowing from the twisted
sidewalls.
[0180] Another illustrative embodiment of a suspended structure
1140 is shown in FIGS. 47A-D. As shown in FIG. 47A, structure 1140
is suspended from ceiling 1142 via a plurality of wires 1144. An
outline of an illustrative person 1146 standing on ground surface
1148 and adjacent to sidewall 1150 is shown for scale. It is
appreciated that this view differs from the view of structure 80 in
FIGS. 4-6 in that more lines 82 are used with structure 1140 than
used with structure 80. This is because the suspension system shown
in structure 80 is diagrammatic and included only for context. The
suspension system shown in FIG. 1140 specifically demonstrates how
utilizing many attachment points relieves the rotational "moment"
stresses at inter-box connections and allows for light weight
connections and reduced sidewall depth. As shown in FIG. 47B,
suspension lines 1144 run from ceiling 1142 to a tab 1152 that is
part of sidewall 1154 of individual box 1156. It is appreciated
that magnet 1158 can be used on sidewall 1154, as well as all the
other sides, to connect adjacent boxes, as previously discussed.
The view in FIG. 47C shows suspension line 1144 attached to the
holding tab 1152, as well as showing magnet 1158. The view in FIG.
47D shows how a cluster of boxes 1154, 1160, 1162, and 1164, being
held together by suspension lines 1144. In addition, angled bracing
wires 1166 may be used to further support the boxes. This may be
useful in earthquake-prone areas, for example.
[0181] As discussed with respect to the development of the tiling
strategies in FIGS. 16 and 22, it is appreciated that the same base
surface can be formed into a structure having boxes of a variety of
shapes. FIGS. 48A-E show the same self-supporting structure 1170,
but assembled using different box configurations. As shown in FIG.
48A, for example, quad tiling or more conventional box-looking
boxes are used to assemble structure 1170. In FIG. 48B, the same
structure 1170 is made from varied-quad tiling boxes. During the
development of the structure itself on computer, different tile
shapes for the surfaces can be calculated and chosen. (See also
FIG. 18.) As previously discussed, and as shown in FIG. 48C, a
diamond pattern can be another choice for structure 1170.
Similarly, Voronoi tiling may alternatively be chosen for structure
1170. Lastly, and as shown in FIG. 48E, a hexagonal tiling can be
employed. This demonstrates how not only the shape of the structure
can be varied to create particular shapes, but also the box
configuration to give those shapes a particular surface look. It
is, in other words, an added design characteristic for such
structures.
[0182] Another illustrative embodiment of the present disclosure
shown in FIGS. 49A-D includes a structure 1180 that is constructed
from a plurality of open surface box frames. In this illustrative
embodiment shown in FIG. 49A structure 1180 is a ceiling structure.
This view includes the outline of a person 1182 standing on a
ground surface 1184 for scale purposes. As shown in the plan view
of FIG. 49B, it is appreciated that the illustrative tiling
structure in this case is hexagonal or Voronoi (see, also, FIGS.
48D and E). These boxes are different, however, in that shown in
FIG. 49C and d they have the look of an open-faced frame. In FIG.
49C, in particular, a flat blank of box 1186 shows how such a box
is formed. This view also shows that when folded, box 1186 includes
a frame surface 1188 around its periphery and an opening 1190. It
is appreciated that all of the boxes in this pattern can be made in
similar manner as box cluster 1186, 1192, 1194, and 1196, also
shown in FIG. 49C. FIG. 49D is a perspective view of box 1186
further showing how it is folded into three-dimensions. By
assembling these boxes in the method previously discussed,
structure 1180 can be formed.
[0183] Perspective views of a structure 1200 and multiple plan
views of box 1202 in flat blank form are shown in FIGS. 50A and B.
In this illustrative embodiment, the boxes that make up structure
1200 are "staggered" similar to a common bond with brick building.
When building a curved form with staggered course boxes, each box
must have a bend to match the profiles of the boxes above and below
it. This bend is modeled in the digital representation of the part
and shown in the unfolding sequence in FIG. 50A and in the unfolded
mesh in part 1202. FIG. 50B shows how this bend and the triangular
faceting that make up the digital model of the boxes are removed
before fabrication resulting in material twisting to create the
required curvature.
[0184] FIGS. 51A-H show another illustrative embodiment of a base
surface design 1230 that includes a subdivided structure portion
1232 and the method of making the same. As shown in FIG. 51A, base
surface 1230 is a complex curve shape serving as an illustrative
ceiling. An outline of a person 1234 on floor surface 1236 is added
for scale. These views demonstrate how the curved surface structure
is created from base surface 1230. As shown in FIG. 51B, the
curvature of the subdivided portion 1238 of the base surface can be
seen clearly. This subsurface is itself further subdivided into
triangular panels approximating the curvature of the original
surface 1240, as shown in FIG. 51C. The subdivided surface 1240 is
then unfolded flat into a single panel shown in FIGS. 51D and G and
reduced to its edges and hard folds for fabrication shown in FIGS.
51E and H. FIG. 51F illustrates how the fabricated part will appear
when folded into position for the installation.
[0185] FIG. 52 is a progression view of a roll-fold quick box 1250
comprising box portions 1252 and 1254 from a flat blank sheet
condition to a final folded box. This foldup strategy enables two
matching box hemispheres to fold up and connect back to back only
using the magnets required for interbox connection to connect the
two hemispheres. Each side has a foldover flap 1255 shown in folded
and unfolded conditions. When folded over, these flaps 1255 slide
into the facing box hemisphere and match magnet locations creating
a positive connection. This foldup strategy enables parts to be
shipped flat and quickly assembled and installed on location and
requires no additional structure or connectors.
[0186] A perspective progression view of a back frame flange box
1270 is shown in FIG. 53. This box configuration will use a frame,
but inside the box not an outer frame or skeletal structure as
previously discussed. In this illustrative embodiment, when in flat
sheet blank form, box 1270 includes two components--the outer box
portion 1272 and box flange frame portions 1274 and 1276. Box
portion 1272 includes sides 1278, 1280, 1282, and 1284 with mating
tab 1286 illustratively extending from sides 1278-1282. With score
line 1288, 1290, 1292, and 1294, sides 1278, 1280, 1282, and 1284
may be folded to begin forming the three-dimensional box. Rivets,
adhesives, or other fastener can be used to secure box 1272 in box
form, as shown. Connection tabs 1296 and 1298 each extend from
sides 1278 and 1282, respectively. Flange portions 1274 and 1276
each include slots 1300 and 1302, respectively, which engage tabs
1296 and 1298, respectively, to fit and secure flanges 1274 and
1276 to box portion 1272.
[0187] FIGS. 54A-E are progression views showing the assembly of an
integral double-back flange box 1310. Similar to prior embodiments,
box 1310 includes a face 1312, sides 1314, 1316, 1318, 1320, and
flanges 1322 and 1324. Lap joint tabs 1326, 1328, 1330, and 1332
extend from sides 1316 and 1320, as shown in FIG. 54A. Tabs 1330,
1334, 1336, 1338, and 1340 extend from flanges 1322 and 1324, as
shown as well. When box 1310 is folded, as shown in FIG. 54B, lap
joint 1326 can be connected to tab 1336; joint 1328 attached to tab
1338; joint 1330 to 1340; and joint 1332 to tab 1334. Securement
may be made mechanically, magnetically, or chemically. The view in
FIG. 54C further shows how box 1310 is assembled. It is
appreciated, as shown in FIGS. 54D and E, that different back
flange configurations can be used. For example, as shown in FIGS.
54A-D, side flanges 1322 and 1324 are employed. Conversely, as
shown in FIG. 54D, top and bottom flanges 1350 and 1352 are
horizontally oriented. By changing the flange orientation, the
boxes are stiffened in both directions.
[0188] Several perspective views of an offset box tab assembly
system are shown in FIGS. 55A-G. Box portions 1360 are shown in
flat blank condition in FIG. 55A. The side walls are bent upward,
as previously discussed with respect to other embodiments. This
embodiment, however, includes fold over offset tabs 1362 and 1364.
Illustratively, each corner includes such tabs 1362 and 1364 as
shown. Each tab portion 1362 and 1364, as shown in FIG. 55b,
includes a fold over portion 1366 and 1368, respectively. Portions
1366 and 1368 are folded as indicated by directional arrows 6, 13,
70, 1372, 1374, as shown in FIGS. 55B and C. This forms tab guides
1376 and 1378. The box sides are then folded over, as shown in
FIGS. 55D and E, so that duplicate box portions 1360 can be
attached together, as shown in FIGS. 55F and G. As shown in the
detail view of FIG. 55G, tab guides 1376 and 1378 engage
corresponding guides 1376 and 1378 of another identical box.
[0189] An illustrative embodiment of a mushroom tab box 1400 is
shown in FIGS. 56A-F. As shown in FIG. 56A, box portions 1402 and
1404 include box face and sides like prior embodiments. In
addition, each box portion includes tabs 1406 extending from the
sides. A panel 1408 includes slots 1410 that coincide with tabs
1406. As shown in FIGS. 56B and C, box portions 1402 and 1404 are
folded into box portions. As shown in FIGS. 56D and E, tabs 1406
are inserted into slot 1410, thereby attaching both box portions
1402 and 1404 together to form box 1400 which is shown in FIG.
56F.
[0190] Another illustrative embodiment of a box assembly system is
shown in FIGS. 57A-E. In this illustrative embodiment, a mechanical
fastener is used to attach box walls together to form a finished
box portion. As shown in the progression view of FIG. 57A, a
conventional box portion 1420, including a face 1422 and sides 1424
and 1426 are folded in directions 1428 and 1430 as shown. When
folded, through holes 1432 form a pattern and a cavity or moat 1434
that can be filled with a casting compound to form a joining tenon,
as shown in FIGS. 57A and B. Mechanical clamp portions 1436 and
1438 straddle each side of wall 1426 of box 1420, as shown in FIGS.
57C and D. Posts 1440 of portion 1436 are configured to extend
through openings 1442 and portion 1438. It is appreciated that
epoxy (or other castable material) can fill moat 1434 so that when
tenon is assembled (cast), a solid securement is formed. FIG. 57D
shows illustrative fold configurations and channels that receive
the epoxy. As shown in this view, holes 1432 are the same as the
prior embodiment, but channels 1444 can be any variety of
configurations to receive the epoxy for structural, assemblage, or
aesthetic considerations.
[0191] As discussed with respect to structure 930 of FIGS. 19A-D, a
design element of such a structure is the facing of the boxes
themselves. In structure 930 a cuspy box is created. The
progression views of FIGS. 58A-F demonstrate how such a cuspy box
1450 is made. As shown in FIG. 58A, cuspy box 1450 is in unfolded
flat blank form. This blank may be cut and scored to create face
portions 1452, 1454, along with sides 1456, 1458, 1460, 1462, 1464,
and 1466. As shown in FIGS. 58B and C, the sides 1458 through 1466
can be folded to draw them upward. Each of the sides 1458-1466
includes a cuff that is folded over to add strength. As shown in
FIG. 58D, both sides of box 1450 are pulled upward in directions
1470 and 1472 to create the multi-angled top surface, as shown in
FIGS. 58E and F to create cuspy box 1450.
[0192] Another illustrative embodiment of a box is box 1480 made up
of box portions 1482 and 1484, is shown in FIGS. 59A and B. In this
illustrative embodiment, box portions 1482 and 1484 are identical
in design making them mirror images that may be coupled together to
form single box 1480. As shown in FIG. 59B, tabs 1486 and 1488
extend from box portions 1482 and 1484, respectively, to assist
attaching box portions 1482 and 1484 together. Holes 1490 and 1492,
for example, align when box portions 1482 and 1484 are joined
together and configured to receive a mechanical fastener, adhesive,
or other attaching structure to fasten box portions 1482 and 1484
together. As shown in this view, box portions 1482 (and 1484 for
that matter) fold open as shown to form an unfolded blank version
of box portion 1482 (and 1484).
[0193] A perspective view of a cluster of Voronoi sleeve boxes 1500
is shown in FIG. 60. Cluster 1500 is made up of boxes 1502, 1504,
1506, and 1508. Box 1508 (as well as boxes 1502-1506 for that
matter) is an illustrative hexagonally-shaped box made from a top
1510, side panel 1512 and bottom 1514. In this illustrative
embodiment, top 1510 includes tabs, such as tab 1516 configured to
engage a side 1518 of side panel 1512. Tab 1516 can be mechanically
or adhesively attached to side 1518 for securing the two together.
Likewise, bottom 1514 includes tabs such as 1520 that likewise is
attachable to side 1518 attaching the two together, as well. It is
appreciated that each tab on top 1510 can attach to a corresponding
side on side panel 1512 thereby attaching top 1510 and side panel
1512 together. Likewise, tabs extending from each edge of bottom
1514 extend upward to attach to side panel 1512 as well. This view
also shows portions 1510, 1512, and 1514 as flat unfolded sheets.
Illustrative magnet locations and alignment holes 1522 on each of
the different portions provide means for securing the portions
together to for the box.
[0194] A ruled surface relief box 1540 and the method of making the
same are shown in FIG. 61. Box 1540 is made up of first portion
1542, back portion 1544, and second portion 1546. The front faces
of 1542 and 1546 are twisted surfaces and the curvature is
approximated, digitally modeled and unrolled using the technique
described in FIG. 51. It is appreciated that the shape of portions
1542 through 1546 are illustrative and can comprise any combination
of curve or straight surfaces. In this illustrative embodiment, a
plurality of tabs 1548 and 1550 extend from surfaces 1552 and 1554
and engage slots 1556 disposed through back portion 1544 twisting
the front faces of 1542 and 1554 into position. This view also
shows how portions 1542, 1544, and 1546 begin life as flat cut
sheets that can be folded into the box form. It is appreciated how
the approximation of highly curved surfaces with such folding
techniques gives rise to a large variety of design and construction
options not available to conventional wall stud/drywall or
paver/uni-size block wall construction.
[0195] A perspective view of a wall mounted structure 1560 attached
to wall 1562 with a shelf system 1564 both in separated and
attached view, is shown in FIG. 62. With respect to structure
system 1560, it can be constructed and mounted similar to that
described in FIGS. 4, 29A-G, 39, and 40, for example. In this
present embodiment, however, columns of boxes, such as columns 1566
and 1568, may have a wider seam between the columns than in the
prior embodiments. Typically, the columns of boxes would connect to
each other via magnets, fasteners, or other attaching means; or the
columns at least be located adjacent or abutting each other. In
this case, the boxes are designed so that the columns have a space
to accommodate other structures, such as shelf rails 1572 and 1574
of shelf system 1564 shown herein. Rails 1572 and 1574 may mount
onto back wall 1562 via fasteners or other means commonly known in
the art. A plurality of shelf brackets, such as 1576 and 1578, may
attach to rails 1572 and 1574, respectively, by means
conventionally known to those skilled in the art of shelf bracket
and rail systems. As shown herein, both the rails 1572 and 1574
attached to the wall 1562 and brackets 1576 and 1578 attach to
rails 1572 and 1574. Shelving, such as shelf 1580, may rest on
brackets 1576 and 1578 to support the same as shown herein. It is
appreciated in this illustrative embodiment that the shelving can
abut the faces of the boxes forming structure 1560 and brackets
1576 and 1578 can be modified to accommodate additional length
needed in some circumstances depending on the thickness of
structure 1560.
[0196] Another illustrative embodiment of the present disclosure
includes another wall structure 1590 attached to wall 1592
according to methods previously discussed herein. This embodiment
illustratively demonstrates the ability to integrate fenestrations
into the wall systems such as doors, televisions, or other objects
that require removal of boxes. In this illustrative embodiment, a
fenestration 1594 is illustratively a window that required the
removal of some of the boxes of structure 1590. A header panel 1596
may be positioned over top the window opening 1594 to accommodate
box cluster 1598. This view also shows how a trim piece 1600 may be
used to border the boxes located at the periphery of window opening
1594. In addition, trim piece 1602 may attach to box cluster 1604
via magnets or other attachment means previously discussed to trim
out the window. This view also shows how shelves 1606 can be
located in sections of removed boxes as needed.
[0197] FIGS. 64A-E shows various views of a structural wall made in
different ways. As shown in FIG. 64A, conventional bricks or blocks
cannot achieve the curved-surface structure as by the method
disclosed herein and shown in FIG. 64B.
[0198] FIG. 64C shows a base surface 1620 in plan, front and side
elevation views. The dashed lines 1622 represent the quad pattern
for the smooth curving form of the surface. Structure 1630 of FIG.
64B is the complex curved wall based on base surface 1620 and
formed by means previously discussed in this disclosure. In
contrast, FIG. 64A shows how that same structure would appear if
made from conventional bricks or single-sized building blocks as
indicated by reference numeral 1640. The difference between the
edge condition of structure 1630 at 1632 and 1640 at 1642 is
obvious. Edge condition 1632 more closely approximates the smooth
shape of base surface 1620 than the stepped blocks of edge
condition 1642. This smooth evenness is due to the contiguous
relationship of all the mating box edges such as mating edges 1634.
The uneven jagged look of edge condition 1642 is due to the
discontinuous (not contiguous) nature of the edge conditions of
neighboring blocks in the structure. As the single-sized orthogonal
blocks are placed in an attempt to match the multi-curving form,
gaps, steps, and spaces must result between the blocks in and
between rows.
[0199] FIGS. 64D and E show different views of base surface 1650,
box structure 1660 made according to the present disclosure and
conventional bricks 1670. Wall 1660 closely approximates base
surface 1650 while structure 1670 does not. Note how the box system
of structure 1660 with its individually sized boxes can more
accurately represent both single and double-curving surface
forms.
[0200] Another illustrative embodiment of the present disclosure
provides a mobile base assembly 1700 used for self-supporting
structure 1702 made according to any of the self-supporting
embodiments discussed herein, as shown in FIG. 65. It is
appreciated that with mobile base assembly 1700, structure 1702 as
disclosed herein may be moved as desired. An underside view of
mobile base assembly 1700 showing illustrative ball casters 1704
attached thereto is shown in FIG. 66. In this illustrative
embodiment, a base panel 1705 is attached to the underside of an
illustrative base module 1706. Base panel 1704 may be made of MDF
or other like or suitable material. Also, in this illustrative
embodiment fasteners 1708 attach base panel 1705 to module 1706.
When turned over, module 1706 and base 1704 may support boxed wall
structures of the embodiments disclosed herein to roll or otherwise
move them along a surface. An illustrative embodiment of a mobile
self-supporting structure 1710 is shown in FIGS. 67 and 68,
respectively. These views show how base panel 1705 is attached to
base module 1706 which are able to support boxes 1712. It is
appreciated these boxes may be resin, cardboard, cellular resin,
solid resin, aluminum composite, or other material as disclosed
herein. The view in FIG. 68 also shows ball casters 1704 and how
they couple to base panel 1705. Again, it is appreciated that any
of the self-supporting boxed structures of any variety or
configurations disclosed herein may be employed with this
embodiment.
[0201] FIGS. 69 and 70 are perspective and detailed views of base
module 1706 of mobile base assembly 1700. The perspective view in
FIG. 69 show several base modules 1706 coupled together. It is
appreciated that each of the base modules do not have to be the
same just as the boxes that form the structures described herein.
As shown in FIG. 70, base module 1706 is shown attached to base
panel 1705 via fasteners 1708. Ball caster 1704 is shown attached
to base panel 1705 as well.
[0202] FIG. 71 is a top view of an unfolded box portion of base
module 1706, and FIG. 72 is a top view of a plurality of base
panels 1705 that attach to module 1706. These views further show
indicia 1714 to assist in matching the proper base module 1706 with
the corresponding base panel 1705. It is appreciated that base
panel 1705 may include holes 1716 or other appropriate structures
to receive casters, wheels, glides, etc. enabling the structure to
move on a surface.
[0203] The views in FIG. 73 through 78 show embodiments of an
integrated lighting feature to create visual lighting affects
inside the boxes of various embodiments of structures disclosed
herein. As shown in FIGS. 73 and 74, for example, structures 1720
may be suspended from a ceiling to produce a cloud-type feature.
Light strips or other lighting mechanisms may be placed in or on
the backside of the boxes to produce a lighting affect. As shown
illustratively herein, boxes 1722 are suspended from the ceiling
via hanging cables 1724. It is appreciated that boxes 1722 may be
made of any materials disclosed herein but illustratively, in this
embodiment, the material may be a cellular resin. Light strips 1726
such as LED lights may be placed on back panel 1728 of box 1722
with lighting elements directed towards the box portion. Zip ties
1730 may be employed to keep the light strips or other lighting
elements attached to back panel 1728. It is appreciated that other
fastening mechanisms such as screws, staples, adhesives (including
tape or glue) may be employed to attach the lighting structures to
the boxes. In this illustrative embodiment, connection cable 1732
may run from light to light to maintain an electrical connection
for all the lights on the structure.
[0204] A top view of back panel 1728 is shown in FIG. 75. It is
appreciated that a plurality of these panels may be attached
together depending on the size and number of boxes used for the
particular structure. Back panel 1728 shows openings 1733 for
hanging cables. Also shown are zip tie openings 1734 for zip ties
1730. To assist in assembling the lighting system, the circuit
direction indicator 1736 may be included or marked on back panel
1728 or the boxes. A magnet pocket 1738 may be used to attach each
box structure to a corresponding back panel 1728. It is appreciated
that a plurality of these magnet pockets 1738 may be employed in
large enough numbers to hold the box onto panel 1728. It is
appreciated that each back panel 1728 may be of different size
and/or shape depending on the corresponding size/shape of the box
being supported or attached thereto (in the case of
non-suspended-self-supporting structures). Further, cable holes
1740 may be periodically placed to allow connection cable 1732 to
run from successive light strips 1726. A perspective, partially
dissembled view of a lighting system shown on a self-supporting
column-type structure is shown in FIG. 76. This view shows box 1742
receiving light strips inside. This view shows how back panel 1728
may be configured to attach to this type of structure as well.
Magnet pockets 1738 attach back panel 1728 to box 1742. Like the
prior embodiment, back panel 1728 includes zip tie opening 1734 and
connection cable opening 1740. In this embodiment, cables 1744 are
shown extended into openings 1740 to supply power to light strips
located in box 1742.
[0205] A detailed view of a lighting assembly attached to the inner
surface of back panel 1728 is shown in FIG. 77. This view shows
light strips 1748 attached to panel 1728 that will attach to box
1742, for illuminating the same. It is appreciated that a plurality
of these light strips 1748 may be employed as shown. This view also
shows zip tie openings 1734 and connection cable pockets 1735. Also
shown in this view are magnet pockets 1738 that illustratively
connect back panel 1728 to box 1742.
[0206] Perspective views of an illuminated wall structure are shown
in FIGS. 78A and B. In this view a plurality of back panels 1728
are fastened to a wall with a plurality of light strips 1748
attached thereto. Translucent boxes 1742 may then be attached via
magnets or other fasteners for permanent or temporary connection to
their respective back panels 1728. It is appreciated that as
disclosed in the other embodiments, the boxes and back panels of
this embodiment may be a variety of sizes to create the desired
wall structure. Not all boxes 1742 and back panels 1728 are the
same sizes. That said, a particular back panel 1728 will correspond
in size to a corresponding box 1742. This allows each of the light
strips 1748 to be attached to back panel 1728 which can then attach
to the wall and all that is left to do is then attach the proper
boxes 1748 to its corresponding back panel to create the particular
structure.
[0207] Another illustrative embodiment shown in FIGS. 79 through 83
includes a tessellated registered print applied to the curved
surface of structures according to embodiments disclosed herein. As
shown in FIG. 79, an original graphic 1750 is separated into a
Cartesian grid 1752. That pattern is then registered onto a curved
surface such as curved surface 1754 on structure 1756. Despite
being applied to a curved or irregular surface, the image does not
become visually distorted. The image uses planar projection to
reduce visual warping. Each portion of the grid forms a box that
when put together will form structure 1756 in a manner as described
with respect to embodiments herein and the graphics. Each
tessellated module is separated into two triangular regions. Pixels
are projected onto these regions and unfolded onto a print file.
The view in FIG. 81 shows an unfolded box 1758 that forms a portion
of structure 1756. The top subsurface 1760 of box 1758 will have a
portion of the graphic 1750 applied thereto so that when all the
individual boxes are assembled into structure 1756, image 1750 is
formed.
[0208] The view in FIGS. 82A through C shows the conversion of
another image into a tessellated registered print on a curved
surface. Print 1770 is again broken up into Cartesian grid 1772.
That print is then converted into a tessellated registered pattern
and applied onto curved structure 1774 like those described
previously. And again, each individual portion of the image as
applied to subsurface 1778 of box 1776 as shown in unfolded form in
FIG. 82C. It is appreciated from these views how despite the
curvature of the facing of structure 1774, the image does not have
the appearance of a corresponding distortion. Instead, the image
has essentially the same appearance as the original flat image like
that shown in FIG. 82A. The progression views shown in FIGS. 83A
through C show the same thing where a pattern 1780 is broken up
into a Cartesian grid 1782 that forms tessellated registered
pattern 1784. Unfolded box 1786 as shown in FIG. 83C demonstrates
again how a portion of the tessellated image is applied to the
subsurface of the unfolded box such that when all of the unique
boxes are assembled together, the final image is formed as well as
the structure and curved surface.
[0209] FIGS. 84 through 86 show various views of magnet snap grid
module assembly 1790. This view shows how a box design 1792 may be
attached to a ceiling structure such as a tiled ceiling grid 1794.
As the side-sectional view in FIG. 85 shows, box 1792 is attachable
to a flange 1796 attached to a "T"-runner-type structure of tiled
ceiling grid 1794. Magnets 1798 may be attached to a back panel
portion 1800 which is configured to attach to a flange 1796
attached to "T"-runner structure 1794. As shown in FIGS. 86A and B,
box module 1792 is attached to a ceiling adjacent ceiling tiles
1802 with none of the attachment means essentially visible. As
shown in FIG. 86B, with box 1792 removed, flange 1796 is shown set
or coupled to the bottom flange of "T"-runner structure 1794 of the
ceiling tile grid. Flange 1796 illustratively includes magnets
which attracts magnets 1798 on box 1792. It is appreciated that in
alternative embodiments flange 1796 may have the magnetic surface
that attracts the box. Additionally, in alternate embodiments,
other fastener structures may be employed in place of the
magnets.
[0210] The views in FIGS. 87A through D show illustrative
embodiments of lensing on the subsurface of boxes employed in the
various embodiments described herein. The view shown in FIG. 87A is
a print file 1810 showing portions of the same printed in gray at
1812. It is appreciated that the printing may be some color having
a level of opacity less than 100%. For example blacks and grays, at
about 50% or 75%, may be employed to create the lensing effect. As
shown in FIG. 87B, no backlighting is provided to boxes 1814 and
1816 with a subsurface lensing 1818 and 1820, respectively. This
view depicts how the visible lensing pattern is lightly
distinguishable with the backlighting off. The lensing effect
becomes more pronounced, however, as shown in FIG. 87C when
backlighting is turned on. In this case, the printed pattern is
more visible than with the backlighting turned off. As shown in
FIG. 87D, with backlighting on and room lights turned off, the
lensing pattern on subsurfaces 1818 and 1820 are even more
pronounced than when the lights in the room are turned on.
[0211] Perspective views of a briefcase module box 1830 and wall
structure 1832 composed of the same are shown in FIGS. 88A and B.
In contrast to other embodiments like the ones shown in ghost lines
at 1834 in FIG. 88, a box may be formed that includes front, back
and all side panels from one folded flat sheet. As shown, box 1830
includes front box portion 1836 and back portion 1838 coupled
together by a spine portion 1840 hingedly attached by scored hinges
1842. Spine portion 1840 provides a clean, solid-looking surface
rather than having an exposed seam formed when attaching front and
rear box portions together as depicted in other embodiments herein.
The transparent view of box 1830 shown in FIG. 89 demonstrates how
the folded box not only includes the clean spine 1840 but may also
employ lighting structures such as zip tie opening 1734 and cable
connection opening 1740 (see FIG. 75, for example). Also shown in
this view is indicia 1844 and the plurality of magnet attachments
1846 which instruct the order within which the box should be put
together and secures to another. The top view of box 1830 in an
unfolded configuration along with an illustrative lighting back
panel 1728 is shown in FIG. 90. This view demonstrates how both the
lighting structures and the box itself may start off as flat panels
and then folded to form a finished box.
[0212] FIGS. 91A through C show perspective views of different
embodiments of tessellated subsurface structures 1850, 1852 and
1858. These structures are made from boxes that include a
tessellated subsurface on each box. As shown in FIGS. 92A through
C, a single box 1860 starting in unfolded configuration, includes a
score line 1864 on its subsurface 1862. As box 1860 is folded, as
shown in FIG. 92B, fold line 1864 causes subsurface 1862 to become
angled along that line. Front subsurface 1862, therefore, becomes a
tessellated subsurface as shown by the front perspective view of
FIG. 92. It is appreciated the box in this view corresponds to
structure 1850 shown in FIG. 91A. It is also appreciated that the
box 1860 may include sidewalls 1866, 1868, 1870, 1872 having
different depths.
[0213] The views shown in FIGS. 93A-C are similar to that shown in
FIGS. 92A through C, but in this case, box 1880 corresponds to box
1852 shown in FIG. 91. As boxes 1880 in FIGS. 93A-C demonstrate,
surface 1882 includes multiple fold lines 1884 and 1886 to provide
a different tessellated surface 1882 than surface 1862 shown in
FIG. 92. Similarly, box 1890 shown in FIGS. 94A through C includes
a tessellated subsurface 1892 having a curved fold line 1894 which
corresponds to box 1858 in FIG. 91C. These views demonstrate how
the tessellated subsurface may include any myriad of designs to
create a desired effect.
[0214] FIGS. 95 through 97 show alternative folding strategies for
individual boxes to create trimless edges. A perspective view of a
structure 1900 similar to those discussed in previous embodiments
is made up of a plurality of boxes. In this embodiment one of the
edges 1902 of structure 1900 is visible. By designing at least the
edge boxes, such as edge box 1904, have a trimless edge 1906, the
overall structure is given a cleaner and more finished look. The
view in FIG. 95B shows an unfolded box 1904 wherein tabs 1908 and
back portion 1910 are folded so they are not visible in relation to
edge 1906. As shown in FIGS. 96A-C, a trimless corner box 1912 is
configured to have trimless side and top edges 1914 and 1916,
respectively. As shown in FIG. 96C, tabs 1918, 1920, 1922, 1924 and
1926 can all be folded so they are not visible when trimless edge
1914 forms a portion of the sidewall of structure 1900. Similarly,
tabs 1819, 1922, 1928, 1930, and 1932 may be folded so no seams
become visible when topside 1916 forms a portion of the top edge of
structure 1900. It is appreciated that these folding schemes make
the fasteners essentially invisible as well. This scheme may also
be used on any type of fold configuration. Similarly, FIGS. 97A-B
show a trimless edge or the top and bottom sides, respectively.
Another folding configuration is a pinwheel fold as shown by
unfolded box 1950 in FIG. 98.
[0215] An illustrative scheme for folding a box portion such as box
1980 is shown in FIGS. 99 through 104. As shown in FIG. 100, box
1980 starts off with an unfolded blank. It is appreciated that
these flat unfolded boxes are often shipped in this condition and
even include magnets 1982 for ease of transport. It is further
appreciated, and as previously described, box 1980 includes a
variety of score lines that dictate how the box will be folded into
its final shape. As shown in FIG. 101, flange 1984, and tabs 1986
and 1988 are all folded as shown and engage tabs 1990 and 1992 of
side portion 1994. As shown in the detailed view, tabs such as tab
1986 may attach to other tabs such as tab 1990 via fasteners or
other attaching means. The same process is continued with back
portion 1996 and side 1998. As depicted in FIGS. 102A and B, slide
flanges 2000, 2002, 2004, and 2006 are all folded over as shown.
Once this is done, as indicated in FIG. 102B, fasteners such as
fasteners 2008 may extend through each of the side panels as shown
to secure the same together. With that completed, and as shown in
FIGS. 103A and B, sidewall 2006 is folded up so sidewalls 2000 and
2002 match up with flange 1984. Fasteners 2008 may be used as shown
to secure those portions of the box together. The same process
occurs with walls 1998 and 2012. With all the folding complete, and
as shown in FIG. 104, additional fasteners 2008 help secure all the
tabs and walls together.
[0216] Another illustrative embodiment of the present disclosure
includes a structural design 2020 composed of triangular
sub-structures 2022 as shown in FIGS. 105-108. An example of such
structure is shown in FIG. 105. In this illustrative embodiment,
triangular sub-structures 2022 are folded boxes of a type similar
to that previously discussed. Those triangular sub-structures 2022
are then combined in a manner also previously described, and
further described herein to form the structural design.
[0217] As shown in FIG. 106C, acute face triangles 2024 with angles
of about 28.degree. or more may be cut and folded into the
triangular sub-structure box 2026. Illustratively, the grain
direction of the triangular surface is about 90.degree. to the
triangle's hypotenuse. To accommodate triangles with very acute
angles, the associated fold lines may be cut with a "V" cutter with
the following illustrative specification: Brand: Magnate, Part
Number: 726, Type: 2 Flute V-Grooving; Degree: 120; Cutting
Diameter: 1''; Shank Diameter: 1/2''; Cutting Length: 15/32'';
Shank Total Length: 11/2''; Material: Carbide Tipped. The cut blank
such as 2022, 2026, and 2028 may then be folded into boxes. Screws
may be used to hold the box shape. The box may also be stapled for
back flange connection. In another embodiment, a combination of
screws on the side walls and staples on the back flange may be
used. Side wall seams may be taped from the inside to help prevent
opening the side wall or corner. This is particularly useful for
modules with long side walls and acute side flap angles.
[0218] This new triangle automation design makes it possible to
handle patterns that are non-grid based. It accomplishes this by
treating the tessellation pattern as a graph and using data
representation techniques associated with graphs and networks to
determine and store the relationships between each box and its
neighbors. This includes the relationships with the outer edges.
This makes it possible to handle different sidewall conditions
automatically for any arbitrary pattern. It also enables organizing
the pattern into ordered clusters to facilitate assembly. The
complicated, potentially arbitrary pattern of parts is, thus, given
an assembly logic by grouping the parts into clusters that have a
standard average size, orientation, and assembly sequence. Labeling
the boxes keep track of this clustering to ensure the boxes are
assembled in the proper order to form the desired shape.
[0219] A plain view of the structure 2020 of FIG. 105 is also shown
in FIG. 107. Clustered region boundaries, shown in bold lines 2030,
accommodate easier sorting of the non-grid logic tessellated
modules during installation. The mock up back panel is divided into
regions designed to accommodate the numerically controlled 3-5 axis
positioning system work envelope.
[0220] The view of a cut triangular sub-structure flat blank 2022
is shown in FIGS. 108A and B. The circular parts are the
illustrative magnet or fastener positions. As shown in Fig. D, this
triangular structure design may include the shown substructure
having a span of about 28''. Four magnets arranged as illustrated
in this figure is recommended. Zip ties may also be used to extend
through adjoining sub-structure side walls to couple them together.
FIG. 108B shows the layout of magnets after the module is folded
into a box.
[0221] The blanks 2040 shown in FIGS. 109 and 110 include new
corner detail used to create more flexibility for the corner
condition of acute triangles. This configuration also separates the
Tung geometry from the rest of the corner flap.
[0222] Although the present disclosure has been described with
reference to particular means, materials and embodiments, from the
foregoing description, one skilled in the art can easily ascertain
the essential characteristics of the invention and various changes
and modifications may be made to adapt the various uses and
characteristics without departing from the spirit and scope of the
disclosure.
* * * * *