3D Sheet Folding Using Reflected Surfaces and Curve Folds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for bending or folding two-dimensional sheet materials into three-dimensional shapes are limited, requiring multiple parts and welding, and cannot incorporate volume without additional folds.
Innovation Solution
A method using a computer device to define primary and secondary surfaces and create a digital instruction for fully developed spreading and subsequent folding of a two-dimensional sheet into a three-dimensional shape, allowing for curve folding without prior tempering of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to fold sheet material into three-dimensional shapes, then the material can be bent along straight lines, but the object must be pieced together from multiple parts and welded
Solution Approach 1:
The patent applies curve folding instead of straight line folding to create three-dimensional shapes. By folding along curved lines, the method enables creation of complex geometries from single sheet pieces without requiring multiple parts to be pieced together and welded, thus reducing device complexity while maintaining ease of manufacture
Solution Approach 2:
The patent segments the folding process into sequential steps where the sheet is folded along multiple curved lines in sequence. This segmentation allows the creation of complex three-dimensional shapes from a single continuous sheet without requiring the sheet to be cut into multiple pieces, resolving the contradiction between manufacturing simplicity and part complexity
2Productivity
If conventional folding methods are used, then the process is simple, but volume cannot be incorporated without additional folds
Solution Approach 1:
By using curved folding lines instead of straight lines, the patent enables the incorporation of three-dimensional volume into the folded object. The curvature of the fold lines allows the sheet to form volumetric shapes more efficiently, increasing object volume without requiring additional folding operations or multiple pieces
3Manufacturing precision
If conventional bending methods are used, then simple shapes can be created, but complex three-dimensional objects require multiple parts and welding
Solution Approach 1:
The patent uses curved folding lines to create complex three-dimensional shapes with high precision. The mathematical definition of curve folds allows for accurate control of the final geometry, enabling complex shapes to be formed from single sheet pieces without requiring multiple parts to be assembled and welded, thus maintaining manufacturing precision while reducing part complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of complex three-dimensional objects without piecing together multiple parts, allows for increased volume without additional folds, and reduces material usage and manufacturing steps.
Implementation Method 1
defining at least one primary surface and at least one corresponding secondary surface, and a geometrical relationship between said primary surface and corresponding secondary surface, wherein the secondary surface is a reflection of the primary surface in a two dimensional plane
Implementation Method 2
Bending a sheet material is typically performed by applying a force to the material, which force must also generally exceed the material's yield strength to achieve a plastic deformation
Data Source
AI summary
The disclosure relates to a method for material processing of a two-dimensional sheet like material. The method comprises: obtaining information related to a desired design of a three dimensional object; obtaining information related to material characteristics of the sheet like material; defining a primary surface and a secondary surface of the desired design; and defining a geometrical relationship between said primary surface and secondary surface, wherein the secondary surface is a reflection of the primary surface in a two dimensional plane, and wherein when said primary surface is concave said secondary surface is convex, or when said primary surface is convex said secondary surface is concave; and providing a digital instruction for a fully developed spreading and subsequent folding of a two dimensional sheet into the obtained desired design, wherein said digital instruction is based on the defined primary and secondary surfaces, respectively, and said obtained material characteristics.