Automated Creasing Apparatus for 3D Sheet Folding
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Solution Overview
Problem
Conventional methods for forming three-dimensional sandwich structures lack automation and efficiency in folding sheets of material into robust, rigid, and durable support structures, particularly for large-scale production.
Innovation Solution
An apparatus comprising a first and second array of creasing elements with actuators that interdigitate to fold a sheet of material into a three-dimensional structure, allowing for automated folding and contraction of the material to form a support structure with enhanced strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sandwich structures are formed using corrugated materials or core materials, then the structure provides basic support, but the strength, rigidity, and durability are insufficient
Solution Approach 1:
The apparatus segments the folding process into multiple discrete operations using arrays of creasing elements that can be independently controlled. The sheet material is divided into multiple panels that are folded and connected through hinges, creating a modular support structure that achieves high strength through geometric configuration rather than material properties alone.
Solution Approach 2:
The invention transforms a two-dimensional sheet material into a three-dimensional support structure through automated folding operations. The apparatus creates spatial configurations with multiple panels arranged in three-dimensional space, providing structural rigidity and strength through geometric form rather than relying solely on material thickness or density.
2Productivity
If automated folding apparatus is implemented for large-scale production, then productivity increases, but device complexity increases
Solution Approach 1:
The automated folding apparatus is segmented into multiple independent arrays of creasing elements, each capable of performing specific folding operations. This modular architecture allows the system to handle complex three-dimensional folding patterns through coordinated action of simpler, repetitive components, increasing productivity while managing device complexity through standardization.
Solution Approach 2:
The apparatus incorporates arrays of creasing elements that automatically score and fold the sheet material as it passes through the system. The material itself is manipulated by the creasing elements to create hinges and connections, reducing the need for additional manual operations or complex auxiliary equipment, thereby increasing productivity without proportionally increasing device complexity.
3Weight of moving object
If folded three-dimensional structures are created from sheet material, then weight is reduced compared to solid structures, but manufacturing precision requirements increase
Solution Approach 1:
The apparatus performs preliminary creasing and scoring of the sheet material before the final folding operation. The arrays of creasing elements pre-mark the fold lines and create hinge regions with appropriate flexibility, ensuring that the subsequent folding operations achieve precise three-dimensional configurations. This preliminary action reduces the precision requirements during the actual folding by preparing the material in advance.
Solution Approach 2:
The invention changes the physical parameters of the sheet material through controlled creasing and folding operations. The creasing elements modify the material's stiffness and flexibility locally at fold lines, creating regions of high precision for structural connections while maintaining flexibility for movement. This parameter change allows the lightweight sheet material to achieve the manufacturing precision required for robust three-dimensional structures.
Data Source
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AI summary
Apparatus and methods for forming three dimensional structures from a sheet of material of a desired medium are described. Examples described include an apparatus for folding a sheet of material to create a folded structure, the apparatus having a first and second array of creasing elements, and at least one actuator for causing relative movement of the first and second array of creasing elements from a first position to a second position.