Foldable Structure Formation via Segmented Slots and Channels
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Solution Overview
Problem
Existing structures like corrugated cardboard and honeycomb boards face limitations in strength, material intensity, manufacturing efficiency, and cost-effectiveness, particularly under varying load directions and thickness constraints.
Innovation Solution
A method and apparatus that score and form material to create slots and channels, allowing for the formation of a foldable structure with connected strips, which can be manipulated to create a lightweight yet robust structure with controlled height and improved throughput speeds, avoiding the need for capping layers and enhancing structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If honeycomb board is used to improve flat crush test performance, then strength is improved, but device complexity increases due to requiring capping layers and minimum thickness constraints
Solution Approach 1:
The structure is segmented into discrete strips separated by slots, with connecting elements at specific intervals. This segmentation allows the structure to achieve strength through the array configuration rather than requiring continuous capping layers, reducing complexity while maintaining flat crush resistance
Solution Approach 2:
The invention transitions from two-dimensional honeycomb cells requiring capping layers to a three-dimensional array of channels extending in multiple directions. This dimensional change allows structural integrity to be achieved through spatial configuration rather than additional layers, eliminating the need for capping layers
2Strength
If corrugated cardboard is used to improve cushioning, then strength is improved, but material intensity increases
Solution Approach 1:
The structure utilizes an array of channels and slots creating a porous configuration that provides cushioning through void space rather than material volume. This allows equivalent or superior strength performance with reduced material quantity compared to solid corrugated cardboard
Solution Approach 2:
The invention creates a composite structure combining strips, slots, connecting elements, and channels into an integrated configuration. This composite approach achieves cushioning performance through the interaction of multiple structural features rather than requiring excessive single-material volume
3Strength
If honeycomb board is used to enhance strength properties, then strength is improved, but productivity decreases due to slower maximum line speed
Solution Approach 1:
The slots and connecting elements are formed during the initial material processing stage before the board is assembled into final configuration. This preliminary action allows the strength-enhancing features to be created during high-speed material formation rather than requiring slower secondary operations, maintaining high productivity
4Ease of manufacture
If sheets are folded directly back on one another to form structure, then ease of manufacture is improved, but weight increases due to doubled-up layers
Solution Approach 1:
Material is removed to create slots and channels, eliminating the need for doubled-up folded layers. The connecting elements are strategically positioned to provide structural continuity without requiring excessive material overlap, reducing weight while maintaining manufacturability through the slot-based configuration
Data Source
AI summary
According to the present disclosure there is provided a method of forming a first structure (150), comprising the steps of: providing one or more slots (124) in a material, thereby to define a plurality of strips (122) of the material, the slots (124) defining a series of connecting elements (128) connecting adjacent strips (122) of the material, the connecting elements (128) being spaced apart along a first direction (130), forming the material to provide: an array of oppositely oriented channels (152), each channel (152) extending in a second direction perpendicular to the first direction, and the array itself extending in the first direction, each channel comprising a base, and sides extending from the base; and a first, non-continuous, outer plane; and a second, non-continuous, outer plane, such that the first structure is foldable along each of the series of connecting elements about the first direction to bring the first outer plane of a first strip toward, and optionally into contact with, the first outer plane of a second, adjacent strip.