A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.
A solar panel rack (100) may comprise a vertical support (105), a transverse support (110), brackets (120) attaching hollow beams to the transverse support (110), and brackets (125) configured to attach solar panels (130) or solar panel assemblies to the hollow beams (115). Internal splices (135) may couple collinearly arranged hollow beams (115) in the solar panel rack (100). Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack (100) and predefine the positions of solar panels (130) or solar panel assemblies to be supported by the solar panel rack (100). Individual components of the solar panel rack (100) may be useful in other structures and applications apart from solar panel racks.
A two-dimensional sheet of material for bending along a bend line to form a three- dimensional article having a load-bearing bend line, the sheet including at least one bend- controlling displacement. The displacement includes a displaced portion displaced from the sheet of material in a thickness direction defined by a sheared face, the displaced portion further including a central portion extending along the bend line and opposing end portions at opposite ends of the central portion; and a stem portion interconnecting the displaced portion to the remainder of the sheet of material. The stem portion is located inwardly of the end portions and defined by opposing termini of the sheared face. In various aspects, the displacements are formed in opposite thickness directions and configured to promote bi-directional precision folding. Methods of forming and using the sheet of material are also described.
A system for low- force roll folding effects bending of a two-dimensional sheet material having one or more predetermined fold lines into three-dimensional article. The system may include a sheet material with bend- facilitating structure extending along a length one or more of the predetermined fold lines, a stand of rollers configured to effect bending of the sheet metal along the bend-facilitating structure, and a driver to move the stand of folding rollers relative to the sheet material along the length of one or more of the predetermined fold lines to effect bending of the sheet material along the bend- facilitating structure. A method for low-force roll folding is also disclosed.
B21D 5/08 - Cintrage des tôles le long de lignes droites, p. ex. pour former un pli simple par un procédé d'étirage dans lequel les pièces à travailler sont mises en forme par passage entre des matrices ou des rouleaux, p. ex. fabrication de profilés utilisant des rouleaux de formage
5.
HIGH-STRENGTH THREE-DIMENSIONAL STRUCTURE AND METHOD OF MANUFACTURE
A structure including a sheet of material bent along bend lines to form a plurality of walls defining an interior volume having a predetermined cross-section. A fold-out tab portion in one of the walls has a peripheral shape complementary to the predetermined cross-section. At least one side of the tab engages an immediately adjacent, corresponding wall thereby defining the predetermined cross-section. The structure may include a bend line defining a first portion and a second portion of the sheet of material, each portion including a pre-formed bend angle flange. The pre-formed bend of the first portion is aligned with the pre-formed bend of the second portion. A section of the first portion may also overlap a section of the second portion thereby forming a multiple-sheet- thick framework. An oven housing with sidewalls, a top and a back, and a removable bottom adjustably disposed within the oven compartment is also disclosed.
A load-bearing chassis for a motor vehicle includes a three-dimensional structure formed by a sheet of material including a plurality of bend lines. Each bend line has adjacent strap-defining structures defining a bending strap with a longitudinal strap axis oriented and positioned to extend across the bend line. Preferably the bend lines are configured and positioned to form a load-bearing chassis member when the sheet of material is bent along the bend lines. The bend lines defining geometrical features of the chassis. A method of forming the chassis is also disclosed.
A two-dimensional sheet material is provided that is suitable for bending along a bend line to form a three-dimensional object. The sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one side of the bend line. A portion of the displacements shear adjacent the bend line and define an edge and an opposed face. The edge and opposed face configured to produce edge-to-face engagement of the sheet material during bending. Alternatively, sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one or both sides of the bend line, and with a plurality of corresponding and cooperating protrusions to improve structural integrity and/or to improve electromagnetic and radio frequency shielding. The sheet material may also be provided with a self-latching structure. A method of preparing and using these sheet materials is also described.
A substantially two-dimensional sheet material is configured for bending along a bend line to form a three-dimensional structure having a hinge along the bend line. The sheet material includes a substantially two-dimensional in a region in which a bend is to be made, and a plurality of displacements in a thickness direction of the sheet material along opposing sides of the bend line, each displacement having a sheared edge extending between end portions thereof and substantially parallel to the bend line. The adjacent sheared edges overlap one another with respect to the bend line to form a hinge structure therebetween extending along the bend line, the hinge structure having hinge ends that conform in shape with the end portions. The hinge structure is dimensioned and configured for multiple bend and unbend cycles thereby providing a monolithic hinge connecting opposing panels of the sheet material on opposing sides of the bend line. A method of preparing and using the hinged three- dimensional structure is also disclosed.
A method of preparing a two-dimensional sheet of material for bending along a bend line to form a three-dimensional article having a fluid-resistant bend includes the steps of forming at least one bend-controlling displacement in the thickness direction of the sheet of material, a portion of a periphery of the bend-controlling displacement proximate the bend line defining a sheared face directed toward an opposed sheet surface in the sheet of material on an opposite side of the bend line, and bending the sheet of material. A balancing of the forces during bending produces face-to-surface engagement between the sheared face and the opposed sheet surface such that the sheet material is substantially fluid-resistant along the bend line.
A method and apparatus for folding of sheet materials for forming a three- dimensional structure from a substantially two-dimensional sheet material includes a restraint assembly for restraining a work piece from movement in one direction, a low flange assembly movably mounted on the frame for biasing the work piece against the restraint assembly and effecting folding along the low-flange fold line, a high flange assembly movably mounted on the frame to effect folding along the high-flange fold line, and a control assembly for sequentially operating the low flange assembly and the high flange assembly. A method of using the method and apparatus for folding of sheet materials, and the structure created thereby, is also disclosed.
B31B 3/00 - Mécanismes caractérisés par le fait que les boîtes ou cartons fabriqués, le sont par pliage de feuilles, de flans ou de bandes d'une seule pièce
11.
METHOD AND APPARATUS FOR FORMING BEND CONTROLLING DISPLACEMENTS IN SHEET MATERIAL
An apparatus for forming bend controlling displacements in sheet materials includes one or more punch blades, a punch blade block having one or more recesses dimensioned and configured to receive the punch blades, a die block having one or more recesses corresponding in number to the number of punch blades, and a die block unit having a receptacle configured to receive the die block, one of the punch blade block and the die block unit being configured to reciprocate with respect to the other. The punch blades and the die block may include hardened steel and the punch blade block and the die block may include non-hardened steel. A method of using the sheet material with bend controlling displacements and method for forming the same is also disclosed.
A load-bearing three-dimensional structure including a skeletal structure formed by a sheet of material having a plurality of bend lines, each bend line including a plurality of folding displacements, wherein the sheet of material is bent along the bend lines into a box-section; and a reinforcing member configured for substantially surrounding a portion of the skeletal structure when bent into a box- section to reinforce the structural integrity of the skeletal structure. A method of manufacturing the three-dimensional structure is also disclosed.
F16M 13/00 - Autres supports ou appuis pour positionner les appareils ou les objetsMoyens pour maintenir en position les appareils ou objets tenus à la main
A two dimensional sheet material (30) is provided that is suitable for bending along a bend line (35) to form a three-dimensional object The sheet material is provided with a plurality of displacements (37) in a thickness direction of the sheet material on one side of the bend line. A portion of the displacements shear adjacent the bend line and define an edge and an opposed face. The edge and opposed face configured to produce edge-to-face engagement of the sheet material during bending Alternatively, sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one or both sides of the bend line, and with a plurality of corresponding and cooperating protrusions to improve structural integrity and/or to improve electromagnetic and radio frequency shielding. The sheet material may also be provided with a self-latching structure (61). A method of preparing and using these sheet materials is also described.
A apparatus for forming a three-dimensional (3D) object from a sheet material preferably includes a sheet material, a shaping die defining a cavity adapted to receive at least a portion of the sheet material, a portion of the cavity having a shape corresponding to a desired surface of the 3D object, and a forming member positioned relative to the sheet material opposite the cavity and having a rigid edge having a shape corresponding to a desired small-radii event of the 3D object. When force is applied to the sheet material and to the forming member, the sheet material is forced against the portion of the cavity to form the desired surface, and the rigid edge is forced against the sheet material to form the desired small-radii event. A method of using the apparatus for spline bending of sheet material is also disclosed.
A method and apparatus for imparting compound folds on sheet material (37) includes a tool base (32) for receiving and supporting the sheet material, a locator (40) for positioning the sheet material relative to the work base, and a bend actuator (33) mounted on the tool base. The bend actuator has an actuator member movable between an initial retracted position and a deployed extended position for applying a force against an unsecured portion of sheet material to effect bending of the sheet material about the first fold line as the actuator member moves from the initial retracted position and contacts the unsecured portion. The bend actuator also has a contact member (60) positioned to abut against an outer portion of the unsecured portion as the actuator member continues to bend the sheet material about the first fold line, wherein the contact member effects bending of the sheet material along the second fold lines as the actuator member continues moving toward the deployed extended position.
B21D 5/04 - Cintrage des tôles le long de lignes droites, p. ex. pour former un pli simple sur des presses particulières avec fixation d'un côté de la pièce
16.
PRECISION FOLDED STRUCTURAL AND AESTHETIC COMPONENT AND SHEET THEREFOR
A sheet material (30) is provided for forming a precision folded structural and aesthetic component of a contoured three-dimension. The sheet material may include a forward-panel bend line separating a forward panel (42) and a fold panel, the forward-panel bend line may be curved to impart contour on at least the fold panel upon bending of the sheet material about the forward-panel bend line, and a fold line extending along the fold panel, the fold line may be substantially straight to impart the contour of the fold panel to the upper panel upon bending of the sheet material about the fold line. The sheet material may include an upper panel, a first upper-panel-flange bend line separating a forward upper flange from a warp zone of the upper panel, the first upper-panel-flange bend line may be curved to impart a first contour on one or more of the first upper flange and the warp zone, a second upper-panel-flange bend line separating a second upper flange from the warp zone, the second upper-panel-flange bend line may be curved to impart a second contour on one or more of the second upper flange and the warp zone, and first and second curved warp zone bend lines separating the warp zone from a remainder of the upper panel, the first and second curved warp zone bend lines configured to localize bending along the bend line and substantially isolate warpage within the warp zone. A method of forming the same is also disclosed.
A plane-to-plane joint is configured for securing planar segments of one or more sheet materials together without the need for additional fasteners. The plane-to- plane joint includes a first planar segment having an upper planar surface, a second planar segment having a lower planar surface, a joinder structure monolithically formed on the first planar segment, the joinder structure including a transition zone located below the upper planar surface and a registration zone extending upwardly from the transition zone and out-of-plane from the planar segment, and an aperture in the second planar segment for receiving the joinder structure. The aperture is dimensioned and configured to cooperate with the registration zone of the joinder structure to register the relative position of the first and second planar segments when the lower planar surface abuts against the upper surface. A method of making and using the plane-to-plane joint is also disclosed.
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