Multi-laminate folded materials for construction of boxes and other objects
OwnerDaniel H. Klinginventor
Life of this patent
Estimating the term…
Abstract
The construction and design of new multi-laminate sheet materials for the fabrication of shipping containers, boxes, furniture, consumer items, and many other products, including those generally using panels in their design, is disclosed. These new materials are produced by employing advanced folding techniques, to yield lightweight, cost effective multi-laminates. At least one layer in the multi-laminate structure is a folded sheet tessellation which, in some embodiments, can have doubly periodic folded geometries with fold creases in multiple non-parallel directions. The various layers of the construction can interlock with each other to collectively provide mechanical stiffness, strength, energy absorption and other properties.
Claims26
A laminate panel comprising at least a first and a second layer of sheet material, wherein:
- the first layer has fold lines that form a first tessellation pattern on the first layer;
- the first tessellation pattern defines polygons;
- each side of the polygons is an edge having endpoints that are vertices,
- at least some of the vertices are each coincident with at least four of the edges, and with at least four of the polygons that are not adjacent to a perimeter of the sheet;
- the first layer has two bounding tangentially conforming surfaces that are planar, cylindrical or curved surfaces;
- the second layer has fold lines that form a second pattern in the second layer;
- the second layer nests into the first layer so that portions of the second layer lie between the two bounding tangentially conforming surfaces;
- the second layer is bonded to the first layer at a plurality of rectangular bonding regions on the first and second layers;
- the bonding regions on the first layer are located between the two bounding tangentially conforming surfaces;
- and
- the second pattern is different than the first tessellation pattern.
A shipping container comprising a laminate panel, the laminate panel comprising at least a first, a second, a third, a fourth, and a fifth sheet of material, wherein:
- the first sheet has fold lines formed therein;
- the fold lines form a first tessellation having a first folded pattern generated by the two cross-section algorithm, with a triangle wave for CCS data;
- a plurality of vertices of the tessellation are each coincident with four polygons of the tessellation, each of the four polygons being non-adjacent to a perimeter of the sheet;
- the second sheet is a plane unfolded sheet or a folded corrugation;
- the third sheet is a plane unfolded sheet or a folded corrugation;
- the second and third sheets are bonded to the first sheet;
- the fourth sheet is bonded to the second sheet;
- the fifth sheet is bonded to the third sheet;
- at least one of third and fourth sheets is a folded corrugation having a second folded pattern different than the first folded pattern;
- and
- the first sheet has a stiffness less than a stiffness of at least one of the other sheets of the shipping container.
A laminate panel comprising at least a first and a second layer of sheet material, wherein:
- the first layer has fold lines that form a first tessellation pattern on the first layer;
- the first tessellation pattern defines polygons;
- each side of the polygons is an edge having endpoints that are vertices;
- at least some of the vertices are each coincident with at least four of the edges, and with at least four of the polygons that are not adjacent to a perimeter of the sheet;
- the first layer is generated by the Wave-Fold Method with an RED wave and an CCS wave;
- the second layer is substantially similar to the first layer;
- and
- the first and second layers are nested and bonded on their mating sides.
Dependencies are inferred from the claim text.