# US 2019/0315045 A1 · Foldable Composite Structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0315045 A1 - Document ID: US20190315045A1 - Status: Published application - Kind: A1 - Application number: 16/381,653 - Filed: 2019-04-11 - Published: 2019-10-17 - Earliest claimed: 2018-04-11 - Assignees: Clemson University - Applicants: Clemson University - Inventors: Joseph Choma - Web page: https://patentgrep.com/patent/US20190315045A1 ## CPC - B29C 53/04: of plates or sheets {(B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00)} - B05D 1/32: using means for protecting parts of a surface not to be coated, e.g. using stencils, resists - B29C 53/06: Forming folding lines by pressing or scoring - B29C 59/007: {Forming single grooves or ribs, e.g. tear lines, weak spots (by moulding B29C37/0057; folding lines B29C53/06; in metal articles B21D17/00; by cutting B26D3/08)} - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - E04C 3/34: of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings (E04C3/36 takes precedence) - B29L 2007/001: {having irregular or rough surfaces (treads for tyres B29L2030/002)} - B29L 2031/10: Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)} - B32B 7/08: by mechanical means - B32B 27/08: of synthetic resin - B32B 27/20: using fillers, pigments, thixotroping agents - B32B 27/38: comprising epoxy resins - B32B 2250/02: 2 layers - B32B 2260/046: Synthetic resin - E04C 3/28: of materials not covered by groups E04C3/04 - E04C3/20 - E04C 3/29: built-up from parts of different material, {i.e. composite structures} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract Foldable composite structures and methods for fabricating foldable composite structures are provided. For example, a method comprises selectively applying a rigidifying substance to a sheet of composite material to define a plurality of hinges; allowing the rigidifying substance to cure; and folding the sheet of composite material along the hinges to form the composite structure. As another example, a method comprises laying out flat a sheet of composite material; masking a plurality of hinges on the sheet; applying a polymer to a sheet face; curing the polymer; removing the masking; and folding the sheet along the hinges to form the composite structure. An exemplary foldable composite structure comprises a planar sheet of composite material folded to define a plurality of surface segments and a plurality of hinges. A portion of the hinges form peaks and the remainder of the hinges form valleys. The hinges are defined between adjacent surface segments. ## Claims ### Claim 1 A method for fabricating a composite structure, comprising: selectively applying a rigidifying substance to a sheet of composite material to define a plurality of hinges; allowing the rigidifying substance to cure; and folding the sheet of composite material along the hinges to form the composite structure. ### Claim 2 (depends on 1) The method of claim 1, wherein the composite material is a textile-based composite. ### Claim 3 (depends on 1) The method of claim 1, wherein the composite material is a fiber-reinforced-polymer (FRP). ### Claim 4 (depends on 3) The method of claim 3, wherein the composite material is a dry fiber reinforcement fabric. ### Claim 5 (depends on 1) The method of claim 1, further comprising: applying a masking material to the sheet of composite material before applying the rigidifying substance; and removing the masking material before folding the sheet of composite material. ### Claim 6 (depends on 1) The method of claim 1, wherein allowing the polymer to cure comprises curing the rigidifying substance over time at ambient temperature. ### Claim 7 (depends on 1) The method of claim 1, further comprising: applying a coating to the hinges after the sheet of composite material is folded to form the composite structure. ### Claim 8 (depends on 1) The method of claim 1, wherein the rigidifying substance is selectively applied using a printer. ### Claim 9 (depends on 1) The method of claim 1, wherein the rigidifying substance is selectively applied by a robotic arm of an automated machine. ### Claim 10 (depends on 1) The method of claim 1, wherein folding the sheet of composite material comprises defining a plurality of surface segments with the hinges between adjacent surface segments, the plurality of surface segments forming the composite structure. ### Claim 11 A method for fabricating a composite structure, comprising: laying out flat a sheet of composite material; masking a plurality of locations of hinges on the sheet of composite material using a masking material; applying a polymer to a face of the sheet of composite material; curing the polymer; removing the masking material; and folding the sheet of composite material along the hinges to form the composite structure. ### Claim 12 (depends on 11) The method of claim 11, further comprising: folding the composite structure into a flat pack configuration to transport the composite structure. ### Claim 13 (depends on 11) The method of claim 11, further comprising: joining the sheet of composite material with a second sheet of composite material. ### Claim 14 (depends on 11) The method of claim 11, further comprising: applying a coating to the composite structure after the sheet of composite material is folded to form the composite structure. ### Claim 15 A composite structure, comprising: a planar sheet of composite material folded to define a plurality of surface segments and a plurality of hinges, wherein the sheet of composite material is folded along the hinges, and wherein the hinges are defined between adjacent surface segments. ### Claim 16 (depends on 15) The composite structure of claim 15, wherein the composite material is a textile-based composite. ### Claim 17 (depends on 15) The composite structure of claim 15, further comprising: a coating for rigidifying the composite structure. ### Claim 18 (depends on 15) The composite structure of claim 15, wherein the composite structure is a reusable framework for a concrete structure. ### Claim 19 (depends on 15) The composite structure of claim 15, wherein the composite structure is a stay-in-place framework for a concrete structure. ### Claim 20 (depends on 15) The composite structure of claim 15, wherein one or more surfaces of the composite structure are configured to be sprayed with concrete.