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US 7,803,466 B2Granted
Expandable panel structures and methods of manufacturing the same
OwnerSean C. Dorsyinventor
Life of this patent
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Abstract
An expandable panel includes a generally planar panel portion, penetrated by several pluralities of spaced parallel cuts. The cuts include aligned sets of apertures and aligned sets of transverse gaps. The panel is expandable by pulling the sides apart, separating the panel along the cuts. The positioning of the apertures and gaps causes the panel portions defined between the parallel cuts to bend apart, defining front and back planes, to which sheathing, surface panels, or “skins,” can be attached. The panel can be locked in its open position by inserting connectors in adjacent aligned gaps.
Claims36
A panel structure comprising:
- a sheet of material configured to move between a nonexpanded position, wherein the sheet of material forms a substantially flat shape, and an expanded position, wherein the sheet of material forms a substantially stepped shape;
- a first side segment formed in the sheet of material and having an outer leg and an inner leg configured to allow the first side segment to bow when the sheet of material moves from the nonexpanded position to the expanded position;
- a second side segment formed in the sheet of material and having an outer leg and an inner leg configured to allow the second side segment to bow when the sheet of material moves from the nonexpanded position to the expanded position;
- an inner segment formed in the sheet of material and having a first leg and a second leg configured to allow the inner segment to bow when the sheet of material moves from the nonexpanded position to the expanded position;
- and
- a spacer configured to maintain the sheet of material in the expanded position.
3 more elements
A method of forming a wall structure comprising:
- providing a panel having a substantially planar portion having front and rear surfaces, right and left side edges, and first and second distal ends, with a central portion defined midway;
- forming a plurality of spaced substantially parallel apertures through the panel portion from the front surface to the rear surface so as to define a pair of first and second panel surfaces facing each other;
- pulling the panel in opposite directions by the right and left side edges, thereby spreading apart the panel along each cut, with the panel portions between the cuts bending apart to define a substantially stepped shape haying front and rear planes;
- using a spacer to secure the panel in its expanded position;
- and
- affixing sheathing to at least one of the front and rear planes of the panel.
3 more elements
An expandable panel structure comprising:
- a substantially planar portion having front and rear surfaces, right and left side edges, and first and second distal ends, with a central portion;
- a plurality of spaced substantially parallel cuts penetrating the panel portion from the front surface to the rear surface;
- the plurality of spaced substantially parallel cuts including a first plurality of cuts spaced a predetermined distance apart, each cut of the first plurality of cuts extending from the first distal end to an aperture provided in the panel at a position spaced away from the central portion toward the first distal end, thereby defining a first plurality of apertures substantially aligned with one another;
- the plurality of spaced substantially parallel cuts further including a second plurality of spaced substantially parallel cuts, each cut of the second plurality of cuts extending from the second distal end to an aperture provided in the panel at a position spaced away from the central portion toward the second distal end, thereby defining a second plurality of apertures substantially aligned with one another, each respective cut in the second plurality of cuts being substantially aligned with a corresponding cut in the first plurality of cuts;
- the plurality of cuts further including a third plurality of cuts spaced from one another between the aligned first and second pluralities of cuts, each cut of the third plurality of cuts extending between an aperture of a third plurality of apertures and an aperture of a fourth plurality of apertures, the third and fourth pluralities of apertures being spaced inward from the first and second distal ends toward the central portion, each of the cuts defining a pair of edges that face each other;
- and
- wherein the panel is configured to expand between a nonexpanded, substantially flat shape and an expanded, substantially stepped shape, by moving the right and left side edges in opposite directions so as to spread apart portions of the panel along each cut and bend the panel portions between the cuts apart to define front and rear planes, and by securing the panel in the expanded, substantially stepped shape by affixing a spacer in one of the plurality of cuts.
4 more elements
A panel structure comprising:
- a panel assembly having a pattern of cuts, a pattern of grooves, and a pattern of apertures configured to move the panel assembly between a nonexpanded position, where the panel assembly forms a substantially flat shape, and an expanded position, where the panel assembly forms a substantially stepped shape;
- and
- a support structure configured to fit within at least one of the pattern of grooves of the panel assembly and maintain the panel assembly in the expanded position.
Dependencies are inferred from the claim text.