Method for folding flat, non-rigid materials to create rigid, three-dimensional structures

A method of making a cover for a light source comprising:

• marking score patterns on a flat non-rigid material, wherein the non-rigid material includes a first outer side and a third outer side, wherein said first and third outer sides are spaced a distance apart, are parallel, and are of substantially the same length,
• a second outer side and a fourth outer side, wherein said second and fourth outer sides are spaced a distance apart, are parallel, and are of substantially the same length,
• a first group of parallel score lines comprising a plurality of score lines which traverse the material between the second outer side and the fourth outer side being parallel and adjacent to the first and third outer sides, further being equally spaced apart relative to each other and relative to the first and third outer sides,
• a second group of parallel score lines comprising a plurality of score lines which traverse the material between the first outer side and the third outer side, are parallel to the second outer side and fourth outer side, and are spaced equal distances apart relative to each other and relative to the first and third outer sides, and
• a third group of score lines comprising a plurality of score lines which traverse the material between the first outer side and the third outer side;
• folding said non-rigid material with mountain and valley folds according to the score patterns into a rigid three-dimensional shape;
• attaching said three-dimensional shape to a base such that said three-dimensional shape is rigid in an X-Y plane and vertically flexible in a Z-direction;
• and
• attaching said three dimensional shape to a light source.

An apparatus for forming a three-dimensional structure comprising:

• a single, flat piece of non-rigid material including
• a first outer side and a third outer side, wherein said first and third outer sides are spaced a distance apart, are parallel, and are of substantially the same length,
• a second outer side and a fourth outer side, wherein said second and fourth outer sides are spaced a distance apart, are parallel, and are of substantially the same length,
• a first group of parallel score lines comprising a plurality of score lines which traverse the material between the second outer side and the fourth outer side being parallel and adjacent to the first and third outer sides, further being equally spaced apart relative to each other and relative to the first and third outer sides,
• a second group of parallel score lines comprising a plurality of score lines which traverse the material between the first outer side and the third outer side, are parallel to the second outer side and fourth outer side, and are spaced equal distances apart relative to each other and relative to the first and third outer sides, and
• a third group of score lines comprising a plurality of score lines which traverse the material between the first outer side and the third outer side, each score line comprising:
• a plurality of segments wherein a first segment begins at the first outer side, said plurality of segments proceeding at alternating angles of about 45° to every score line of the first group of score lines, and a last segment terminating at the third outer side.

An apparatus for forming a three-dimensional structure comprising:

• a single, flat piece of non-rigid material including:
• a first outer side and a third outer side, wherein said first and third outer sides are spaced a distance apart, are parallel, and are of substantially the same length;
• a second outer side and a fourth outer side, wherein said second and fourth outer sides are spaced a distance apart, are parallel, and are of substantially the same length;
• a first group of three parallel score lines which traverse the single flat piece of material from the second outer side to the fourth outer side being parallel and adjacent to the first outer side;
• a second group of three parallel score lines which traverse the single flat piece of material from the second outer side to the fourth outer side being parallel and adjacent to the first group of three parallel score lines;
• a third group of three parallel score lines which traverse the single flat piece of material from the second outer side to the fourth outer side being parallel and adjacent to the second group of three parallel score lines;
• a fourth group of three parallel score lines which traverse the single flat piece of material from the second outer side to the fourth outer side being parallel and adjacent to the third group of three parallel score lines and the third outer side;
• a fifth group of parallel score lines comprising a plurality of score lines which traverse the single flat piece of material from the first outer side to the third outer side, are parallel to the second outer side and fourth outer side, and are spaced equal distances apart relative to each other;
• and
• a sixth group of score lines comprising a plurality of score lines which traverse the single flat piece of material from the first outer side to the third outer side, each score line comprising:
• a first segment proceeding from the first outer side to a first line of the first group of three parallel score lines at a substantially 45° angle to the first outer side;
• a second segment proceeding from the first line of the first group of three parallel score lines to a second line of the first group of three parallel score lines at a substantially 45° angle such that the first segment and second segment form a substantially 90° angle;
• a third segment proceeding from the second line of the first group of three parallel score lines to a third line of the first group of three parallel score lines at a substantially 45° angle such that the third segment and second segment form a substantially 90° angle;
• a fourth segment proceeding from the third line of the first group of three parallel score lines to a first line of the second group of three parallel score lines at a substantially 45° angle such that the fourth segment and third segment form a substantially 90° angle;
• a fifth segment proceeding from the first line of the second group of three parallel score lines to a second line of the second group of three parallel score lines at a substantially 45° angle such that the fifth segment and fourth segment form a substantially 90° angle;
• a sixth segment proceeding from the second line of the second group of three parallel score lines to a third line of the second group of three parallel score lines at a substantially 45° angle such that the sixth segment and fifth segment form a substantially 90° angle;
• a seventh segment proceeding from the third line of the second group of three parallel score lines to a first line of the third group of three parallel score lines at a substantially 45° angle such that the seventh segment and sixth segment form a substantially 90° angle;
• an eighth segment proceeding from the first line of the third group of three parallel score lines to a second line of the third group of three parallel score lines at a substantially 45° angle such that the eighth segment and seventh segment form a substantially 90° angle;
• a ninth segment proceeding from the second line of the third group of three parallel score lines to a third line of the third group of three parallel score lines at a substantially 45° angle such that the ninth segment and eighth segment form a substantially 90° angle;
• a tenth segment proceeding from the third line of the third group of three parallel score lines to a first line of the fourth group of three parallel score lines at a substantially 45° angle such that the tenth segment and ninth segment form a substantially 90° angle;
• an eleventh segment proceeding from the first line of the fourth group of three parallel score lines to a second line of the fourth group of three parallel score lines at a substantially 45° angle such that the eleventh segment and tenth segment form a substantially 90° angle;
• a twelfth segment proceeding from the second line of the fourth group of three parallel score lines to a third line of the fourth group of three parallel score lines at a substantially 45° angle such that the twelfth segment and eleventh segment form a substantially 90° angle;
• and
• a thirteenth segment proceeding from the third line of the fourth group of three parallel score lines to the third outer side at a substantially 45° angle such that the thirteenth segment and twelfth segment form a substantially 90° angle.