CN101489855A - Precision folded structural and aesthetic component and sheet therefor - Google Patents

Precision folded structural and aesthetic component and sheet therefor Download PDF

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Publication number
CN101489855A
CN101489855A CNA2007800259067A CN200780025906A CN101489855A CN 101489855 A CN101489855 A CN 101489855A CN A2007800259067 A CNA2007800259067 A CN A2007800259067A CN 200780025906 A CN200780025906 A CN 200780025906A CN 101489855 A CN101489855 A CN 101489855A
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China
Prior art keywords
panel
wiggle
flange
sheet material
warp zone
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CNA2007800259067A
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Chinese (zh)
Inventor
马克斯·W·德尼
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IND ORIGAMI LLC
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IND ORIGAMI LLC
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Publication of CN101489855A publication Critical patent/CN101489855A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/20Bending sheet metal, not otherwise provided for
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08Front or rear portions
    • B62D25/14Dashboards as superstructure sub-units

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Instrument Panels (AREA)

Abstract

A sheet material 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 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.

Description

Precision folded structural and parts attractive in appearance and be used for the sheet material of these parts
The cross reference of related application
The application requires the U.S. Provisional Patent Application No.60/799 of submission on May 9th, 2006,215 preceence, and its full content is herein incorporated with for referencial use.
The application also requires the U.S. Provisional Patent Application No.60/799 of submission on May 9th, 2006,217 preceence, and its full content also is herein incorporated with for referencial use.
Technical field
The design of relate generally to sheet material of the present invention and precision bending, to form the structure of the contoured three-dimensional that has structural and aesthetic property parts simultaneously, and the using method that relates to sheet material, and the method that relates more particularly to crooked and warpage structure and form this structure.
Background technology
Known the whole bag of tricks is used for forming three-dimensional structure by two-dimensional sheet.For example, camber jack, pressing equipment and other metal cold shaping equipment are used for sheet material is formed three-dimensional body for a long time.
Recently, the use of computerized numberical control (CNC) equipment has been used to handle sheet material so that about predefined curved line bending.For example, laser beam cutting, water spray cutting, punching press, punching, molded, casting, three dimentional printing shaping, flow forming, machinework, chemical etching, photoetching etc. have been used for along predefined curved line forming slit or groove at sheet material, so that crooked and control is crooked along this wiggle.
The example of prior art has people's such as Gitlin U.S. Patent No. 6,640,605, wherein discloses a kind of bent sheet to form the method for three-dimensional structure, and this three-dimensional structure comprises frame and shell, inside and outside structure, and various lid and strut member.
Existing method about predefined curved line bent sheet successfully forms three-dimensional body usually, but is restricted by the producible 3D shape of this method.For example, such method is generally used for forming some three-dimensional bodies like this, these three-dimensional bodies have the plane domain that extends between the adjacent flex line, or the curve regions of extending between the adjacent flex line, and this curve regions is roughly along this adjacent flex curvature of a curve.But, so far, arrange that on sheet material predefined curved line is unfavorable for forming complicated three-dimensional structure usually, this three-dimensional structure has the complicated bend contour area that is defined between the adjacent flex line.
For example, early stage vehicle generally includes the framework that structure integrity is provided, and car body panel and other non-structure member are attached to this framework.The configuration of such routine allows designer and builder to provide various decorations for attachment member, thereby provides whole joyful aesthetic appearance for vehicle.
For the monolithic body structure of nearest appearance, vehicle is provided with one-piece frame and body structure usually, and it comprises structural and the aesthstic element of unstructuredness.But, be attached on the monolithic body shell or this monolithic body shell in sub-component still comprise one or more framing member and one or more trim boards that are attached to this framing member that structural integrity is provided for framework.
For example, instrument panel structure (" I/P structure ") is to provide support the structure that also provides structural constituent for vehicle and attachment point is provided for air bag etc. for Steering gear, combination meter and other instrument carrier panel parts.This I/P generally includes one or more frame members or inner structure part, and these members are attached to the monolithic body shell, usually near the A post, and can be this framework extra structure integrity is provided.Be attached to the inner structure part and provide complete and joyful outward appearance for vehicle interior such as the external ornament of instrument carrier panel etc.
Recently, having more, the I/P structure of complex geometry forms by hydraulic forming and other Sheet Metal Forming Technology.But such I/P structure remains instrument carrier panel usually and is attached to frame member or inner structure part on it.Similarly, the part number that is used to finish Automobile instrument is more relatively, therefore assembles the required work of various parts and can not ignore.
Therefore, need a kind ofly form improving one's methods of contoured three-dimensional structure by sheet material, this method has overcome the above-mentioned of known structure and method and other shortcoming.
Summary of the invention
In short, one aspect of the present invention relates to a kind of sheet material that is used to form the three-dimensional structure of moulding.This sheet material comprises separately header board and the forward-panel bend line of folded sheet and the fold line that extends along folded sheet, in case this forward-panel bend line is bent with to form profile at least on folded sheet during about the forward-panel bend line bent sheet.This fold line can be straight basically, with about the fold line bent sheet time so that upper board forms the profile of folded sheet.
Sheet material can comprise the additional fold-line that folded sheet is separated from the additional fold plate.Additional fold-line can be straight basically, about the additional fold-line bent sheet time, to make second folded sheet form the profile of first folded sheet, wherein, when bending fold line and additional fold-line, via the folded sheet and second folded sheet, upper board can form the profile of forward-panel bend line.
Sheet material can comprise the forward-flange wiggle (forward-panel-flange bend line) that separates header board and forward-flange.About forward-flange wiggle bent sheet the time, the forward-flange wiggle can be bent, and forms profile with on one or more in header board and forward-flange.The forward-flange wiggle can be a S shape, forms recessed and protruding profile thus on header board.
Forward-panel bend line can be to recessed, to form convex profile at least a portion of upper board.Between the forward-panel bend line and first fold line first distance can be different from the second distance between first fold line and second fold line, and the front edge of the upper board of second fold line qualification can separate with header board thus.The comparable second distance of first distance is short, makes header board recessed backward from front edge thus.
Sheet material can comprise the first upper-panel-flange wiggle (upper-panel-flange bend line), and upper flange separated with the warp zone of upper board before it made.The first upper-panel-flange wiggle can be bent, to form first profile on one or more in first upper flange and warp zone.The second upper-panel-flange wiggle can make second upper flange and warp zone separate.The second upper-panel-flange wiggle can be bent, to form second profile on one or more in second upper flange and warp zone.The warp zone of first and second bendings (curved warp zone) wiggle can make the remainder of warp zone and upper board separate.The warp zone bend lines of first and second bendings can be configured to along wiggle local bending (localize bending), and the warpage in the substantial barrier warp zone.First and second warp zone bend lines all can terminate in the point of crossing place.First and second warp zone bend lines all can have compound curvatures.Wiggle can have less radius of curvature near the part of point of crossing, stops in warp zone wrinkling near point of crossing thus.
In one embodiment, at least one in wiggle and the fold line can be formed with a plurality of slits that pass sheet material.Adjacent slots alternately is positioned at least one the either side in wiggle or the fold line.In wiggle and the fold line at least one can be formed with a plurality of dislocations.Adjacent displacements alternately is positioned at least one the either side in wiggle or the fold line.
Another aspect of the present invention relates to the three-dimensional structure that comprises above-mentioned sheet material.The formation method that relates in one aspect to three-dimensional structure more of the present invention, this method comprise step that above-mentioned sheet material is provided, along the step of forward-panel bend line bent sheet with along the step of fold line bent sheet.
Of the present invention relating in one aspect to again is used to form the sheet material with contoured three-dimensional structure, this three-dimensional structure comprises upper board, the first upper-panel-flange wiggle that the preceding upper flange and the warp zone of upper board are separated, be bent on first upper flange and warp zone one or more, to form the first top flange bend line of first profile, the second upper-panel-flange wiggle that second upper flange and warp zone are separated, this second upper-panel-flange wiggle is bent forming second profile on one or more in second upper flange and warp zone, and the warp zone bend lines that makes first and second bendings that the remainder of warp zone and upper board separates.The warp zone bend lines of first and second bendings is arranged to along the warpage in wiggle local bending and the substantial barrier warp zone.
The first upper-panel-flange wiggle can be recessed along first direction, and the second upper-panel-flange wiggle can be along recessed with the uneven second direction of first direction, and wherein the warp zone elastic deformation is to adapt to the differently contoured of the first and second upper-panel-flange wiggles.
In one embodiment, first and second wiggles terminate in the point of crossing place.First and second wiggles can have compound curvatures.The part of the close point of crossing of wiggle can have less radius of curvature, stops in warp zone wrinkling near the point of crossing place thus.
In one embodiment, at least one in wiggle and the fold line can be formed with a plurality of slits that pass sheet material.Adjacent slots alternately is positioned at least one the either side of fold line or wiggle.In wiggle and the fold line at least one can be formed with a plurality of dislocations.Adjacent displacements alternately is positioned at least one the either side in wiggle or the fold line.
The three-dimensional structure that comprises above-mentioned sheet material that relates in one aspect to again of the present invention.The method that forms three-dimensional structure that relates in one aspect to again of the present invention, this method comprise step that above-mentioned sheet material is provided, along the step of the first and second upper board wiggle bent sheet.First and second warp zone bend lines can allow warpage in the warp zone, to adapt to the variation profile that first and second dash-panel-flange bend line form.
The method that relates in one aspect to the sheet material, instrument carrier panel and the formation instrument carrier panel that are used to form instrument carrier panel (dashboard) more of the present invention with three-D profile.Sheet material can comprise the dash-panel-flange bend line (dash-panel-flange bend line) of separating instrument carrier panel (dash panel) and dash-panel-flange, when about the dash-panel-flange bend line bent sheet, dash-panel-flange bend line can be bent with on one or more in instrument carrier panel and dash-panel-flange and form profile; Separate the dash-panel bend line of the instrument carrier panel and first folded sheet, when about the dash-panel bend line bent sheet, dash-panel bend line can be bent to form profile at least on first folded sheet; First fold line that first folded sheet and second folded sheet are separated, first fold line can be straight basically, to form the profile of first folded sheet on second folded sheet about the first fold line bent sheet time; Second fold line that second folded sheet and instrument carrier panel are separated, second fold line can be straight basically, to make instrument carrier panel form the profile of second folded sheet when about the second fold line bent sheet; The first instrument plate flange wiggle that the front panel flange and the warp zone of instrument carrier panel are separated, first instrument plate flange wiggle can be bent, to form first profile on one or more in first instrument plate flange and warp zone; The second instrument plate flange wiggle that second instrument plate flange and warp zone are separated, second instrument plate flange wiggle can be bent, to form second profile on one or more in second instrument plate flange and warp zone; The warp zone bend lines of first and second bendings that the remainder of warp zone and instrument carrier panel is separated, the warp zone bend lines of first and second bendings can be configured to along the warpage in wiggle local bending and the substantial barrier warp zone.
Dash-panel-flange bend line can be a S shape, forms recessed and protruding profile thus on instrument carrier panel.Dash-panel bend line can be by recessed down, to form raised profile upwards at least a portion of instrument carrier panel.Between the dash-panel bend line and first fold line first distance can be different from the second distance between first fold line and second fold line, and the front edge of the instrument carrier panel of second fold line qualification can separate with instrument carrier panel thus.The comparable second distance of first distance is short, makes instrument carrier panel recessed above front edge thus.
In one embodiment, first and second wiggles terminate in the point of crossing place.First and second wiggles all can have compound curvatures.The part of the close point of crossing of wiggle can have less radius of curvature, stops in warp zone wrinkling near the point of crossing place thus.
In another embodiment, sheet material comprises the instrument carrier panel of being delineated by the wiggle of a plurality of bendings (curved bend line), each wiggle is formed and is configured to form the profile of preliminary election when about the wiggle bent sheet of bending on instrument carrier panel, and be formed and be configured to form top web (upper beam web), top beam flange, lower beam flange by the crossbeam that a plurality of straight wiggles are delineated, the shape of cross section of its center member is set by the one or more caps that are arranged on the sheet material.
The manufacture method of instrument carrier panel comprises: above-mentioned sheet material is provided; Along the dash-panel-flange bend line bent sheet; Along the dash-panel bend line bent sheet; Along the first and second fold line bent sheet; And along the first and second dash-panel-flange bend line bent sheet, wherein first and second warp zone bend lines allow warpage in the warp zone, to adapt to the variation profile that is formed by first and second dash-panel-flange bend line.
Another aspect of the present invention relates to the sheet material that is used to form the precision folded vehicle member with structural and aesthetic beauty parts.Sheet material can comprise the instrument carrier panel of being delineated by the wiggle of a plurality of bendings, each wiggle is formed and is arranged to form the profile of preliminary election when about the wiggle bent sheet of bending on instrument carrier panel, and can be formed and be arranged to form top web, top beam flange and lower beam flange by the crossbeam that a plurality of straight wiggles are delineated, the shape of cross section of its center member is set by the one or more caps that are arranged on the sheet material.
Accurately folding structural and aesthetic beauty parts with contoured three-dimensional structure of the present invention, the method that is used for the sheet material of these parts and forms these parts have further feature and advantage, these feature and advantage will be from becoming more obvious the accompanying drawing of this combination He in the following detailed description of the present invention, wherein accompanying drawing and explanation all are used to explain principle of the present invention.
Description of drawings
From detailed description given below and only for illustrative purpose and can understand the present invention more fully the accompanying drawing that provides, so these explanations and accompanying drawing do not constitute restriction of the present invention, and wherein:
Fig. 1 is arranged for the birds-eye view that bends to according to the example two dimensional sheet material of contoured three-dimensional structure of the present invention;
Fig. 2 is the partial enlarged view of taking from the details 2-2 among Fig. 1 of the two-dimensional sheet among Fig. 1;
Fig. 3 is the two-dimensional sheet front, perspective view on after the bending according to the present invention among Fig. 1;
Fig. 4 is front, perspective view on after the bending according to the present invention another of Fig. 3;
Fig. 5 is the below transparent view of Fig. 3;
Fig. 6 is arranged for the birds-eye view that bends to according to another example two dimensional sheet material of contoured three-dimensional structure of the present invention;
Fig. 7 A is the birds-eye view according to the two-dimensional sheet of another exemplary embodiments that is set to be used for accurately to be folded to form vehicle structure of the present invention;
Fig. 7 B is the enlarged view that the sheet material among Fig. 7 A is taken from the 7B-7B details among Fig. 7 A;
Fig. 8 A-8E is a series of transparent view, shows according to the present invention along the wiggle pleated sheet of Fig. 7;
Fig. 9 A-9E is respectively the enlarged perspective of Fig. 8 A-8E;
Figure 10 is the further enlarged perspective that the vehicle structure among Fig. 8 E and the 9E is observed from the right front of vehicle structure;
Figure 11 is the further enlarged perspective that the vehicle structure among Fig. 8 E and the 9E is observed from the right abaft of vehicle structure;
Figure 12 is the further enlarged perspective that the vehicle structure among Fig. 8 E and the 9E is observed from the left front of vehicle structure;
Figure 13 is the further enlarged perspective of the vehicle structure among Figure 12;
Figure 14 is the further enlarged perspective that the vehicle structure among Fig. 8 E and the 9E is observed from the bottom of vehicle structure; With
Figure 15 is the fragmentary, perspective view of the vehicle structure among Fig. 8 E and the 9E when being installed on the vehicle.
The specific embodiment
To refer in detail to various embodiment of the present invention below, the shown in the drawings and description hereinafter of its example.Though the present invention will be described in conjunction with exemplary embodiment, it should be understood that these descriptions do not plan the present invention is limited to those exemplary embodiments.On the contrary, the present invention not only plans to cover these exemplary embodiments, also plans to cover various replacements, modification, equivalence and other embodiment, and these all will be included in the spirit and scope of the present invention of appended claims qualification.
Usually, the invention provides the contoured three-dimensional structure that forms by two-dimensional sheet.Especially, flat two-dimensional sheet is set for along predefined curved line bending, has the three-dimensional structure in complicated bend zone with formation, and this three-dimensional structure can strengthen the architectural feature and the aesthetic features of this structure.
For the present invention, " two-dimensional sheet " is meant and is as general as flat sheet material, so that sheet material can be stacked each other on it, but sheet material can have various local punching presses, punching and/or further feature again, and these features are ornamental or structural.
Usually, sheet material comprises one or more wiggles or fold line, and these lines are configured to be convenient to along the predefined paths bending, the feasible profile that forms on the part at sheet material when along the wiggle bent sheet corresponding to wiggle curvature.From hereinafter understanding, this profile can be formed on the adjacent part of sheet material, or be given to sheet material away from part.Alternatively, or additionally, can be formed on by intersecting the warp zone that wiggle or fold line delineate corresponding to the profile of a plurality of crooked curvatures of a curve, wherein distortion is limited and adapts to various profiles.Preferably, warpage is limited in the warp zone and fold is prevented from.Sheet material of the present invention also comprises straight wiggle, and this wiggle is convenient to form structure member, and in an illustrated embodiment, this structure member is a hollow cross.
For the present invention, " wiggle " is predefined paths, and sheet material is bent so that along wiggle plastic deformation about this path, forms 3D shape thus." fold line " is wiggle, and the part of sheet material on the either side of this wiggle is bent to cover (lay over) substantially each other.It should be understood that except plastic deformation sheet material also can experience elastic deformation to a certain degree.
It should be understood that can make ins all sorts of ways forms wiggle of the present invention, so that along the wiggle bending.For example, the precision bending technology of industry origami (Industrial Origami) can be used for design and/or wiggle of the present invention is provided, this technology all has description: No.6 in following US Patent, 481, Method For Precision Bending Of A Sheet Of Material And Slit SheetTherefor and No.6 in 259,877, Method For Precision Bending Of Sheet OfMaterials in 349, Slit Sheets Fabrication Process, and description arranged all in following U.S. Patent Application Publication file: the Method For Precision Bending Of SheetOf Materials among the No.2003/0037586, Slit Sheets Fabrication Process; Techniques For Designing And Manufacturing Precision-Folded among the No.2004/0134250, High Strength, Fatigue-Resistant Structures And Sheet Therefor; SheetMaterial With Bend Controlling Displacements And Method For Forming TheSame among the No.2004/0206152; Method Of Designing Fold Lines In SheetMaterial among the No.2005/0005670; Process Of Forming Bend-ControllingStructures In A Sheet Of Material among the No.2005/0061049, The Resulting Sheet And Die Sets Therefor; Method For Precision Bending Of Sheet Of Materials among the No.2005/0064138, Slit Sheets Fabrication Process; Sheet Material WithBend Controlling Grooves Defining A Continuous Web Across A Bend Line AndMethod For Forming The Same among the No.2005/0097937; Techniques ForDesigning And Manufacturing Precision-Folded among the No.2005/0126110, High Strength, Fatigue-Resistant Structures And Sheet Therefor; SheetMaterial With Bend Controlling Displacements And Method For Forming TheSame among the No.2005/0257589; Fatigue-Resistance Sheet Slitting Method AndResulting Sheet among the No.2006/0021413; Tool System For Bending SheetMaterials And Method Of Using Same among the No.2006/0053857; And the SheetMaterial With Bend Controlling Displacements And Method For Forming TheSame among the No.2006/0075798.The whole contents of these patents and patent application is herein incorporated with for referencial use.
With reference now to accompanying drawing,, wherein similar parts are represented with similar Reference numeral in whole accompanying drawing.Fig. 1 shows flat sheet material 30, and it is configured to form three-dimensional structure.In an illustrated embodiment, sheet material is configured to form the three-dimensional structure 32 of the instrument panel assembly form shown in Fig. 3.In an illustrated embodiment, instrument carrier panel (dashboard) is configured and sets size to be used in the automobile.But instrument carrier panel can be set for vehicle, Industry Control or other machine component of other type.But it should be understood that sheet material can be configured to form a plurality of three-dimensional structures, this three-dimensional structure includes but not limited to machine structural parts, automobile body plate, other vehicle structure etc.The suitable material that can be used for sheet material includes but not limited to the sheet material of thin specification and thick specification, for example steel plate, stainless steel sheet, aluminium sheet and other metal and alloy, plastics and other extensible material.It should be understood that sheet material can be not japanning, japanning and/or that scribble coating and/or other material structural and/or unstructuredness in advance, as film, foam, hole pattern and/or other suitable material.
In an illustrated embodiment, sheet material 30 comprises dash-panel-flange bend line 35, and this dash-panel-flange bend line is divided into the form of instrument or instrument carrier panel 37 and dash-panel-flange 39 to header board, as shown in Figure 1.Dash-panel-flange bend line 35 roughly is set to the distortion in local elasticity during the predefined paths bending, this predefined paths such as wiggle of mentioning below and fold line.For example, dash-panel-flange bend line 35 can be arranged on the form in the slit (events) 40 of wiggle 35 either sides, so that and accurately control along wiggle 35 bendings, in Fig. 2, clearly show that this slit 40.Slit 40 can be slit, groove, dislocation and in the above-mentioned patent of industrial origami and other adequate measure described in the patent application, and the whole contents of these patents and patent application is herein incorporated with for referencial use.
Although wiggle is described with term " dash-panel-flange bend line " and other particular term of proposing below, although and the zone of the close wiggle of sheet material is described with term " instrument carrier panel ", " dash-panel-flange " and other particular term of proposing below, the normally relevant part of these terms is that they are used to describe and explain each other roughly orientation and their wiggles separately.Therefore, these terms should not be considered to concrete qualification but should be considered to be used to explain the relevant portion of sheet material and the spatial orientation of wiggle.
In some respects, dash-panel-flange is similar to conventional flange part and is that it can be instrument carrier panel structural integrity is provided, even quite Rou Xing sheet material hardening.But according to the present invention, dash-panel-flange bend line is configured to make in instrument carrier panel and the dash-panel-flange one or both to form profile.Dash-panel-flange bend line can have the bending of S shape, and this forms corresponding profile on instrument carrier panel and dash-panel-flange when sheet material is crooked about dash-panel-flange bend line.It should be understood that dash-panel-flange bend line can have other curved shape, include but not limited to protruding, recessed and wavy shape, on adjacent instrument carrier panel or dash-panel-flange both or one of them, to form profile.It will also be appreciated that when not needing profile on instrument carrier panel or dash-panel-flange, wiggle can be straight.
With reference to figure 1, sheet material 30 also comprises dash-panel bend line 42, and it separates the instrument carrier panel 37 and first folded sheet 44.Dash-panel bend line 42 is curves, with when forming profile when being similar to above-mentioned mode about dash-panel-flange bend line 35 about dash-panel bend line 42 bent sheet on first folded sheet 44.In an illustrated embodiment, dash-panel bend line 42 is recessed down, so that form convex profile on first folded sheet 44 when such bending shown in Figure 4 and 5.Will be appreciated that, depend on the curvature of dash-panel bend line 42 and the relative angle that instrument carrier panel (dash panel) 37 is bent with respect to first folded sheet 44, the bending of dash-panel bend line 42 can be formed on instrument carrier panel 37 and first folded sheet 44 the two or one of them.More be shown clearly in as Fig. 5, instrument carrier panel 37 is outwards recessed.It should be understood that according to the present invention the bending of dash-panel bend line also can change, this bending can be recessed on, wavy and/or other curved shape.
With reference to figure 1, sheet material 30 also comprises first fold line 46, its make first folded sheet 44 with replenish or second folded sheet 47 separate.In this embodiment, first fold line 46 roughly is straight, forms the profile of first folded sheet 44 to make second folded sheet 47 about first fold line, 46 bent sheet the time, and this profile is corresponding to the bending of dash-panel bend line 42.Because first fold line 46 is straight basically, and because second folded sheet 47 roughly is folded into and is positioned at first folded sheet, 44 tops, thereby first fold line 46 makes second folded sheet 47 roughly form the profile of first folded sheet 44, as shown in Figure 5.Replenish or second fold line 49 makes second folded sheet 47 open in 51 minutes with instrument face plate (dashboard panel).As shown in Figure 5, second fold line 49 also is straight haply, to make instrument face plate 51 form the profile of second folded sheet 47 basically about second fold line, 49 bent sheet the time.
In an illustrated embodiment, first distance D 1 between the dash-panel bend line 42 and first fold line 46 is different from the second distance D2 between first fold line 46 and second fold line 49, as shown in Figure 1.As shown in Figure 5, it is spaced apart with instrument carrier panel 37 that such setting causes the front edge 53 of the instrument carrier panel 51 that limited by second fold line 49.As shown in Figure 1, first distance D 1 makes instrument carrier panel 37 depressions exceed front edge 53, shown in Fig. 3-5 less than second distance D2 thus.
In another embodiment of the present invention, space sheet material 30a is similar to above-mentioned sheet material 30, but comprises the fold line with crooked part, as shown in Figure 6.Similar Reference numeral is used for describing the similar parts of sheet material 30 and 30a.
In this embodiment, reclinate dash-panel bend line 42a separates the instrument carrier panel 37a and the first folded sheet 44a in mode similar to the above.In this embodiment, the first fold line 46a with profile separates the first folded sheet 44a and the second folded sheet 47a, and comprises the middle body 46a ' of the bending between two straight parts.Fold-line apertures 70 is the sweep of the first fold line 46a and straight part separately, and prevents to produce in the transitional region between sweep and straight part wrinkling thus.Similarly, the second fold line 49a with profile separates the second folded sheet 47a and instrument carrier panel 51a, and comprises the middle body 49a ' of the bending between two straight parts.Fold-line apertures 70 may extend into the straight part of the partial sum of bending of the second fold line 49a and makes the two separately, and prevents to produce in the transitional region between the straight part of the partial sum of bending wrinkling thus.
In operation and using, sheet material 30a uses in identical with above-mentioned sheet material 30 basically mode.
Forward another aspect of the present invention now to, warp zone can form crooked corresponding complexity or the compound-contoured with a plurality of wiggles, and because the warpage that complexity or compound-contoured cause can be limited in this warp zone, this is because warp zone is delineated by the bending or the fold line that intersect.With reference to figure 1, sheet material 30 comprises first instrument plate flange wiggle 54, and its front panel flange 56 separates with the warp zone 58 of instrument carrier panel 51.First instrument plate flange wiggle 54 is bent, to form first profile on warp zone 58.Similarly, second instrument plate flange wiggle 60 separates second instrument plate flange 61 and warp zone 58, and this wiggle 60 also is crooked to form second profile on warp zone 58.It will be appreciated that these two dash-panel-flange bend line or one of them can form profile on flange or warp zone 58, or if desired, on each flange and warp zone 58, form profile.
The remainder 67 of warp zone 58 and instrument carrier panel 51 is delineated and separated to the warp zone bend lines 63 and 65 of first and second bendings.The warp zone bend lines 63 and 65 of first and second bendings is configured such that the bending that is subjected to along the crooked dash-panel-flange bend line influence of warp zone bend lines is localized.Like this, warp zone bend lines 63 and 65 is isolated in warpage in the warp zone 58 basically.First and second warp zone bend lines 63 and 65 all terminate in point of crossing 68.In addition, first and second warp zone bend lines 63 and 65 all have composite curvature.Preferably, the part 63 ' and 65 ' of warp zone bend lines 63 and 65 close point of crossing 68 has the radius of curvature littler than more outer part.So radius of curvature reduce can prevent that close point of crossing 68 places are wrinkling warp zone 58 in.In an illustrated embodiment, the radius of curvature of two parts all extends (for example two parts 63 ' and 65 ' all are recessed into) downwards along identical direction.Same-direction concavity can similarly prevent in warp zone 58 wrinkling near point of crossing 68 places like this.
In operation and using, the preforming of sheet material, preferably has wiggle and fold line, and promptly sheet material can be provided with slit 40, and is smooth during transportation and is located in on-the-spot crooked in the expectation purpose.This sheet material can be sequentially along each line bending or simultaneously about two or more wiggle bendings.
In the additional embodiments shown in Fig. 7-15, please note Fig. 7 A, the figure shows smooth sheet material 130, this sheet material is configured to form the three-dimensional structure 132 of instrument panel structure (I/P structure) form, shown in Fig. 8 E.In an illustrated embodiment, the I/P structure is configured and sets size to be applicable to automobile, still, should know that this sheet material can be configured to form a plurality of three-dimensional structures, and this three-dimensional structure includes but not limited to physical construction and parts attractive in appearance, vehicle structure etc.
Shown in exemplary embodiment in, sheet material comprises a plurality of straight wiggles 133 and warp zone bend lines 135.This warp zone bend lines 135 is provided in usually during the predefined paths bending and makes the elastic deformation localization, and this predefined paths is following warp zone bend lines and fold line.For example, warp zone bend lines 135 can be arranged on the form in the slit 137 on the warp zone bend lines either side, so that accuracy control is along the bending of warp zone bend lines, this slit 137 is more clearly shown in Fig. 7 B.Slit 137 can be other suitable form of describing in the patent of slit, groove, dislocation or above-mentioned industrial origami and the patent application, and its full content is herein incorporated with for referencial use.
Usually, straight wiggle 133 is set to form dashboard cross member 139, as shown in figure 11, the length of this crossbeam extension Vehicular instrument panel and its are dimensioned and are configured to be suitable for being installed to vehicle near A post place, as hereinafter describing in detail.Warp zone bend lines 135 is set to form right lower dash panel 161.The main purpose of crossbeam 139 is to provide structure integrity for I/P structure and vehicle, and the main purpose of instrument carrier panel provides the main board with profile attractive in appearance, to increase the aesthetic appearance of interior trim.By pressing the order shown in Fig. 8 A-8E along the wiggle pleated sheet, two-dimensional sheet forms three-dimensional I/P structure of the present invention.
With reference to figure 9A and 9B, left and right corridor flange 142 and 144 is with respect to a left side and right tunnel flange 146 and 147 bendings, it is bent with respect to front control plate flange 149 conversely, and it is bent with respect to bottom beam flange 151 conversely, so that the intermediate structure shown in Fig. 9 B to be provided.Corridor flange and the flange that is associated are dimensioned and are configured to and cooperate with the driving system passage with other known way.
With reference to figure 9B and 9C, bottom beam flange 151 is with respect to top beam flange 153 bendings, and it is conversely with respect to bottom beam web 154 bendings, and it is conversely with respect to lower beam flange 156 bendings, so that the intermediate structure shown in Fig. 9 c to be provided.So far, formed straight sweep ground and formed box beam, it traverses vehicle inside and between the A of vehicle post.
With reference to figure 9C and 9D, lower beam flange 156 is with respect to upper dash panel 158 bendings.And a left side and right lower dash panels 160 and 161 are with respect to upper dash panel 158 bendings, and this also causes lower-left instrument carrier panel 160 with respect to right lower dash panel 161 bendings.Action although it is so also partly forms box beam, but the bending that complex outline is also set up in such action discusses in more detail as following.
With reference to figure 9D and 9E, left and right beam wing flap 163 and 165 is with respect to lower dash panels 160 and 161 bendings, as central control board wing flap 167.Each wing flap all comprises flap fastener apertures 168, and it finally aligns with beam fixed orifice 170, as shown in Figure 1.In order to improve structural integrity and to help alignment, left and right beam wing flap 163 and 165 is provided with left and right cap 172 and 174, and each all has the corresponding profile of cross-sectional profiles of the box beam on arbitrary end with the I/P structure.For example, the shape of cross section of the right-hand member of box beam is represented or provided to the profile that Figure 11 shows right cap 174 how, and Figure 12 shows the contour representation of left cap 172 or the mode of shape of cross section of the left end of box beam is provided.In many aspects, what go through in box beam of the present invention and above-mentioned patent and the application is similar, and has identical advantage thus, and the full content of these patents and application is herein incorporated with for referencial use.
According to a further aspect in the invention, the I/P structure also is configured to form the upper and lower instrument carrier panel of wide flange profile, shown in Fig. 7 A.Especially, be formed contour area with the crooked corresponding complexity or the combination profile of the warp zone bend lines 135 of a plurality of bendings, wherein lower-left instrument carrier panel 160 forms the profile that roughly skims over, and it is roughly along with the profile of the warp zone bend lines 135 that lower-left instrument carrier panel 160 is separated from upper dash panel 158 and right lower dash panel 161.On the contrary, right lower dash panel 161 is defined by the warp zone bend lines 135 that intersects, and crooked thus to adapt to the various profiles that form thereon.The warpage of right lower dash panel 161 is greatly limited, because right lower dash panel 161 is marked boundary by the warp zone bend lines 135 that intersects.
Forward remaining figure now to.Figure 10 shows the right front view of folding I/P structure, and shows the bending of lower-left instrument carrier panel 160 and the complicated bend of right lower dash panel 161 thus. Lower dash panels 160 and 161 is provided with decoration hole 175 and 177, and it allows to decorate and is fixed to the I/P structure.For example, decorative leather can utilize these holes and be attached to this I/P structure.Lower-left instrument carrier panel 160 also comprises mark 179 and is used for various switches accordingly and the opening of other vehicle control.In an illustrated embodiment, mark is etched or routed directly in the sheet material, is used for illuminating mark from behind and needing avoids additional parts to support this mark.
With reference to Figure 11 and 12, crossbeam is provided with a left side and right opening 181 and 182, so that be connected to vehicle monolithic body shell.For example, bolt 184 can extend from the vehicle monolithic vehicle body installation portion 186 near the A post 188 of vehicle, as shown in figure 15.
For the ease of the explanation of claims and accurately definition, term " left side " or " right side ", " on " or the position of " top ", D score or " bottom ", " inside " and " outside " feature shown in being used to reference to the accompanying drawings feature of the present invention is described.
In many aspects, the modification of various accompanying drawings is similar to the accompanying drawing of revising previously, and represents corresponding parts with the identical Reference numeral of suffix " a ".
The above stated specification of the concrete exemplary embodiments of the present invention is in order to illustrate and illustrative purposes.These are described is not to be used for exhaustive or to limit the invention to disclosed exact form, and many modifications and variations are possible according to above-mentioned instruction apparently.These exemplary embodiments are selected and to describe be in order to disclose certain principles of the present invention and their practical application, make those skilled in the art implement thus and use various exemplary embodiments of the present invention, with and various substitutions and modifications.Scope of the present invention is limited by claims and equivalent thereof.

Claims (30)

1, a kind of sheet material that is used to form the three-dimensional structure of moulding, described sheet material comprises:
The forward-panel bend line of header board and folded sheet separately, described forward-panel bend line is bent, with in case form the preliminary election profile during about described forward-panel bend line bent sheet at least on described folded sheet; With
Along the fold line that described folded sheet extends, described fold line is formed, with in case make upper board form the described preliminary election profile of described folded sheet during about described fold line bent sheet.
2, sheet material according to claim 1, wherein, described fold line is straight basically.
3, sheet material according to claim 1 also comprises:
The additional fold-line of separating described folded sheet and additional fold plate, described additional fold-line are straight basically, with in case make during about described additional fold-line bent sheet second folded sheet form the profile of first folded sheet,
Wherein, in case when crooked described fold line and additional fold-line, described upper board is via described folded sheet and second folded sheet and form the profile of described forward-panel bend line.
4, sheet material according to claim 1 also comprises:
The forward-flange wiggle that separates described header board and forward-flange, described forward-flange wiggle is bent, with in case form profile on one or more in described header board and forward-flange during about described forward-flange wiggle bent sheet.
5, sheet material according to claim 3, wherein, described forward-flange wiggle is a S shape, forms protruding and recessed profile thus on described header board.
6, sheet material according to claim 1, wherein, described forward-panel bend line is recessed downwards, to form the profile of epirelief at least a portion of described upper board.
7, sheet material according to claim 1, wherein, between described forward-panel bend line and described first folded sheet first distance is different from the second distance between described first fold line and described second fold line, thereby the front edge and the described header board of the described upper board that is limited by described second fold line separate.
8, sheet material according to claim 7, wherein, described first distance is shorter than second distance, and described thus header board is recessed above described front edge.
9, sheet material according to claim 1 also comprises:
The first upper-panel-flange wiggle of upper flange and the warp zone of described upper board separately, the described first upper-panel-flange wiggle are bent with formation first profile on one or more in first upper flange and described warp zone;
The second upper-panel-flange wiggle of second upper flange and described warp zone separately, the described second upper-panel-flange wiggle are bent with formation second profile on one or more in described second upper flange and warp zone; With
Separate the warp zone bend lines of first bending of remainder of described warp zone and described upper board and the warp zone bend lines of second bending, the warp zone bend lines of the warp zone bend lines of described first bending and second bending is configured to along the warpage in wiggle local bending and the described warp zone of substantial barrier.
10, sheet material according to claim 9, wherein, described first warp zone bend lines and second warp zone bend lines terminate in the point of crossing place, and
Described first warp zone bend lines and second warp zone bend lines have compound curvatures, and the part of the close described point of crossing of wherein said wiggle has less radius of curvature, stop in described warp zone wrinkling near described point of crossing thus.
11, sheet material according to claim 1, wherein, in described wiggle and the described fold line at least one is formed with a plurality of slits that pass described sheet material, and adjacent slit alternately is positioned on described at least one the either side in described wiggle or the fold line.
12, sheet material according to claim 1, wherein, at least one in described wiggle and the described fold line is formed with a plurality of dislocations, and wherein adjacent dislocation alternately is positioned on described at least one the either side in described wiggle or the fold line.
13, a kind of three-dimensional structure comprises sheet material according to claim 1.
14, a kind of method that forms three-dimensional structure comprises:
Sheet material according to claim 1 is provided;
Along the crooked described sheet material of forward-panel bend line; With
Along the crooked described sheet material of fold line.
15, a kind of sheet material that is used to form the three-dimensional structure of moulding, described sheet material comprises:
Upper board;
The first upper-panel-flange wiggle of upper flange and the warp zone of described upper board separately, the described first upper-panel-flange wiggle are bent with formation first profile on one or more in first upper flange and described warp zone;
The second upper-panel-flange wiggle of second upper flange and described warp zone separately, the described second upper-panel-flange wiggle are bent with formation second profile on one or more in described second upper flange and warp zone; With
Separate the warp zone bend lines of first bending of remainder of described warp zone and described upper board and the warp zone bend lines of second bending, the warp zone bend lines of the warp zone bend lines of described first bending and second bending is configured to along the warpage in described wiggle local bending and the described warp zone of substantial barrier.
16, sheet material according to claim 15, wherein, the described first upper-panel-flange wiggle is recessed downwards along first direction, and the described second upper-panel-flange wiggle is along recessed downwards with the uneven second direction of described first direction, wherein, described warp zone elastic deformation is to adapt to the differently contoured of the described first upper-panel-flange wiggle and the second upper-panel-flange wiggle.
17, sheet material according to claim 15, wherein,
Described first wiggle and second wiggle all terminate in the point of crossing place; And
Described first wiggle and second wiggle all have compound curvatures, and the part of the close described point of crossing of wherein said wiggle has less radius of curvature, thereby stop in described warp zone wrinkling near described point of crossing.
18, sheet material according to claim 15, wherein, at least one in described wiggle and the described fold line is formed with a plurality of slits that pass described sheet material.
19, sheet material according to claim 18, wherein, adjacent slit alternately is positioned on described at least one the either side in described wiggle or the fold line.
20, sheet material according to claim 15, wherein, at least one in described wiggle and the described fold line is formed with a plurality of dislocations, and wherein adjacent dislocation alternately is positioned on described at least one the either side in described wiggle or the fold line.
21, a kind of three-dimensional structure comprises sheet material according to claim 15.
22, a kind of method that forms instrument carrier panel comprises:
Sheet material according to claim 15 is provided;
Along the first upper board wiggle and the second upper board wiggle bent sheet, wherein, first warp zone bend lines and second warp zone bend lines allow warpage in described warp zone, to adapt to the variation profile that is formed by first instrument plate flange wiggle and second instrument plate flange wiggle.
23, a kind of sheet material that is used to form the three-dimensional instrument carrier panel of moulding, described sheet material comprises:
The dash-panel-flange bend line of instrument carrier panel and dash-panel-flange separately, described dash-panel-flange bend line is bent, with in case form profile on one or more in described instrument carrier panel and dash-panel-flange during about described dash-panel-flange bend line bent sheet;
Separate the dash-panel bend line of the described instrument carrier panel and first folded sheet, described dash-panel bend line is bent, with in case form profile at least on described first folded sheet during about described dash-panel bend line bent sheet;
First fold line that separates described first folded sheet and second folded sheet, described first fold line is straight basically, with in case form the profile of described first folded sheet during about the described first fold line bent sheet on described second folded sheet;
Second fold line that separates described second folded sheet and instrument carrier panel panel, described second fold line is straight basically, with in case form the profile of described second folded sheet during about the described second fold line bent sheet on described instrument carrier panel panel;
The first instrument plate flange wiggle of front panel flange and the warp zone of described instrument carrier panel panel separately, described first instrument plate flange wiggle is bent, with formation first profile on one or more in first instrument plate flange and described warp zone;
The second instrument plate flange wiggle of second instrument plate flange and described warp zone separately, described second instrument plate flange wiggle is bent, with formation second profile on one or more in described second instrument plate flange and warp zone; With
Separate the warp zone bend lines of first bending of remainder of described warp zone and described instrument carrier panel panel and the warp zone bend lines of second bending, the warp zone bend lines of the warp zone bend lines of described first bending and second bending is configured to along the warpage in described wiggle local bending and the described warp zone of substantial barrier.
24, sheet material according to claim 23, wherein, described dash-panel-flange bend line is a S shape, forms recessed and protruding profile thus on described instrument carrier panel.
25, sheet material according to claim 23, wherein, described dash-panel bend line is recessed downwards, to form the profile of epirelief at least a portion of described instrument carrier panel panel.
26, sheet material according to claim 23, wherein, between described dash-panel bend line and described first fold line first distance is different from the second distance between described first fold line and described second fold line, thereby the front edge and the described instrument carrier panel of the described instrument carrier panel panel that is limited by described second fold line separate.
27, sheet material according to claim 26, wherein, described first distance is recessed above described front edge less than the described thus instrument carrier panel of described second distance.
28, sheet material according to claim 23, wherein,
Described first wiggle and second wiggle all terminate in the point of crossing place; And
Described first wiggle and second wiggle all have compound curvatures, and the part of the close described point of crossing of wherein said wiggle has less radius of curvature, thereby stop in described warp zone wrinkling near point of crossing.
29, a kind of instrument carrier panel comprises sheet material according to claim 23.
30, a kind of method that forms instrument carrier panel comprises:
Sheet material according to claim 23 is provided;
Along the dash-panel-flange bend line bent sheet;
Along the dash-panel bend line bent sheet;
Along first fold line and the second fold line bent sheet; With
Along first instrument plate flange wiggle and second instrument plate flange wiggle bent sheet, wherein first warp zone bend lines and second warp zone bend lines allow warpage in described warp zone, to adapt to the variation profile that is formed by described first instrument plate flange wiggle and second instrument plate flange wiggle.
CNA2007800259067A 2006-05-09 2007-05-09 Precision folded structural and aesthetic component and sheet therefor Pending CN101489855A (en)

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US79921706P 2006-05-09 2006-05-09
US79921506P 2006-05-09 2006-05-09
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JP2009536582A (en) 2009-10-15
RU2008148332A (en) 2010-06-20
EP2021256A2 (en) 2009-02-11
KR20090011016A (en) 2009-01-30
WO2007134114A3 (en) 2008-11-06
WO2007134114A2 (en) 2007-11-22
US20070262128A1 (en) 2007-11-15

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