KR20090011016A - Precision folded structural and aesthetic component and sheet therefor - Google Patents

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

Precisely folded structural-aesthetic elements and their sheets {PRECISION FOLDED STRUCTURAL AND AESTHETIC COMPONENT AND SHEET THEREFOR}

This application claims the priority of US Provisional Application No. 60 / 799,215, filed May 9, 2006, the entire contents of which are incorporated herein by reference.

This application also claims the priority of US Provisional Application No. 60 / 799,217, filed May 9, 2006, the entire contents of which are incorporated herein by reference.

The present invention relates generally to the design and precise bending of a sheet of material to form a shaped three-dimensional structure with structural-aesthetic elements and to methods of use thereof, and more particularly to a curved and warped structure and a method of forming the same. will be.

Various methods are known for forming three-dimensional structures from two-dimensional sheet materials. For example, press brakes, stamping equipment and other cold forming metal equipment have been used for a long time to form sheet materials into three-dimensional objects.

Recently, computer numerically controlled (CNC) devices have been used to treat sheet material to be easily bent around predetermined lines. For example, laser cutting, hydraulic cutting, stamping (squeeze), forming, casting, three-dimensional shaping, roll forming, machining, chemical milling, photolithography, etc. may be used to form slits or grooves in the sheet material along predetermined bending lines. It has been controlled to bend easily along the bend line.

A typical prior art is US Pat. No. 6,640,605 to Gitlin et al., Which discloses a method of bending sheet material to form three-dimensional structures including housings, casings, internal and external structures, and various covers and supports. To start.

This conventional method of bending around a bending line to predetermine the sheet material is generally successful in forming a three-dimensional object, but the three-dimensional shape obtainable by this method is limited. For example, such methods are typically employed to form a three-dimensional object having a flat area extending between adjacent bends or a curved area extending between adjacent bends along the curvature of the adjacent bends. At present, however, drawing a predetermined bend on the sheet material is generally not helpful in forming a complex three-dimensional structure having complex curved shaped areas in contact between adjacent bends.

For example, early vehicles generally included a frame to provide structural integrity to which body panels and nonstructural elements are attached. Such a general shape allows designers and manufacturers to give a variety of decorations to the attached elements to give the vehicle an overall appealing aesthetic appearance.

As a more recent example of monolithic construction, a vehicle is often provided with a single frame-body structure that includes both structural and nonstructural aesthetic elements. However, sub-parts attached to or within a monolithic frame continued to include one or more structural members and one or more aesthetic panels attached to such structural members to provide structural integrity to the frame.

For example, instrument panel structures (I / P structures) are structures that support steering wheels, instrument clusters, and other dashboard elements while providing structural elements to mounting points for vehicles, airbags, and the like. Such I / Ps generally comprise one or more skeleton or internal structural members attached to a monolithic frame adjacent to an A pillar and may provide additional structural integrity to the frame. An external aesthetic member, such as a dashboard panel, for example, is attached to the internal structural member to provide a vehicle interior with an attractive final appearance.

More recently, hydroforming and other stamping processes have resulted in the formation of I / P structures with more complex shapes. However, such I / P structures are generally still intended to be framing or internal structural members to which dashboard panels are attached. As such, the number of parts required to complete the dashboard of the vehicle is relatively large, and the labor required to assemble these various parts is not trivial.

There is a need for an improved method of forming a three-dimensional structure shaped from sheet material that can overcome various disadvantages of known structures and methods.

One aspect of the present invention relates to a sheet member for forming a shaped three-dimensional structure. The sheet material is a line separating the front panel and the folding panel, wherein the sheet material is curved to at least give a predetermined shape on the folding panel when the sheet material is bent about this line; And a fold line extending along the fold panel. The fold line is substantially straight to give the top panel a predetermined shape of the fold panel when the sheet material is folded about this line.

The sheet material may further include an auxiliary fold line separating the folding panel from the auxiliary folding panel. The auxiliary fold line can be substantially straight so that the sheet material bends about this line to impart the shape of the first fold panel to the second fold panel, and the shape of the front panel bend is the fold panel when the fold line and the auxiliary fold line are bent. And through the second folding panel to the upper panel.

The sheet material may further comprise a front panel-flange bend that separates the front panel and the front panel flange. This front panel-flange bend can be curved to impart a shape on at least one of the front panel and the front panel flange when the sheet material is bent against the front panel-flange bend. The front flange bend may be S-shaped to impart a concave and convex shape to the front panel.

The front panel bend may be concave down to impart an upwardly convex shape on at least a portion of the top panel. The first gap between the front panel bend and the first folding panel may be different from the second gap between the first fold line and the second fold line such that the front edge of the top panel formed by the second fold line is spaced apart from the front panel. . The first interval may be shorter than the second interval such that the front panel is indented past the front edge.

The sheet material may further comprise a first top panel-flange bend that separates the front top flange from the flexure region of the top panel. The first top panel-flange bend can be curved to impart a first shape on at least one of the front top flange and the flexure region. The second top panel-flange bend may separate the second top flange from the flexion zone. The second top panel-flange bend can be curved to impart a second shape on at least one of the second top flange and the flexure region. The first and second curved bending zone bends can separate the bending zone from the remainder of the top panel. The first and second curved bend area bends can be configured to localize the bends along the bend and substantially isolate the bends within the bend area. Both the first and second flexion zone bends can terminate at the intersection. Both the first and second flexion zone bends can have a compound curvature. Some of the bend lines adjacent to the intersection may have a smaller radius of curvature to prevent creases in the warpage region adjacent to the intersection.

In one embodiment, at least one of the bend line and the folding line may be formed with a plurality of slits penetrating the sheet material. Adjacent slits may be alternately located on one side of at least one of the bend line and the folding line. A plurality of displacement parts may be formed in at least one of the bent line and the folded line. Adjacent displacements may be alternately positioned on at least one side of the bend line and the fold line.

Another aspect of the present invention relates to a three-dimensional structure comprising the sheet material described above. Another aspect of the present invention relates to a method of providing the above-described sheet material, bending the sheet material along the front panel bend line, and bending the sheet material along the fold line to form a three-dimensional structure.

Another aspect of the invention relates to a sheet material for forming a shaped three-dimensional structure. The sheet material includes an upper panel; A first top panel-flange bend line that is curved to impart a first shape on at least one of the front top flange and the flex region of the top panel to separate the front top flange from the flex region; A second top panel-flange bend line configured to impart a second shape on at least one of the second top flange and the bend area to separate the second top flange from the bend area; And first and second curved flexural region bends separating the flexural region from the remainder of the top panel. The first and second curved bend area bends are configured to localize the bends along the bend line and substantially isolate the bends within the bend area.

The first top panel-flange bending line may be concave down along the first direction, and the second top panel-flange bending line may be concave down along the second direction that is not parallel to the first direction. The flexion zone elastically deforms to accommodate different shapes of the first and second top panel-flange bends.

In one embodiment, both the first and second bend lines terminate at intersections. Both the first and second bends may have a compound curvature. Some of the bend lines adjacent to the intersection may have a smaller radius of curvature to prevent creases in the warpage region adjacent to the intersection.

In one embodiment, at least one of the bend line and the folding line may be formed with a plurality of slits penetrating the sheet material. Adjacent slits may be alternately located on one side of at least one of the bend line and the folding line. A plurality of displacement parts may be formed in at least one of the bent line and the folded line. Adjacent displacements may be alternately positioned on at least one side of the bend line and the fold line.

Another aspect of the present invention relates to a three-dimensional structure comprising the sheet material described above. Another aspect of the invention is directed to a method of forming a dashboard comprising providing the sheet material described above, and bending the sheet material along the first and second upper panel bends. The first and second flexion zone bends may be bent in the flexion zone to accommodate different shapes imparted by the first and second dashboard-flange bends.

Another aspect of the present invention relates to a sheet member for forming a three-dimensional dashboard, the dashboard and a method of forming the dashboard. The sheet material is a line separating the dash panel and the dash panel flange, the dash panel-flange bending line, which is curved to give a shape on at least one of the dash panel and the dash panel flange when the sheet material is bent about this line; A line separating the dash panel and the first folding panel, the dash panel bending line being curved to give a shape on the first folding panel when the sheet material is bent about this line; A line that separates the first folding panel from the second folding panel, the first folding line being substantially straight so as to impart the shape of the first folding panel on the second folding panel when the sheet material is bent about this line; A line that separates the second folding panel from the dashboard panel, the second folding line being substantially straight so as to give the dashboard panel the shape of the second folding panel when the sheet material is bent about this line; A first dashboard-flange bend line that is curved to impart a first shape on at least one of the first dashboard flange and the flexure region of the dashboard panel to separate the dashboard flange from the flexure region; A second dashboard-flange bend line that is curved to impart a second shape on at least one of the second dashboard flange and the bending zone to separate the second dashboard flange from the bending zone; And first and second curved flexure zone bends configured to localize the bending along the flexure and substantially isolate the flexure within the flexure zone to separate the flexure zone from the rest of the dashboard panel.

The dash panel-flange bend may be S-shaped to impart both concave and convex shapes to the dash panel. The dash panel bends may be recessed downward to impart an upwardly convex shape to at least a portion of the dashboard panel. The first spacing between the dash panel bend and the first fold line may be different from the second spacing between the first fold line and the second fold line such that the front edge of the top panel formed by the second fold line is spaced apart from the front panel. . The first interval may be shorter than the second interval such that the front panel is indented past the front edge.

Both the first and second bend lines terminate at intersections. Both the first and second bends may have a compound curvature. Some of the bend lines adjacent to the intersection may have a smaller radius of curvature to prevent creases in the warpage region adjacent to the intersection.

In another embodiment, the sheet member comprises a dash panel outlined by a plurality of curved bends and a cross beam outlined by a plurality of straight bends. Each curved bend is shaped and configured to give a predetermined shape on the dash panel when the sheet material is bent about this bend. The straight bend is shaped and configured to form the upper beam web, the upper beam flange and the lower beam flange. The cross sectional shape of the cross beam is determined by one or more caps provided on the sheet material.

The dashboard forming method provides the sheet material described above, the sheet material is bent along the dash panel-flange bend line, the sheet material is bent along the dash panel bend line, and the sheet material is first and second fold lines Along the first and second dashboard-flange bends. Bend within the flexion zone by the first and second flexion zone bends to accommodate different shapes imparted by the first and second dashboard-flange bends.

Another aspect of the invention relates to a sheet material for forming a precisely folded vehicle member having structural-aesthetic elements. The sheet material may comprise a dash panel outlined by a plurality of curved bends and a cross beam outlined by a plurality of straight bends. Each curved bend is shaped and configured to give a predetermined shape on the dash panel when the sheet material is bent about this bend. The straight bend is shaped and configured to form the upper beam web, the upper beam flange and the lower beam flange. The cross sectional shape of the cross beam is determined by one or more caps provided on the sheet material.

Precisely folded structural-aesthetic elements with shaped three-dimensional structures according to the invention, sheets for them and methods of forming them are described in detail in the accompanying drawings included in the present application and in conjunction with these figures illustrating the principles of the invention. It has a number of features and advantages which are presented in more detail in the description and are to be understood through them.

The invention will be more clearly understood from the following detailed description and the accompanying drawings, which are given for purposes of illustration only and are not intended to limit the invention.

1 is a plan view of an exemplary two-dimensional sheet material configured to be bent into a three-dimensional structure shaped according to the present invention;

FIG. 2 is an enlarged partial view of the two-dimensional sheet material of FIG. 1 taken along line 2-2 of FIG. 1;

3 is a top front perspective view of the two-dimensional sheet material of FIG. 1 after bending in accordance with the present invention;

4 is another upper front perspective view of FIG. 3 after being bent in accordance with the present invention;

5 is a bottom perspective view of FIG. 3;

6 is a plan view of another exemplary two-dimensional sheet material configured to be bent into a three-dimensional structure shaped according to the present invention;

7A is a plan view of a two-dimensional sheet material configured to be accurately folded in the form of another exemplary embodiment of a vehicle structure in accordance with the present invention;

FIG. 7B is an enlarged detail view of the sheet material of FIG. 7A taken within line 7B-7B in FIG. 7A;

8A-8E are a series of perspective views illustrating the process of folding the sheet material along the bending line of FIG. 7 in accordance with the present invention;

9A-9E are enlarged perspective views of FIGS. 8A-8E;

10 is another enlarged perspective view of the vehicle structure of FIGS. 8E and 9E, viewed from the front right side of the vehicle structure;

11 is another enlarged perspective view of the vehicle structure of FIGS. 8E and 9E, viewed from the rear right of the vehicle structure;

12 is another enlarged perspective view of the vehicle structure of FIGS. 8E and 9E, viewed from the front left side of the vehicle structure;

13 is another enlarged perspective view of the vehicle structure of FIG. 12;

14 is another enlarged perspective view of the vehicle structure of FIGS. 8E and 9E, viewed from the bottom of the vehicle structure;

15 is a partial perspective view of the vehicle structure of FIGS. 8E and 9E installed in a vehicle.

Reference is made in detail to various embodiments of the invention, examples of which are illustrated in the accompanying drawings and the description below. While the present invention will be described in connection with the illustrated embodiments, it will be understood that the description is not intended to limit the invention to the exemplary embodiments. Rather, the invention is intended to cover various alternatives, modifications, equivalents and other embodiments that may be included within the spirit and scope of the invention as defined by the appended claims as well as the exemplary embodiments.

In general, the present invention provides for the formation of shaped three-dimensional structures from two-dimensional sheet materials. In particular, the flat two-dimensional sheet member is configured to be bent along a predetermined bending line to form a three-dimensional structure of a complex curved area capable of improving both structural and aesthetic features.

In the present invention, "two-dimensional sheet material" refers to a sheet material that is spherically flat so that it may be laminated with each other, but may be partially stamped, punched and / or other various features as may be surface area or structural. .

Generally, the sheet material includes one or more bending lines or fold lines configured to facilitate bending along a predetermined path to impart a portion corresponding to the curvature of the bending line to a portion of the sheet material when bending the sheet material along the bending line. do. The form may be imparted to an adjacent portion of the sheet material or transferred to a distant portion of the sheet material as will be apparent below. Alternatively, or additionally, the shape corresponding to the curvature of the multiple bend lines is imparted to the warpage region, which is outlined by crossing the bend lines or fold lines. The deflection within the deflection zone is limited and accommodates various forms. Preferably, the warpage is defined within the warpage area, and creases are prevented. The sheet material of the present invention also includes structural elements and straight bending lines that facilitate the formation of hollow cross beams in the illustrated embodiment.

In the present invention, the "bending line" is a predetermined path, in which the sheet material is bent along to form a three-dimensional shape by causing plastic deformation along the bending line. A "fold line" is a bending line in which portions of the sheet material on either side of the bending line are bent and stacked substantially in turn. It will be appreciated that the sheet material may experience some elastic deformation along the bending line in addition to plastic deformation.

It will be appreciated that a variety of means may be used to form the bending line of the present invention to facilitate bending along the bending line. For example, Industrial Origami's precision bending technology can be used to design and / or provide the bending lines of the present invention. The technique is described in the following patents and applications, the contents of which are hereby incorporated by reference: Method For Precision Bending Of A Sheet Of Material And Slit Sheet Therefor U.S. Patent No. 6,481,259, Method For Precision Bending Of Sheet Of Materials, Slit Sheets Fabrication Process, U.S. Patent No. 6,877,349, Precisely Bending Method and Slit Sheet US Patent Application No. 2003/0037586 entitled Method For Precision Bending Of Sheet Of Materials, Slit Sheets Fabrication Process, Methods for Designing and Manufacturing High Strength Fatigue Resistance Structures of Precision Bending and Techniques For Designing And Manufacturing Precision-Folded, High Strength, Fatigue-Resistant Structures And Sheet Therefor) US Patent Application 2004/01342 50, US Patent Application No. 2004/0206152 entitled Sheet Material With Bend Controlling Displacements And Method For Forming The Same , Method Of Designing U.S. Patent Application No. 2005/0005670 entitled Fold Lines In Sheet Material , Methods of Forming Bending Control Structures of Sheets, Sheets Obtained from the Processes and Die Sets For The Processes of Forming Bend-Controlling Structures In A Sheet Of Material, The US Patent Application No. 2005/0061049 entitled Resulting Sheet And Die Sets Therefor , US Patent Application Named Method For Precision Bending Of Sheet Of Materials, Slit Sheets Fabrication Process Article No. 2005/0064138, the sheet material and a method of manufacturing through the bending lines with a bending control groove that forms a continuous web (sheet material with bend controlling Gr ooves Defining A Continuous Web Across A Bend Line And Method For Forming The Same , US Patent Application No. 2005/0097937, for designing and manufacturing a high strength, fatigue resistant structure of precision bending and its sheets ( Techniques For Designing And manufacturing Precision-folded, High Strength, Fatigue-Resistant Structures and sheet Therefor) of the name of the US Patent Application No. 2005/0126110, the sheet material and a method of manufacturing the bending displacement control (sheet material With bend controlling displacements and method for Forming the Same) US Patent Application No. 2005/0257589, Fatigue-Resistance Sheet Slitting Method And Resulting Sheet , US 2006/0021413, for sheet material bending manufacturing system and method using the same (Tool system for Bending Sheet Materials and method of using Same) is the name of the US Patent Application No. 2006/0053857 and section Controlling the displacement of the sheet material and a method of manufacturing (Sheet Material With Bend Controlling Displacements And Method For Forming The Same) is the name of the US Patent Application No. 2006/0075798.

The same components throughout the several figures return to the figures designated by the same reference numerals and refer to FIG. 1. 1 shows a flat sheet material 30 configured to form a three-dimensional structure. In the illustrated embodiment, the sheet material is configured to form a three-dimensional structure 32 in the shape of the dashboard assembly shown in FIG. In the illustrated embodiment, the dashboard is constructed and standardized for use in motor vehicles. However, the dashboard can be configured for use with other types of vehicles, industrial control devices or other mechanical assemblies. However, it will be appreciated that the sheet material may be configured to form multiple three-dimensional structures, including but not limited to mechanical structural elements, body panels, other vehicle structures, and the like. Suitable materials for the sheet material include, but are not limited to, sheet and thick standard metals, plastics and other soft materials such as sheet steel, stainless sheet, aluminum sheet, other metals and alloys. It will also be appreciated that the sheet material may be laminated with materials such as films, foams, meshes, and / or other suitable materials as unpainted, prepainted and / or coated and / or other structural and / or nonstructural materials.

In the illustrated embodiment, the sheet member 30 has a dash panel-flange bending line 35 separating the dash panel flange 39 and the front panel in the form of a gauge or dash panel 37 as shown in FIG. 1. It includes. The dash panel-flange bending line 35 is typically configured to localize the elastic deformation during bending along a predetermined path, which is the bending line or fold line described below. For example, the dash panel-flange bending line 35 is in the form of an event 40 disposed on either side of the bending line 35 in order to allow the bending to be easily and accurately controlled along the bending line 35. This event 40 may be more clearly shown in FIG. 2. The event 40 may be in the form of slits, grooves, displacements, and other suitable means described in the aforementioned patents and applications of Industrial Origami, the content of which is incorporated herein by reference.

The bending line will be discussed in terms of "dash panel-flange bending line" and other specific terms mentioned below, and the area of the sheet material adjacent to the bending line is also referred to as "dash panel," "dash panel flange" and other mentioned below. As will be discussed in specific terms, these terms relate to each other and their respective bending lines in that they are used to describe and refer to their overall background. As such, the term should not be considered as limiting in particular, but should be considered to refer to the spatial background of the bending line and the relevant portions of the sheet material.

In some respects, the dash panel-flanges are similar to conventional flanges in that they can provide structural integrity to the dash panel by, for example, reinforcing what could otherwise be a highly flexible sheet material. However, according to the present invention, the dash panel flange bending line is configured to give shape to one or both of the dash panel and the dash panel flange. The dash panel flange bending line may have an "S" shaped curvature that will impart a shape corresponding to both the dash panel and the dash panel flange upon bending the sheet material along the bending line. It will be appreciated that the dashpanel-flange bending line is not limited thereto, but may have other curved shapes including convex, concave and corrugated to give shape to both adjacent dashpanels or dashpanel flanges. . It will also be appreciated that the bending line can be straight if no shape is required for either the dash panel or the dash panel flange.

Referring to FIG. 1, the sheet member 30 includes a dash panel bending line 42 separating the dash panel 37 and the first folding panel 44. The dash panel bending line 42 is shaped in the first folding panel 44 upon bending of the sheet material along the dash panel bending line 42 in a manner similar to that of the dash panel-flange bending line 35 described above. Bend to give. In the illustrated embodiment, the dash panel bending line 42 is recessed downward to impart an upwardly convex shape to the first folding panel 44 upon bending, as shown in FIGS. 4 and 5. According to the curvature of the dash panel bending line 42 and the relative angle at which the dash panel 37 is bent with respect to the first folding panel 44, the curvature of the dash panel bending line 42 is folded with the dash panel 37 first first. It will be appreciated that one or both of panels 44 may be imparted. As best shown in FIG. 5, dash panel 37 is concave outward. It will be appreciated that the curvature of the dash panel bending line may vary in accordance with the present invention in that it may be concave upward, wavy and / or otherwise curved.

Referring again to FIG. 1, the sheet member 30 also includes a first fold line 46 that separates the first fold panel 44 from the auxiliary or second fold panel 47. In the present embodiment, the first folding line 46 is a second folding panel in the form of the first folding panel 44 corresponding to the curvature of the dash panel bending line 42 when bending the sheet material along the folding line. In order to impart to 47, it is substantially straight. As the first fold line 46 is substantially straight and the second fold panel 47 is folded over so as to rest on the first fold panel 44, the first fold line 46 is as shown in FIG. The shape of the first folding panel 44 will be given to the second folding panel 47. Auxiliary or second fold line 49 separates second fold panel 47 from dashboard panel 51. The second fold line 49 provides the dashboard panel 51 with substantially the shape of the second fold panel 47 when bending the sheet material along the second fold line 49 as shown in FIG. 5. To be substantially straight.

In the illustrated embodiment, the first spacing D1 between the dash panel bending line 42 and the first fold line 46 is the first fold line 46 and the second fold line (as shown in FIG. 1). It is different from the second interval D2 between 49). This configuration allows the front edge 53 of the dashboard panel 51 formed by the second fold line 49 to be spaced apart from the dash panel 37 as shown in FIG. 5. As shown in FIG. 1, since the first interval D1 is shorter than the second interval D2, the dash panel 37 is recessed over the front edge 53 as shown in FIGS. 3-5.

In another embodiment of the present invention, the dimensional sheet material 30a is similar to the sheet material 30 described above, but includes a fold line having a curved portion as shown in FIG. Similar reference numerals have been used for the description of similar components of the sheet members 30, 30a.

In this embodiment, the downwardly curved dash panel bending line 42a separates the dash panel 37a and the first folding panel 44a in a similar manner as described above. In this embodiment, the shaped first fold line 46a separates the first fold panel 44a from the second fold panel 47a and includes a curved central portion 46a 'between the two straight portions. . The fold line hole 70 separates the curved portion and the straight portion of the first fold line 46a, thereby preventing any wrinkles (crises) that may occur in the transition region between the curved portion and the straight portion. Likewise, the shaped second fold line 49a separates the second fold panel 47a from the dashboard panel 51a and includes a curved central portion 49a 'between the two straight portions. The fold line hole 70 extends to and separates the curved and straight portions of the second fold line 49a to prevent wrinkles that may occur in the transition region between the curved and straight portions.

In operation and use, the sheet material 30a is used in substantially the same manner as the sheet material 30 described above.

Looking now at another aspect of the present invention, a complex or complex shape corresponding to the curvature of multiple bending lines can be imparted to the warpage area, and the warpage resulting from the complex or complex shape is such that the warpage area is folded or folded. The contour is drawn by intersecting the lines and thus can be defined within the bending zone. Referring to FIG. 1, the sheet member 30 includes a first dashboard-flange bending line 54 that separates the front dashboard flange 56 from the flexure region 58 of the dashboard panel 51. The first dashboard-flange bending line 54 is curved to impart a first shape to the flexure region 58. Similarly, the second dashboard-flange bending line 60 separates the second dashboard flange 61 from the bending area 58, and the bending line 60 is also curved to define the second shape in the bending area 58. To give. Either or both of the dashboard-flange bending lines can give shape to either the flange or flexion zone 58 or, if desired, to each flange and flexion zone 58.

The first and second curved flexural region bending lines 63, 65 delineate and separate the flexural region 58 from the remainder 67 of the dashboard panel 51. The first and second curved flexural zone bending lines 63, 65 are configured to localize the bending affected by bending the dashboard-flange bending line along the flexural zone bending line. As such, the flexion zone bending lines 63, 65 substantially isolate the torsion within the flexion zone 58. Both first and second flexion zone bending lines 63, 65 terminate at intersection 68. In addition, both the first and second flexion zone bending lines 63, 65 have a compound curvature. Preferably, the portions 63 ', 65' of the flexion zone bending lines 63, 65 adjacent to the intersection 68 have a smaller radius of curvature than the portion outside them. This reduced radius of curvature can prevent wrinkling in the flexion zone 58 adjacent the intersection 68. In the illustrated embodiment, the radius of curvature of both parts extends in the same direction (eg, both parts 63 ', 65' are concave downwards). Such a concave shape in the same direction can likewise prevent wrinkles in the bending area 58 adjacent to the intersection 68.

In operation and use, the sheet material is preferably preformed with bending lines and fold lines, i.e., the sheet material has an event 40, is concave flat and can be bent in place at the desired destination. The sheet material may be bent continuously along each individual line or simultaneously for two or more bend lines.

In another illustrated embodiment as shown in FIGS. 7-15, a flat sheet member 130 configured to form a three-dimensional structure 132 in the form of an instrument panel structure (I / P structure) shown in FIG. 8E. Reference is made to FIG. 7, which illustrates. In the illustrated embodiment, the I / P structure is constructed and standardized for use in automobiles, the sheet material is configured to form multiple three-dimensional structures including, but not limited to, mechanical and aesthetic elements, vehicle structures, and the like. It will be appreciated.

In the exemplary embodiment shown, the sheet material includes a plurality of straight bending lines 133 and flexural region bending lines 135. The bending zone bending line 135 is typically configured to localize the elastic deformation during bending along a predetermined path, which is the bending zone bending line or fold line mentioned below. For example, the flexion zone bending line 135 may be in the form of an event 137 disposed on either side of the flexion zone bending line so that bending along the flexion zone bending line is easily performed and accurately controlled. 137 is shown more clearly in FIG. 7B. Event 137 may be in the form of slits, grooves, displacements, and other suitable means described in the aforementioned patents and applications of Industrial Origami, the content of which is incorporated herein by reference.

Generally, the straight bending line 133 extends the length of the vehicle dashboard and has an instrument panel cross as shown in FIG. 11 having a size and configuration that is attached to the vehicle adjacent to the A-pillar as described in more detail below. It is provided to form the beam 139. A flexure zone bending line 135 is provided to form the dash panel 161 on the lower right side. While the main purpose of the crossbeam 139 is to provide structural integrity to the vehicle and the I / P structure, the main purpose of the dash panel is to provide a body panel having a satisfactory shape that adds to the aesthetic appearance of the interior. By bending the sheet material along the bending line in the order illustrated in Figs. 8A-8E, the two-dimensional sheet material forms the three-dimensional I / P structure of the present invention.

9A and 9B, the left and right tunnel flanges 142 and 144 are then bent against the front console flange 149 and left and right tunnel flange bends again against the bottom beam flange 151. Bending about 146 and 147 provides the intermediate structure shown in FIG. 9B. Tunnel flanges and associated flanges are sized and configured to cooperate with the drive train tunnel in a well known manner.

9B and 9C, the bottom beam flange 151 is then bent against the top beam flange 156, which is then bent relative to the bottom beam web 154 and again to the bottom beam flange 156. It provides the intermediate structure shown in Figure 9C. To date, straight bends are formed to form a box beam that partially intersects the vehicle interior between the A-pillars of the vehicle.

9C and 9D, the lower beam flange 156 is bent relative to the upper dash panel 158. As shown in FIG. In addition, the left and right lower dash panels 160 and 161 are bent relative to the upper dash panel 158, which causes the lower left dash panel 160 to be bent relative to the right lower dash panel 161. While this operation partially forms the box beam, this operation also produces complex shaped curvatures, as described in more detail below.

9D and 9E, the left and right beam flaps 163 and 165 are bent against the lower dash panels 160 and 161 which are the center console flaps 167. Each flap includes a flap fastening hole 168 that will ultimately be aligned with the beam fastening hole 170 as shown in FIG. 1. To enhance structural integrity and assist alignment, the left and right beam flaps 163 and 165 have left and right caps 172 and 174, each having a profile corresponding to the cross-sectional profile of the box beam on either end of the I / P structure. ). For example, FIG. 11 shows how the profile of the right cap 174 indicates or provides the cross-sectional shape of the right end of the box beam, while FIG. 12 shows that the profile of the left cap 172 is the left end of the box beam. It shows the way to provide the cross-sectional shape of. In many respects, the box beam of the present invention is similar to that described in the foregoing patents and applications, the contents of which are incorporated herein by reference, and therefore have the same advantages.

According to another aspect of the present invention, the I / P structure may also be configured to impart a wide flange shape to the upper and lower dash panels as shown in FIG. 7A. In particular, a complex or complex shape corresponding to the curvature of the multiple curved flexural region bending lines 135 is gentle in the shape region, ie the lower left dash panel 160 generally follows the shape of the flexural region bending line 135. The curved area bending line separates the lower left dash panel 160 from the upper dash panel 158 and the lower right dash panel 161. In contrast, the right dash panel 161 is bounded by intersecting the flexure region bending line 135 with the flexure that accommodates the various shapes imparted. The bending of the lower right dash panel 161 is greatly limited as the right lower dash panel 161 is outlined by crossing the bending area bending line 135.

Referring to the remaining figures, FIG. 10 is a right front view of the bent I / P structure, thus showing the curvature of the lower left dash panel 160 and the complex curvature of the lower right dash panel 161. Lower dash panels 160 and 161 have trim holes 175 and 177 to secure the trim to the I / P structure. For example, leather trims can be attached to I / P structures utilizing these holes. Lower left dash panel 160 further includes a cover 179 and corresponding openings for various switches and other vehicle controls. In the illustrated embodiment, the label is etched or directly followed by the sheet material, thereby providing an opportunity to backlight the label while eliminating the need for additional parts having such a label.

11 and 12, the cross beam has left and right openings 181, 182 to facilitate attachment to the vehicle integral frame. For example, the bolt 184 may extend from the vehicle mount 186 adjacent the A-pillar 188 of the vehicle, as shown in FIG. 15.

For convenience in the description and precise limitations of the appended claims, "left" or "right", "up" or "upper", "lower" or "lower", "inner" or "external" Are used to describe features of the present invention with reference to the location as indicated in the figures.

In many aspects, variations of the various figures are similar to the preceding variants, with the same reference numerals appended "a" designating corresponding parts.

The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The above exemplary embodiments are selected and described in order to enable those skilled in the art to make and use the exemplary embodiments of the present invention and its various alternatives and modifications by describing certain principles and practical applications thereof. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

Claims (30)

In the sheet member for forming a shaped three-dimensional structure, A line separating the front panel and the folding panel, the front panel bending line curved to give a predetermined shape on at least the folding panel when the sheet material is bent about this line; And A folding line extending along the folding panel, the folding line being formed to give the upper panel a predetermined shape of the folding panel when the sheet member is folded about this line Sheet material comprising a. The method of claim 1, The folding line is a sheet member, characterized in that the straight line. The method of claim 1, A line separating the folding panel from the auxiliary folding panel, further comprising an auxiliary folding line that is substantially straight so as to impart the shape of the first folding panel to the second folding panel when the sheet material is bent about this line, The form of the front panel bent line is a sheet member, characterized in that is provided to the upper panel through the folding panel and the second folding panel when the folding line and the auxiliary folding line is bent. The method of claim 1, A line separating the front panel and the front panel flange, the front panel-flange curved to impart a shape on at least one of the front panel and the front panel flange when the sheet member is bent about the front panel-flange bending line The sheet member further comprises a bend line. The method of claim 3, The front flange bent line is S-shaped to give a concave and convex shape to the front panel. The method of claim 1, And the front panel bend line is concave down to impart an upwardly convex shape on at least a portion of the top panel. The method of claim 1, The first spacing between the front panel bend and the first folding panel is defined by the second spacing between the first fold line and the second fold line such that the front edge of the upper panel formed by the second fold line is spaced apart from the front panel. Sheet material characterized by being different. The method of claim 7, wherein And the first interval is shorter than the second interval such that the front panel is indented past the front edge. The method of claim 1, A first top panel-flange bend line that is curved to impart a first shape on at least one of the front top flange and the bend region of the top panel to separate the front top flange from the bend region; A second top panel-flange bend line that is curved to impart a second shape on at least one of a second top flange and the bend region to separate the second top flange from the bend region; And First and second curved bend area bends configured to localize the bends along the bend and substantially isolate warpage within the bend area to separate the bend area from the remainder of the top panel Sheet material characterized in that it further comprises. The method of claim 9, Both the first and second bend region bends terminate at the intersection, Wherein the first and second bend zone bends both have a compound curvature, and a portion of the bend line adjacent to the intersection has a smaller radius of curvature to prevent wrinkling in the bend region adjacent to the intersection. The method of claim 1, At least one of the bent line and the fold line is formed with a plurality of slits penetrating the sheet material, adjacent sheets are characterized in that alternately located on one side of the bent line and the fold line. The method of claim 1, At least one of the bent line and the fold line is formed with a plurality of displacement portion, the sheet material, characterized in that adjacent displacements are alternately located on one side of at least one of the bent line and the fold line. A three-dimensional structure comprising the sheet material according to claim 1. Providing a sheet material according to claim 1; Bending the sheet material along a front panel bend; The sheet member is bent along a fold line. In the sheet member for forming a shaped three-dimensional structure, Upper panel; A first top panel-flange bend line that is curved to impart a first shape on at least one of the front top flange and the bend region of the top panel to separate the front top flange from the bend region; A second top panel-flange bend line configured to impart a second shape on at least one of a second top flange and the flexure region to separate the second top flange from the flexure region; First and second curved bend area bends configured to localize the bends along the bend and substantially isolate the bends within the bend areas to separate the bend areas from the remainder of the top panel. Sheet material comprising a. The method of claim 15, The first upper panel-flange bending line is concave down along a first direction, the second upper panel-flange bending line is concave down along a second direction that is not parallel to the first direction, and the bending And the region is elastically deformed to accommodate different shapes of the first and second top panel-flange bends. The method of claim 15, Both of the first and second bend lines terminate at intersections, Wherein both the first and second bend lines have a compound curvature, and a portion of the bend line adjacent to the intersection has a smaller radius of curvature to prevent wrinkles in the bending area adjacent to the intersection. The method of claim 15, At least one of the bent line and the folding line is a sheet member, characterized in that a plurality of slits penetrating the sheet member. The method of claim 18, Adjacent slits are alternately located on one side of at least one of the bending line and the folding line. The method of claim 15, At least one of the bent line and the fold line is formed with a plurality of displacement portion, the sheet material, characterized in that adjacent displacements are alternately located on one side of at least one of the bent line and the fold line. A three-dimensional structure comprising the sheet material according to claim 15. Providing a sheet material according to claim 15; The sheet material is bent along the first and second upper panel bends to accommodate the different shapes imparted by the first and second dashboard-flange bends to the first and second flexion zone bends. And bending the inside of the bending area by the method of forming a dashboard. In the sheet material for forming a shaped three-dimensional dashboard, A line separating the dash panel and the dash panel flange, the dash panel-flange bending line being curved to impart a shape on at least one of the dash panel and the dash panel flange when the sheet material is bent about the line; A line separating the dash panel and the first folding panel, wherein the dash panel bend line is curved to give a shape on the first folding panel when the sheet material is bent about the line; A line that separates the first folding panel from the second folding panel, the first folding being substantially straight so as to impart the shape of the first folding panel on the second folding panel when the sheet material is bent about this line line; A line that separates the second folding panel from the dashboard panel, the second folding line being substantially straight so as to give the dashboard panel the shape of the second folding panel when the sheet material is bent about this line; A first dashboard-flange bend line that is curved to impart a first shape on at least one of a first dashboard flange and a flexure region of the dashboard panel to separate the dashboard flange from the flexure region; A second dashboard-flange bend line that is curved to impart a second shape on at least one of a second dashboard flange and the flexure region to separate the second dashboard flange from the flexure region; And First and second curved bend area bends configured to localize bends along the bend and substantially isolate warpage within the bend area to separate the bend area from the rest of the dashboard panel Sheet material comprising a. The method of claim 23, wherein The dash panel-flange bending line is characterized in that the S-shape to give both the concave and convex shape to the dash panel. The method of claim 23, wherein And wherein the dash panel bend line is concave downward to impart an upwardly convex shape to at least a portion of the dashboard panel. The method of claim 23, wherein The first spacing between the dash panel bend and the first fold line is defined between the first fold line and the second fold line such that the front edge of the upper panel formed by the second fold line is spaced apart from the front panel. Sheet material characterized by being different from 2 intervals. The method of claim 26, And the first interval is shorter than the second interval such that the front panel is indented past the front edge. The method of claim 23, wherein Both the first and second bend lines terminate at the intersection, Wherein both the first and second bend lines have a compound curvature, and a portion of the bend line adjacent to the intersection has a smaller radius of curvature to prevent wrinkles in the bending area adjacent to the intersection. A dashboard comprising the sheet material according to claim 23. Providing a sheet member according to claim 23; Bending the sheet material along a dash panel-flange bending line; Bending the sheet member along a dashed panel bending line; Bending the sheet material along first and second fold lines; Bending the sheet material along the first and second dashboard-flange bends to accommodate different shapes imparted by the first and second dashboard-flange bends A method of forming a dashboard, characterized by bending the lines within the bending zone by lines.

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