WO2021091892A1

WO2021091892A1 - Rolling brake apparatus for sheet material

Info

Publication number: WO2021091892A1
Application number: PCT/US2020/058698
Authority: WO
Inventors: Andres Daniel MENDOZA
Original assignee: Northside Heating & Air Conditioning, Llc
Priority date: 2019-11-04
Filing date: 2020-11-03
Publication date: 2021-05-14
Also published as: TW202128307A

Abstract

A handheld brake apparatus configured for use in creasing sheet materials. The brake apparatus includes a roller body configured to be grasped by a hand of a user and to be moved over a surface of a sheet material. Spaced apart rollers are rotatably mounted to the roller body and each includes a creasing edge that contacts and roll along the sheet material as the brake apparatus is moved. The creasing edge is configured to provide a crease in the sheet material along a roller travel path.

Description

ROLLING BRAKE APPARATUS FOR SHEET MATERIAL

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/930,103, filed on November 4, 2020, and entitled ROLLING BRAKE APPARATUS FOR SHEET METAL, which is incorporated herein by reference in its entirety.

FIELD

[0002] The present invention relates generally to cutting, bending and scoring sheet materials. More particularly, the present invention relates to a hand-operated rolling brake apparatus for sheet materials.

BACKGROUND

[0003] Many construction and fabrication materials, including particularly sheet materials such as sheet metal, gypsum board (e.g., SHEETROCK ® brand gypsum boards), roofing tile, house wrap, as well as other types of construction materials used throughout the construction, fabrication, repair (e.g., automotive repair), and other industries, including glass, tile, flooring, and the like, are frequently scored prior to being bent and/or cut into their final intended shape. Ideally, these scoring, bending, and cutting processes can occur quickly, safely, and accurately.

[0004] As a specific example, in the heating, ventilation, and air conditioning (HVAC) industry, lightweight sheet metal is used to create supply and return ductwork and other sheet metal applications in the HVAC field and other fields, including hoods, boxes, rain shields, etc. While standard ducting is available and may be used to create a majority of the supply and return air duct systems, custom duct sections are also often required. This customization often includes custom sized and custom shaped duct sections. It also includes duct sections that are modified so that they are stiffer than originally constructed. Often, stiffened duct sections are required by applicable construction codes. Duct that is not sufficiently stiffened can warp or deform, which may result in impaired air flow, noise, etc. during operation. There are a variety of methods of stiffening HVAC duct sections. One method, called beading, uses a beading machine to create multiple parallel bands or "beads" that extend around the periphery of the duct section to create stiffness.

[0005] With reference to Figure 1, another method uses an apparatus called a brake to create creases, such as X-shaped creases 100, across one or more of the faces 102 of a section of duct 104. A brake is a metalworking machine that creates bends and creases in sheet metal. A typical brake consists of a flat surface onto which the material is placed and a straight clamping bar, often 2 feet to 14 feet in length, that holds a portion of the material firmly against the flat surface during the bending process while leaving another portion of the material free. To form the bend, a portion of the sheet metal is inserted into the brake and then clamped between the flat base surface and the straight clamping bar. The free end of the material is then bent about the clamping bar. The angle of the bend can be varied to any angle, but the practical limit is often approximately 120 degrees.

[0006] Using this method, the X-shaped creases 100, which are also called cross brakes, may be formed from two diagonal and intersecting creases formed across the faces 102 of the duct 104. The length of bend that can be formed at one time is limited in length to the length of the brake device (including the clamping bar and flat surface). To produce a longer bend, subsequent bending operations are required. This requires the sheet material to be moved and repositioned in the brake apparatus. This repositioning step takes time since the user must repeatedly stop the bending process, re-position the sheet material in the correct new location and orientation, and then restart the bending process. These repositioning steps can lead to inconsistent results (i.e., inaccurate bending) if the user is not very careful to re-position the sheet material in the brake with the correct angle and correct position.

[0007] Other disadvantages of creating beads and bends in sheet materials include the high costs and weight of the machines required to carry out those functions. Creating beads requires a beading machine and a creating the cross brakes requires a brake. While these machines can make the process of stiffening ductwork a fairly simple process, they are relatively expensive and are not easily transported. For example, conventional brakes often cost $1000 or more and can weigh 60 pounds or more. For this reason, it is often inconvenient and too expensive to use these machines when creating custom ductwork on a client site. In some cases, creating custom duct work requires the appropriate machinery to be purchased and then transported to the client site. In other cases, the technician may be required to leave the client site simply to use an off-site brake or beading machine.

[0008] Lastly, conventional brakes are capable of producing only straight lines that, due to their construction and mode of operation, typically must span the entire width of the sheet metal material. These conventional brakes are incapable of producing creases that span only a portion of the sheet material, are incapable of producing bent or curved sections, and are restricted to use on an "interior" portion of the sheet metal (i.e., away from the edges of the material). Instead, conventional brakes generally form creases whose ends extend to the edge (i.e., the perimeter) of the sheet material.

Accordingly, what is needed, is a brake apparatus for bending sheet materials, such as for creating cross brakes and other custom-shaped bends in HVAC duct. Additionally, what is needed is a brake apparatus that is easily mobile and that can be easily transported and used at various work locations and that does not require a large, difficult to transport machine. Also, what is needed is a brake apparatus that is capable of producing bends in sheet materials of any length and that is not limited to any particular length when making a single bend and that can make bends that are not simply straight lines that begin and end at the perimeter edge of the sheet material.

NOTES ON CONSTRUCTION

[0009] The use of the terms “a”, “an”, “the” and similar terms in the context of describing embodiments of the invention are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising”, “having”, “including” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The terms “substantially”, “generally” and other words of degree are relative modifiers intended to indicate permissible variation from the characteristic so modified. The use of such terms in describing a physical or functional characteristic of the invention is not intended to limit such characteristic to the absolute value which the term modifies, but rather to provide an approximation of the value of such physical or functional characteristic.

[0010] Terms concerning attachments, coupling and the like, such as “attached”, “connected” and “interconnected”, refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable and rigid attachments or relationships, unless otherwise specified herein or clearly indicated as having a different relationship by context. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.

[0011] The use of any and all examples or exemplary language (e.g., “such as” and “preferably”) herein is intended merely to better illuminate the invention and the preferred embodiments thereof, and not to place a limitation on the scope of the invention. Nothing in the specification should be construed as indicating any element as essential to the practice of the invention unless so stated with specificity.

SUMMARY

[0012] The above and other needs are met by a handheld rolling brake apparatus configured for use in creasing sheet materials. The brake apparatus includes a roller body sized and configured to be moved over a surface of the sheet material and to be grasped and operated by a hand of a user. A pair of spaced apart rollers is rotatably mounted to the roller body. A creasing edge on each roller is configured to make contact, to roll along, and to provide a crease in the sheet material along a roller travel path.

[0013] In some embodiments, the roller body has a front end, a back end, and an elongate axis passing through a midline of both the front end and back end. The roller travel path is parallel with the elongate axis as the roller body is moved. In some embodiments, the rollers are configured to be mounted to the roller body at a position that is laterally offset from the midline. In certain embodiments, the brake apparatus includes a sliding roller assembly for slidably mounting the rollers to the roller body such that the rollers may slide between and be selectively held at a first position, where the roller travel path is positioned along the midline, and a second position, where the roller travel path is offset from the midline. The sliding roller assembly may include a slide track housing mounted to the roller body that has an internal track. A sliding carrier includes a sliding end that slides within the slide track housing along the internal track between the first and second positions. The sliding carrier further includes a mounting end that mounts to the rollers and to be selectively fixedly held at each of the first and second positions.

[0014] In certain embodiments, the roller body includes a handle section and a roller support section that is removably mounted to a bottom of the handle section. The rollers are rotatably mounted to the roller support section and are removably mounted to the handle section via the roller support section. The roller support section may include a pair of L-shaped support tracks that each has a first leg joined at an angle to a second leg. The first leg of each L-shaped support track is preferably removably mounted to a bottom surface of the handle section such that the second leg of each L-shaped support track extends downwards away from the bottom surface of the handle section. The L-shaped support tracks are positioned to provide a space between the second legs, wherein the rollers are rotatably located between the spaced apart second legs of the L-shaped support tracks.

[0015] Certain embodiments of the invention further include one or more slots formed in roller body configured to receive the rollers and fasteners for rotatably mounting the rollers in the one or more slots. In some cases, the fasteners pass through a first portion of the roller body, through the rollers in the one or more slots, and then through a second portion of the roller body.

[0016] According to certain embodiments of the invention, the roller body includes a handle section configured to be grasped by a user during the operation of the brake apparatus. A roller support section rotatably holds the rollers. Lastly, an offset member is mounted between the handle section and the roller support section such that the handle section spaced away from the roller support section by the offset member. In some cases, the handle section is spaced vertically above the roller support section by the offset member. In some cases, the handle section is spaced laterally to a side of the roller support section by the offset member. In still other case, the handle section includes a left handle section spaced laterally to a left side of the roller support section by a left offset member and a right handle section spaced laterally to a right side of the roller support section by a right offset member.

[0017] In certain embodiments of the invention, the rollers are mounted a distance D away from each other, where D is measured along a line parallel with an elongate axis extending through a front end and a back end of roller body and through the rollers, wherein the distance D is preferably between 2.5 and 3.5 inches.

[0018] The present invention also contemplates a method for creating creases in sheet materials. The method includes the step of providing a handheld rolling brake apparatus having rollers with a creasing edge, as detailed above, contacting the sheet material with the creasing edge of the rollers, and then moving the brake apparatus over the sheet material along an elongate axis to form a crease section in the sheet material that is parallel with the elongate axis. Certain embodiments further include the step of forming a first crease section with the elongate axis oriented in a first direction and then forming a second crease section connected to the first crease with the elongate axis oriented in a second direction that is different from the first direction. In certain embodiments of the method, the crease section is formed entirely in an interior portion of the sheet material such that a beginning point and an end point of the crease section is spaced away from and does not contact any edge of the sheet material. In certain embodiments of the method, a maximum length of the crease section is formed by the brake apparatus may be varied. Finally, according to certain embodiments of the method, the crease section is curved. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Further advantages of the invention are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numerals represent like elements throughout the several views, and wherein:

[0020] Figure 1 is a section of sheet metal ductwork used in connection with HVAC systems having X-shaped strengthening creases provided therein;

[0021] Figure 2 is a lower perspective view illustrating a rolling brake apparatus configured for use in creasing sheet material according to an embodiment of the present invention;

[0022] Figure 3 is a side elevation view of the rolling brake apparatus of Figure 3;

[0023] Figure 4 is a front elevation view of the rolling brake apparatus of Figure 3;

[0024] Figure 5 is a front elevation view depicting a roller used in brake apparatus of Figure 3;

[0025] Figure 6 is an exploded view of the rolling brake apparatus of Figure 3;

[0026] Figure 7 is a side elevation view of a rolling brake apparatus according to an alternative embodiment of the present invention;

[0027] Figure 8 is a sectional view of the brake apparatus of Figure 7, shown along line A- A;

[0028] Figure 9 depicts a rolling brake apparatus in the process of creasing sheet material according to an embodiment of the present invention;

[0029] Figure 10 depicts a section of sheet material with creases that may be created using a rolling brake apparatus of the present invention; [0030] Figure 11 depicts a computer numerical control (CNC) machine having a single roller for use in creasing sheet material according to an alternative embodiment of the present invention;

[0031] Figure 12 is a side elevation view that depicts a rolling brake apparatus according to an alternative embodiment of the present invention;

[0032] Figure 13 is a sectional view of the brake apparatus of Figure 12, shown along line B-B

[0033] Figure 14 is a front elevation view of a brake apparatus having a slide roller assembly according to an embodiment of the present invention;

[0034] Figure 15 is a side elevation view of the brake apparatus of Figure 14;

[0035] Figure 16 is a partial cutaway view depicting the sliding roller assembly of Figure 14 with a right end portion of a slide track housing removed;

[0036] Figure 17 is a sectional view of the sliding roller assembly of Figure 15, shown along line C-C; and

[0037] Figure 18 includes perspective views depicting rolling brake apparatuses, each with a different handle design, according to various alternative embodiments of the present invention.

DETAILED DESCRIPTION

[0038] Referring now to the drawings in which like reference characters designate like or corresponding characters throughout the several views, there is shown in Figures 2-5, a brake apparatus 200 configured for use in creasing sheet materials, such as sheet metal, according to an embodiment of the present invention. The brake apparatus 200 includes a weighted elongate roller body 202 having a front end 204, a back end 206, and an elongate axis 208 extending through the front end and back end. The brake apparatus 200 also preferably includes a pair of rollers 210 rotatably mounted to the weighted roller body 202. However, the present invention also encompasses embodiments that utilize only a single roller 210 or that utilize more than two rollers. The rollers 210 are preferably positioned such that a sharp creasing edge 212 of each roller extends below a bottom surface 214 of the roller body 202 and is configured to contact a sheet material surface below the roller body and to crease the sheet material as the brake apparatus 200 is moved over the sheet material.

[0039] As illustrated best in Figure 6, the apparatus 200 preferably includes one or more support tracks 216 for removably mounting the rollers 210 to a bottom surface 218 of the roller body 202, which facilitates maintenance, exchanging and replacement of the rollers. For example, the apparatus 200 may be re-configured for different applications by exchanging the type of roller body 202 or rollers 210. This might include, for example, different sheet material types, including different thicknesses or gauges, as well as different functions, including scoring, bending, cutting, etc. This could include the use of rollers 210 that have different a crease edge shape (e.g., rounded, sharp), sharpness, diameters, thicknesses, creasing edge profile/pattem (e.g., continuous, slitted, perforated, etc.), and the like. In this particular embodiment, a pair of L-shaped support tracks 216 is removably mounted to the bottom surface 218 of the roller body 202 in a spaced apart relationship to one another via fasteners 220. A pair of rollers 210 is rotatably mounted and can freely spin within the space between the support tracks 216 via nuts 222 and bolts 224.

[0040] With reference now to Figures 7 and 8, an alternative apparatus 200' having a different mounting configuration for rollers 210 is provided. In this case, rollers 210 are inserted into slots 226 (one of which is illustrated in Figure 8) formed in roller body 228. A countersunk bore 230 is formed in roller body 228 and removable fasteners 232 are then inserted through the bore 230 to rotatably mount rollers 210 within slots 226. This alternative apparatus 200' is also provided with a body 202 having one or more handles 234 that may be removably connected to or integrally formed with the roller body 228 and that facilitate use of the apparatus.

[0041] Additionally, an alternative embodiment of the apparatus 200 having a different type of handle 234 is shown in Figures 12 and 13. In particular, a single contoured (i.e., rounded) handle 234 is spaced vertically above the roller support section 252 by an offset member 254. Handles having other shapes, including those better suited for left-handed or right-handed users are also contemplated. Additionally, handles, such as handle 234, may also be placed on or extend away from the left or right side of the roller support section 252 by a suitable left or right offset member (not shown). Additional alternative embodiments of the apparatus 200, each having a modified handle 234, are also shown in Figure 18. One side of each alternative apparatus is shown in the various views of Figure 17. The opposite side (i.e., the side now shown) of each alternative apparatus is identical to (and the reverse of) the illustrated side. As shown, the apparatus 200 may be formed with a body 202 incorporating a variety of shapes, including handle spheroid, cuboid, and other shapes. The body 202 may include a handle 234 connected to a roller support section 252 by an offset member 254. Additionally, portions of the body 202, such as the handle 234, may be shelled or hollowed in order to reduce overall weight and cost of production, as shown in view (d). Additionally, grip-improving elements 280, including surface structures (e.g., raised ridges or contours) and surface textures may be provided to improve a user's ability to securely grasp and use the apparatus 200.

[0042] With reference to Figure 9, brake apparatus 200 is configured create a crease sections 236 in faces 238 of sheet material 240 that are parallel with the elongate axis 208. As shown in Figure 10, the creases formed by brake apparatus 200 may include diagonal creases 242 that span the entire width of the sheet material 238 and that form the cross brakes discussed earlier. Those creases may also include custom creases 244, which span only a portion of the width of the sheet material 238, are restricted to an "interior" portion of the sheet material (i.e., away from the edges of the material), or that include bent or curved sections.

[0043] As shown in Figures 3 and 7, rollers 210 are preferably spaced a distance D away from each other. In these particular embodiments, distance D is approximately 2.5 inches to approximately 3.5 inches. Placement of the rollers 210 too closely together would reduce their ability to work together to be "self-guiding." Placing the rollers 210 too far away would likely require the size and weight of the apparatus 200 to be increased and would decrease the maneuverability of the apparatus. Preferably two spaced apart rollers 210 are used, which allows for accurate and consistently straight lines to be created. When two rollers 210 are used, the leading roller guides the trailing roller. Preferably, the rollers 210 are configured roll in either direction (i.e., either roller can function as the leading/trailing roller). However, as shown in Figure 11, a single roller 210 may be used in connected with a motion-controlled brake apparatus 246, where movement of the apparatus is guided. In this particular embodiment, the brake apparatus 246 is a formed as part of a computer numerical control (CNC) setup, which is controlled by a computer and has 360° of freedom of movement when creating creases 248 in sheet material 250. In other embodiments, a single roller 210 may be used in a hand-operated brake apparatus 246 whose motion is governed by a guide, such as a straight edge.

[0044] Referring again to Figures 2-4, preferably, the weight and dimensions of the roller body 202 are such that the apparatus can be easily transported from one work site to another work site and carried and operated effectively with a single hand of a user. In this particular embodiment, the roller body 202 is approximately 4.5 inches in length (measured from the front end 204 to the back end 206), 3 inches in height (measured vertically from the bottom of the creasing edge to the top of the brake apparatus), and 2 inches in width. The creasing edge 212 of the rollers 210 are preferably sharp enough, when combined with the weight of the weighted roller body 202, to produce creases in sheet material with only minimum additional downward pressure from the technician, depending on the thickness or gauge of the sheet material. In this particular case, the roller body 202 weighs approximately 5 pounds to approximately 7 pounds. For sheet material thickness or gauges that are typical in the HVAC industry, only an additional downward pressure of approximately 50 pounds to approximately 65 pounds would be needed to create suitable creases using the brake apparatus 200.

[0045] The rollers 210 are preferably arranged along a parallel line with one another and with the elongate axis 208. This elongate axis is preferably positioned on a midline LI of the roller body, such that the rollers 210 are located on a plane that extends vertically along midline LI and along axis 208 down the length of the roller body 202. This will enable a user to place their weight directly over the center of the roller body 202 and onto the rollers 210. However, an "offset" embodiment, where the rollers 210 are laterally offset (i.e., to the right or to the left) from the roller body 202 is also contemplated. This embodiment might be useful, for example, in cramped worked environments (e.g., comers, etc.) where space is limited. In still other embodiments, it is contemplated that the rollers 210 might be moved laterally from a center position to one or more offset positions to the left and/or right of the center of the roller body.

[0046] For example, with reference to Figures 14-17, there is provided a brake apparatus 260 having a set of rollers 210 that can translate laterally leftwards or rightwards away from a center position, located along a midline LI, to an offset position, located along an offset line L2. Brake apparatus 260 is provided with a sliding roller assembly 262 for slidably mounting the rollers 210 to the roller body 202 such that the rollers may slide between the center position to the offset position shown by 210'. The sliding roller assembly 262 also permits the rollers to be selectively held at either the center position or offset position (or in one or more intermediate positions).

[0047] The sliding roller assembly 262 includes a slide track housing 264 that is mounted to a bottom of the roller body 202. The slide track housing 264 is provided with an internal track 266. A sliding carrier 268 includes a sliding end 270 that slides within the slide track housing 264 along the internal track 266. In preferred embodiments, the sliding end 270, the internal track 266, or both are provided with a non-friction or low friction coating or surface 272. The sliding carrier 268 also includes a mounting end 274 (a threaded end in this case) that is configured to mount to the rollers 210. In this particular case, the mounting end 274 is mounted to an L-shaped support track 216 that is, in turn, mounted to a pair of rollers 210. An arrester 276 is used to hold the carrier 268 in a selected position. In this case, the arrester 276 is a bolt that may be tightened in order press the support track upwards against the bottom of the slide track housing 264 when the roller 210 is located in the desired location. In certain embodiments, the internal track 266 may be provided with one or more stops 278 that limits the distance that the carrier 268 can travel along the track. For example, a first stop 278 may be provided to stop the carrier 268 such that the roller 210 is stopped below midline LI. Another stop (not shown) may be provided to stop the carrier 268 at the opposite end of the internal track 266 when the roller is located below offset line L2.

[0048] Although this description contains many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments thereof, as well as the best mode contemplated by the inventor of carrying out the invention. The invention, as described herein, is susceptible to various modifications and adaptations as would be appreciated by those having ordinary skill in the art to which the invention relates.

Claims

CLAIMS What is claimed is:

1. A handheld rolling brake apparatus configured for use in creasing sheet materials, the brake apparatus comprising: a roller body sized and configured to be moved over a surface of the sheet material and to be grasped and operated by a user; a pair of spaced apart rollers that are rotatably mounted to the roller body; a creasing edge on each roller that is configured to make contact, to roll along, and to provide a crease in the sheet material along a roller travel path.

2. The brake apparatus of claim 1 wherein the roller body has a front end, a back end, and an elongate axis passing through a midline of both the front end and back end and wherein the roller travel path is parallel with the elongate axis as the roller body is moved.

3. The brake apparatus of claim 2 wherein the rollers are configured to be mounted to the roller body at a position that is laterally offset from the midline.

4. The brake apparatus of claim 3 further comprising a sliding roller assembly for slidably mounting the rollers to the roller body such that the rollers may slide between and be selectively held at a first position, where the roller travel path is positioned along the midline, and a second position, where the roller travel path is offset from the midline, the sliding roller assembly having: a slide track housing mounted to the roller body and having an internal track; and a sliding carrier having: a sliding end configured to slide within the slide track housing along the internal track between the first and second positions; and a mounting end configured to mount to the rollers and to be selectively fixedly held at each of the first and second positions.

5. The brake apparatus of claim 1 wherein the roller body comprises a handle section and a roller support section removably mounted to a bottom of the handle section, wherein the rollers are rotatably mounted to the roller support section and are removably mounted to the handle section via the roller support section.

6. The brake apparatus of claim 5 wherein the roller support section comprises a pair of L- shaped support tracks, each L-shaped support track having a first leg joined at an angle to a second leg, the first leg of each L-shaped support track removably mounted to a bottom surface of the handle section such that the second leg of each L-shaped support track extends downwards away from the bottom surface of the handle section, the L-shaped support tracks positioned to provide a space between the second legs, wherein the rollers are rotatably located between the spaced apart second legs of the L-shaped support tracks.

7. The brake apparatus of claim 1 further comprising: one or more slots formed in roller body configured to receive the rollers; fasteners rotatably mounting the rollers in the one or more slots.

8. The brake apparatus of claim 7 wherein fasteners pass through a first portion of the roller body, through the rollers in the one or more slots, and then through a second portion of the roller body.

9. The brake apparatus of claim 1 wherein the roller body comprises a handle section configured to be grasped by a user during the operation of the brake apparatus, a roller support section configured rotatably hold the rollers, and an offset member mounted between the handle section and the roller support section such that the handle section spaced away from the roller support section by the offset member.

10. The brake apparatus of claim 9 wherein the handle section is spaced vertically above the roller support section by the offset member.

11. The brake apparatus of claim 9 wherein the handle section is spaced laterally to a side of the roller support section by the offset member.

12. The brake apparatus of claim 9 wherein the handle section comprises a left handle section spaced laterally to a left side of the roller support section by a left offset member and a right handle section spaced laterally to a right side of the roller support section by a right offset member.

13. The brake apparatus of claim 1 wherein the rollers are mounted a distance D away from each other, where D is measured along a line parallel with an elongate axis extending through a front end and a back end of roller body and through the rollers, wherein the distance D is between 2.5 and 3.5 inches.

14. A method for creating creases in sheet materials: providing a handheld rolling brake apparatus having: an elongate roller body having a front end and a back end and being sized and configured to be held in a hand of a user; a pair of rollers rotatably mounted to the roller body and spaced a distance D away from each other; a creasing edge formed on each of the rollers that is configured to make contact, to roll along, and to provide a crease in the sheet material along a roller travel path as the roller is moved over the sheet material; an elongate axis extending through the front end and back end and through the creasing edge of each roller; contacting the sheet material with the creasing edge of the rollers; and moving the brake apparatus over the sheet material along the elongate axis to form a crease section in the sheet material that is parallel with the elongate axis.

15. The method of claim 14 further comprising the step of forming a first crease section with the elongate axis oriented in a first direction; and forming a second crease section connected to the first crease with the elongate axis oriented in a second direction that is different from the first direction.

16. The method of claim 14 wherein the crease section is formed entirely in an interior portion of the sheet material such that a beginning point and an end point of the crease section is spaced away from and does not contact any edge of the sheet material.

17. The method of claim 14 wherein a maximum length of the crease section is formed by the brake apparatus may be varied.

18. The method of claim 14 wherein the crease section is curved.