Cut-fold shape technology for engineered molded fiber boards
Inventors
Herdt, Julee Ann • Schauermann, Kellen Scott • Hunt, John F.
Assignees
US Department of Agriculture USDA • University of Colorado Denver
Publication Number
US-9740799-B2
Publication Date
2017-08-22
Expiration Date
2031-12-02
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Abstract
A three-dimensional engineered shaped fiber configuration is formed using determined structural requirements for a three-dimensional engineered shaped fiber configuration and ascertained properties of an engineered molded fiber fiberboard material. A first cut on a top surface and a second cut on a bottom surface of the fiberboard material are calculated. These calculations are based, at least in part, on the structural requirements properties of the fiberboard material. The first cut and the second cut each have a depth, a width, and a position. The first cut and the second cut have a spacing between them such that the flat piece of fiberboard material can be folded at a point located in the spacing between the first cut and second cut to position a first portion of the fiberboard material at a particular angle with respect to a second portion of the fiberboard material.
Core Innovation
The invention provides a method and technology for forming a three-dimensional engineered shaped fiber configuration from a flat engineered molded fiber (EMF) fiberboard material. The method involves determining structural requirements for the desired three-dimensional shape and ascertaining the properties of the EMF fiberboard material. Based on these inputs, a first cut on the top surface and a second cut on the bottom surface of the fiberboard are calculated, each having a specific depth, width, and position. The spacing between these cuts enables the flat fiberboard piece to be folded at a point between the cuts to position different portions of the material at defined angles to create a three-dimensional shape.
The technology addresses deficiencies in existing structural insulated panels (SIPs), especially those relying on stressed-skin designs using oriented strand board (OSB) skins. These existing SIPs suffer from material redundancy, environmental concerns due to chemical use in OSB, limited flexibility, and difficulties integrating construction components. Traditional methods for creating three-dimensional EMF shapes require dedicated molds for each shape variant, which is costly and limits production to planar or simply curved forms. The disclosed cut, fold, shape (CFS) technology offers a structurally enhanced and cost-effective method to produce a virtually limitless variety of three-dimensional EMF shapes without the need for expensive molds.
The CFS method allows precise engineering of cuts, indents, and folds in the EMF fiberboard material based on the material properties and structural requirements. These three-dimensional shapes can be formed using computer-controlled fabrication or manual methods, resulting in interlocking assemblies suitable for building panels, furniture, packaging, and other applications. The method enables the production of complex rib angles and multi-planar surfaces, permitting design flexibility not achievable with current wet-formed or stressed-skin SIP manufacturing methods.
Claims Coverage
The patent includes two independent claims directed to a method performed by a computer system and a computer program product for controlling a CNC cutting device to create three-dimensional shaped panels from flat fiberboard sheets. Four inventive features are presented.
Method for calculating and controlling cuts to create hinged fold joints
The method includes receiving structural properties of the flat fiberboard and geometric properties of the desired three-dimensional panel, calculating positions, widths, depths, and lengths for a first cut on the top surface and a second cut on the bottom surface of the fiberboard sheet. These cuts are spaced and dimensioned to form a hinged fold joint that meets the required structural and performance properties for the three-dimensional shaped panel. The method further generates control values for a CNC cutting device to implement these cuts.
Computer system control of CNC cutting device
The computer system is configured to control the CNC cutting device directly using the generated control values to perform the cuts on the fiberboard sheet, thereby implementing the calculated hinged fold joints.
Computer program product with instructions for calculating and generating cutting controls
The computer program product comprises instructions that retrieve structural and geometric properties, calculate structural and performance requirements, compute positions and dimensions of the top and bottom cuts to form the hinged fold joint, generate control values formatted for CNC cutting instructions, and output those control values.
Inclusion of rib angle as a variable defining fold angle
The physical and geometric properties include a rib angle value defining the desired angular relationship between portions of the fiberboard on either side of the hinged fold joint when folded to form the three-dimensional shape.
The independent claims cover a computer-implemented method and computer program product that calculate and control precise cuts on a flat fiberboard to create hinged fold joints. This enables the transformation of flat sheets into engineered three-dimensional shaped panels with specified structural and geometric properties, controlling a CNC cutting device for fabrication.
Stated Advantages
Allows production of varying shaped and angled ribs from flat fiberboard material without requiring expensive molds.
Enables improved structural and geometric characteristics of SIP panels compared to traditional three-dimensional wet-formed panels.
Facilitates easy design and fabrication adjustments using digital fabrication, allowing product precision and close design tolerances.
Supports creation of a SIP panel core with multiple, geometrically-shaped core options and integration of inserts to assist folding and locking, improving assembly efficiency and potentially eliminating adhesives.
Allows consideration and positioning of geometric inserts for ideal foam dispersion and non-bending during SIP fabrication.
Provides the capability to produce nearly unlimited three-dimensional shapes and configurations from engineered molded fiberboard materials.
Documented Applications
Use in structural insulated panels (SIP) for building construction across residential, commercial, industrial, educational, agricultural, medical, temporary, and disaster/emergency shelters.
Application in furniture and furnishings, including children's furniture and toys.
Use in ceiling, wall, and floor skins and surfaces, as well as in lighting and concrete formwork.
Applications in aerospace, automotive, railway, displays, stage sets, electronics, renewable energy equipment, sports equipment, packaging and containers, and specialty products.
Use in product-as-package design and materials for arts, crafts, and various industrial fabrication components.
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