Sheet material with bend controlling displacements and method for forming the same

Abstract

A method of preparing a sheet of material for bending along a bend line includes the step of forming at least one displacement in the thickness direction of the sheet of material, the displacement including a flat zone substantially parallel to the sheet of material with a portion of the periphery of the flat zone extending along and adjacent to the bend line, and including an angled transition zone interconnecting the flat zone with a remainder of the sheet of material. The forming step is preferably accomplished using one of a stamping process, a punching process, a roll-forming process and an embossing process. A sheet of material suitable for bending using the process also is disclosed, as are the use of coatings, shin guards and displacing the area of the sheet between bending inducing slits.

1 . A method of preparing a sheet of material for bending along a bend line comprising the step of:
 forming at least one displacement in the thickness direction of the sheet of material, the displacement including a flat zone substantially parallel to the sheet of material with a portion of the periphery of the flat zone extending along and adjacent to the bend line, and including an angled transition zone interconnecting the flat zone with a remainder of the sheet of material.   
     
     
         2 . The method as defined in  claim 1  wherein,
 the forming step providing the portion of the periphery adjacent the bend line with an edge and the sheet of material with a corresponding opposed face configured and positioned to produce edge-to-face engagement of the sheet of material during bending.   
     
     
         3 . The method as defined in  claim 2  wherein,
 the forming step shears the sheet of material entirely through the thickness dimension along the portion of the periphery.   
     
     
         4 . The method as defined in  claim 1  wherein,
 the forming step is accomplished using one of a stamping process, a punching process, a roll forming process, a shearing knife-based and an embossing process.   
     
     
         5 . The method as defined in  claim 1  wherein,
 during the forming step, forming a plurality of displacements in the sheet of material along the bend line with each displacement having a flat zone having a periphery portion proximate the bend line to provide a plurality of edges and opposed faces for edge-to-face bending of the sheet of material.   
     
     
         6 . The method as defined in  claim 5  wherein,
 during the forming step, forming the plurality of displacements along the bend line with each flat zone having the periphery portion substantially superimposed on the bend line.   
     
     
         7 . The method as defined in  claim 6  wherein,
 the forming step is accomplished using one of a stamping process, a punching process, a roll forming process, a shearing knife-based and an embossing process.   
     
     
         8 . The method as defined in  claim 7  wherein,
 the forming step is accomplished using a turret press to form each of the plurality of displacements, wherein the turret press is relocated with respect to the sheet of material to the desired location of each of the plurality of displacements.   
     
     
         9 . The method as defined in  claim 7  wherein,
 the forming step is accomplished using a modular die set including a number of die units corresponding in number to the number of displacements.   
     
     
         10 . The method as defined in  claim 9  wherein,
 the plurality of displacements are differently sized, wherein the die units are similarly differently sized and complementary in number and size to the plurality of displacements.   
     
     
         11 . The method as defined in  claim 6  wherein,
 during the forming step, positioning the periphery portion of displacements on opposite side of the bend line at a jog distance from each other less than the thickness dimension of the sheet of material.   
     
     
         12 . The method as defined in  claim 11  wherein,
 the jog distance is in the range of about −0.5 to about +0.5 times the thickness dimension of the sheet of material.   
     
     
         13 . The method as defined in  claim 12  wherein,
 during the forming step, forming the peripheral portions of displacements on opposite sides of the bend line to define bending straps oriented to extend obliquely across the bend line.   
     
     
         14 . The method as defined in  claim 13  wherein,
 the bending straps have a strap width that is approximately 2-5 times the thickness of the material.   
     
     
         15 . The method as defined in  claim 1 , and the step of:
 after the forming step, adhering a layer of coating material to the sheet of material across the portion of the periphery of the displacement.   
     
     
         16 . The method as defined in  claim 15  wherein,
 the adhering step forms a continuous layer of flexible coating material.   
     
     
         17 . The method as defined in  claim 1  wherein,
 the flat zone is elongated and includes curved ends.   
     
     
         18 . The method as defined in  claim 17  wherein,
 the periphery of the curved ends is formed semicircular in shape.   
     
     
         19 . The method as defined in  claim 1  further comprising:
 bending the sheet of material along the bend line.   
     
     
         20 . The method as defined in  claim 19  wherein,
 the bending step is accomplished manually.   
     
     
         21 . The method as defined in  claim 1  further comprising:
 further working the displacement to flatten the displacement back into a cavity formed during the forming step.   
     
     
         22 . A sheet of material suitable for bending along a bend line comprising:
 a sheet of material having at least one displacement in a thickness direction of the sheet of material, the displacement including a flat zone substantially parallel to the sheet of material with a portion of the periphery of the displacement extending along and adjacent to the bend line, and including an angled transition zone interconnecting the flat zone with a remainder of the sheet of material.   
     
     
         23 . The sheet of material as defined in  claim 22  wherein,
 the portion of the periphery adjacent the bend line includes an edge and the sheet of material includes a corresponding opposed face configured and positioned to produce edge-to-face engagement of the sheet of material on opposite sides of the portion of the periphery during bending.   
     
     
         24 . The sheet of material as defined in  claim 23  wherein,
 the sheet of material is formed with a plurality of displacements positioned along the bend line.   
     
     
         25 . The sheet of material as defined in  claim 24  wherein,
 alternating displacements are positioned longitudinally along and on opposite sides of the bend line to define bending straps between adjacent ends of displacements extending across the bend line.   
     
     
         26 . The sheet of material as defined in  claim 25  wherein,
 the lateral jog distance between the portion of the periphery on opposite sides of the bend line is less than the thickness dimension of the sheet of material.   
     
     
         27 . The sheet of material as defined in  claim 26  wherein,
 the lateral jog distance is in the range of about −0.5 to about +0.5 times the thickness dimension of the sheet of material.   
     
     
         28 . The sheet of material as defined in  claim 27  wherein,
 the lateral jog distance is about zero and the portions of the periphery are substantially superimposed on the bend line.   
     
     
         29 . The sheet of material as defined in  claim 22  wherein,
 the portion of the periphery of the displacement is sheared completely through the thickness dimension of the sheet of material.   
     
     
         30 . The sheet of material as defined in  claim 22  wherein,
 the sheet of material is bent along the bend line.   
     
     
         31 . The sheet of material as defined in  claim 30  wherein,
 the sheet of material is bent in a direction opposed to the direction of the displacement.   
     
     
         32 . The sheet of material as defined in  claim 22 , and a continuous layer of coating material adhered to at least one surface on the sheet of material after the displacement is formed. 
     
     
         33 . The sheet of material as defined in  claim 32  wherein,
 the sheet of material is bent along the bend line without fracturing the continuous layer of coating material.