Method of bending sheet materials and sheet therefor

Abstract

A sheet of material formed for bending along a bend line including a sheet of material ( 30 ) includes a plurality of dividing slits ( 37 ) and a plurality of strap slits ( 39 ) formed therethrough. The dividing slits extending substantially along a desired bend line ( 35 ) and divide the sheet of material into first and second planar regions ( 32, 33 ). The strap slits intersect the desired bend line and adjacent pairs of strap slits form a bending strap therebetween. The bending strap has a longitudinal strap axis intersecting the desired bend line. The sheet of material may be formed of composite materials. A method of forming and using the sheet of material is also disclosed.

1 . A sheet of material formed for bending along a bend line comprising: a sheet of material having at least one dividing slit extending substantially along a desired bend line dividing said sheet of material into first and second planar regions, and at least two strap slits formed through said sheet of material intersecting said desired bend line, wherein said strap slits form a bending strap therebetween, said bending strap having a longitudinal strap axis intersecting said desired bend line. 
     
     
         2 .- 23 . (canceled) 
     
     
         24 . A method of forming a sheet of material for bending along a bend line comprising the steps of: forming at least one dividing slit through said sheet of material extending substantially along a desired bend line thereby dividing said sheet of material into first and second planar regions; and forming at least two strap slits through said sheet of material intersecting said desired bend line, thereby forming a bending strap between said strap slits, said bending strap having a longitudinal strap axis intersecting said desired bend line. 
     
     
         25 . The method of  claim 24 , said method further comprising the step of: after the forming steps but before the assembling step, mounting at least one component to at least one of said first and second planar regions. 
     
     
         26 . A method of forming a sheet of material for bending along a bend line comprising the steps of: forming a plurality of dividing slits through said sheet of material extending substantially along a desired bend line thereby dividing said sheet of material into first and second planar regions; and forming a plurality of substantially parallel strap slits through said sheet of material intersecting said desired bend line, thereby forming a bending strap between adjacent pairs of said strap slits, said bending strap having a longitudinal strap axis intersecting said desired bend line. 
     
     
         27 . The method of  claim 26 , wherein prior to the forming steps, selecting a sheet of elastically deformable material for slitting. 
     
     
         28 . The method of  claim 26 , said method further comprising the step: prior to the forming steps, selecting a sheet of composite material for slitting. 
     
     
         29 . The method of  claim 26 , wherein said forming steps are accomplished simultaneously. 
     
     
         30 . The method of  claim 26 , wherein said forming steps are accomplished by forming at least three dividing slits and at least a pair of strap sets, and each strap set disposed between adjacent ones of said dividing slits, each strap set having at least three strap slits forming at least two substantially parallel bending straps therebetween. 
     
     
         31 . The method of  claim 30 , wherein said strap-slits forming step is accomplished by forming at least a pair of said strap sets parallel to one another such that the strap axis of a first of said strap sets is parallel to the strap axis of a second of said strap sets. 
     
     
         32 . The method of  claim 30 , wherein said strap-slits forming step is accomplished by forming at least a pair of said strap sets nonparallel to one another such that the strap axis of a first of said strap sets intersects the strap axis of a second of said strap sets. 
     
     
         33 . The method of  claim 32 , wherein said strap-slits forming step is accomplished by forming strap sets symmetrically about a transverse axis which extends substantially transverse to said desired bend line. 
     
     
         34 . The method of  claim 26 , wherein said strap-slits forming step is accomplished by forming each said strap with a substantially straight intermediate portion. 
     
     
         35 . The method of  claim 26 , wherein said strap-slits forming step is accomplished by forming an end of at least one of said strap slits with a enlarged stress-relieving end opening. 
     
     
         36 . The method of  claim 35 , wherein said strap-slits forming step is accomplished by forming at least one of said strap slits with a stress-relieving end radius to increase the cross-sectional area of an adjacent bending strap as said adjacent bending strap merges with a respective one of said planar regions. 
     
     
         37 . The method of  claim 26 , wherein said strap-slits forming step is accomplished by forming an adjacent pair of said strap slits each with a stress-relieving end radius to increase the cross-sectional area of an adjacent bending strap as said adjacent bending strap meets a respective one of said planar regions. 
     
     
         38 . The method of  claim 37 , wherein said forming steps are accomplished by simultaneously forming said stress-relieving end radius to interconnect said at least one of said strap slits and an adjacent dividing slit. 
     
     
         39 . The method of  claim 26 , wherein said forming steps are accomplished by forming at least one interconnected dividing slit and adjacent strap slit. 
     
     
         40 . The method of  claim 26 , wherein said strap forming step is accomplished by forming said strap slits such that said strap axis is oblique to said desired bend line. 
     
     
         41 . The method of  claim 26 , said method further comprising the step: prior to the forming steps, selecting a sheet of composite material having a substantially uniform thickness; wherein said strap-slit forming step is accomplished by forming adjacent ones of said strap slits such that each said bending strap includes a minimum width dimension that is less than or substantially equal to the thickness of said sheet of material. 
     
     
         42 . The method of  claim 26 , said method further comprising the step of: after the forming steps, bending the sheet of material about said desired bend line. 
     
     
         43 . The method of  claim 26 , said method further comprising the step of: forming an assembly recess in each of said first and second planar regions for locating and securing said sheet of material during assembly. 
     
     
         44 . The method of  claim 43 , said method further comprising the step of: after the forming steps, bending the sheet of material about said desired bend line; assembling said sheet of material with another device such that a respective locating protrusion extends through said each said assembly recess. 
     
     
         45 . The method of  claim 44 , said method further comprising the step of: after the forming steps but before the assembling step, mounting a component to at least one of said first and second planar regions.