Hinged Three-Dimensional Structure Formed With Two-Dimensional Sheet of Material

Abstract

A substantially two-dimensional sheet material is configured for bending along a bend line to form a three-dimensional structure having a hinge along the bend line. The sheet material includes a substantially two-dimensional in a region in which a bend is to be made, and a plurality of displacements in a thickness direction of the sheet material along opposing sides of the bend line, each displacement having a sheared edge extending between end portions thereof and substantially parallel to the bend line. The adjacent sheared edges overlap one another with respect to the bend line to form a hinge structure therebetween extending along the bend line, the hinge structure having hinge ends that conform in shape with the end portions. The hinge structure is dimensioned and configured for multiple bend and unbend cycles thereby providing a monolithic hinge connecting opposing panels of the sheet material on opposing sides of the bend line. A method of preparing and using the hinged three-dimensional structure is also disclosed.

1 . A method of preparing a substantially two-dimensional sheet material for bending along a bend line to form a three-dimensional structure having a hinge along the bend line, the method comprising:
 obtaining a sheet material that is substantially two-dimensional in a region in which a bend is to be made; and   forming a plurality of displacements in a thickness direction of the sheet material along opposing sides of the bend line, each displacement having a sheared edge extending between end portions thereof and substantially parallel to the bend line, wherein adjacent sheared edges overlap one another with respect to the bend line to form a hinge structure therebetween extending along the bend line, the hinge structure having hinge ends that conform in shape with the end portions;   wherein the hinge structure is dimensioned and configured for multiple bend and unbend cycles thereby providing a monolithic hinge connecting opposing panels of the sheet material on opposing sides of the bend line.   
     
     
         2 . The method of  claim 1 , wherein the obtaining step is accomplished by obtaining a mild steel sheet material. 
     
     
         3 . The method of  claim 1 , wherein the forming step is accomplished by forming the displacement such that the sheared edge is a distance from the bend line that is at least 75% the thickness (“T”) of the sheet material. 
     
     
         4 . The method of  claim 3 , wherein the forming step is accomplished by forming the displacement sheared edges with the substantially linear portion extending between curved portions, and such that adjacent sheared linear portions and curved portions overlap one another for a distance that is at least approximately 6T. 
     
     
         5 . The method of  claim 1 , wherein the forming step is accomplished by forming displacement faces opposing the displacement sheared edges, the method further comprising the step of bending one of said opposing panels relative the other opposing panel about the bend line to produce edge-to-face engagement between at least a portion of the sheared edges and a portion of the respective displacement faces. 
     
     
         6 . The method of  claim 1 , further comprising the step of bending one of said opposing panels about the bend line relative to the other opposing panel. 
     
     
         7 . The method of  claim 1 , further comprising the step of bending one of said opposing panels about the bend line relative to the other opposing panel. 
     
     
         8 . The method of  claim 7 , further comprising the step of bending and unbending said one opposing panel about the bend line relative to the other opposing panel at least 10 times. 
     
     
         9 . The method of  claim 1 , further comprising the step of assembling the sheet material into a three-dimensional structure wherein one of said opposing panels provides a hinged panel for the three-dimensional structure that can be opened and closed. 
     
     
         10 . A substantially two-dimensional sheet material configured for bending along a bend line to form a three-dimensional structure having a hinge along the bend line, the sheet material comprising:
 a sheet material substantially two-dimensional in a region in which a bend is to be made; and   a plurality of displacements in a thickness direction of the sheet material along opposing sides of the bend line, each displacement having a sheared edge extending between end portions thereof and substantially parallel to the bend line;   wherein adjacent sheared edges overlap one another with respect to the bend line to form a hinge structure therebetween extending along the bend line, the hinge structure having hinge ends that conform in shape with the end portions; and   wherein the hinge structure is dimensioned and configured for multiple bend and unbend cycles thereby providing a monolithic hinge connecting opposing panels of the sheet material on opposing sides of the bend line.   
     
     
         11 . The sheet material of  claim 10 , wherein the sheet material is mild steel. 
     
     
         12 . The sheet material of  claim 10 , wherein the sheared edge is a distance from the bend line that is at least 75% the thickness (“T”) of the sheet material. 
     
     
         13 . The sheet material of  claim 10 , wherein the displacement sheared edges comprise a substantially linear portion, and wherein adjacent sheared linear portions overlap one another for a distance that is at least approximately 3T. 
     
     
         14 . The sheet material of  claim 13 , wherein the substantially linear portion extends between curved portions, and wherein adjacent sheared linear and curved portions overlap one another for a distance that is at least approximately 5T. 
     
     
         15 . The sheet material of  claim 10 , further comprising displacement faces opposing the displacement sheared edges, the displacements configured to produce edge-to-face engagement between at least a portion of the sheared edges and a portion of the respective displacement faces while bending one of said opposing panels relative the other opposing panel about the bend line. 
     
     
         16 . The sheet material of  claim 10 , the hinge structure is configured to bend and unbend at least 10 times. 
     
     
         17 . The sheet material of  claim 10 , the hinge structure is configured to bend and unbend at least 50 times. 
     
     
         18 . A three-dimensional structure comprising the sheet material  claim 10 , wherein one of said opposing panels forms a hinged access cover for access to a portion of the three-dimensional structure. 
     
     
         19 . The three-dimensional structure of  claim 18 , wherein the structure is a box, and the hinged access cover is a lid providing access to an interior portion of the three dimensional structure. 
     
     
         20 . A substantially two-dimensional sheet material configured for bending along a bend line to form a three-dimensional structure having a hinge along the bend line, the sheet material comprising:
 a sheet material substantially two-dimensional in a region in which a bend is to be made; and   a plurality of tongues positioned along opposing sides of the bend line, each tongue having a face directed toward the bend line and extending substantially parallel to the bend line, the tongue extending between end portions diverging away from the bend line;   wherein adjacent faces overlap one another with respect to the bend line to form a hinge structure therebetween extending along the bend line, the hinge structure having hinge roots that conform in shape with the end portions; and   wherein the hinge structure is dimensioned and configured for multiple bend and unbend cycles thereby providing a monolithic hinge connecting opposing panels of the sheet material on opposing sides of the bend line.