System for low-force roll folding and methods thereof

Abstract

A system for low-force roll folding effects bending of a two-dimensional sheet material having one or more predetermined fold lines into three-dimensional article. The system may include a sheet material with bend-facilitating structure extending along a length one or more of the predetermined fold lines, a stand of rollers configured to effect bending of the sheet metal along the bend-facilitating structure, and a driver to move the stand of folding rollers relative to the sheet material along the length of one or more of the predetermined fold lines to effect bending of the sheet material along the bend-facilitating structure. A method for low-force roll folding is also disclosed.

1 . A method for low-force roll folding of a two-dimensional sheet material having one or more predetermined fold lines into a three-dimensional article, said method comprising:
 providing a sheet material with bend-facilitating structure extending along a length of one or more of said predetermined fold lines;   providing a stand of folding rollers configured to effect bending of said sheet metal along said bend-facilitating structure; and   moving said stand of folding rollers relative to the sheet material along said length of one or more of said predetermined fold lines to effect bending of the sheet material along said bend-facilitating structure.   
     
     
         2 . A method for low-force roll folding according to  claim 1 , said method further comprising:
 driving the sheet material through said stand of folding rollers.   
     
     
         3 . A method for low-force roll folding according to  claim 1 , said method further comprising:
 driving the sheet material through a plurality of stands of folding rollers in order to effect a series of incremental cross-sectional profiles upon the sheet material.   
     
     
         4 . A method for low-force roll folding according to  claim 1 , said method further comprising:
 providing said sheet material with bend-facilitating structure along a length of diverging predetermined fold lines.   
     
     
         5 . A method for low-force roll folding according to  claim 1 , said method further comprising:
 providing said sheet material with bend-facilitating structure along a non-linear length of predetermined fold lines.   
     
     
         6 . A method for low-force roll folding according to  claim 1 , wherein said folding rollers are substantially cylindrical and roll along the sheet material adjacent to but removed from said fold lines. 
     
     
         7 . A method for low-force roll folding according to  claim 1 , further comprising:
 adjusting the rotational axes of said folding rollers relative to one another in order to accommodate spring back along said predetermined fold lines.   
     
     
         8 . A method for low-force roll folding according to  claim 1 , further comprising:
 manually rolling said stand of folding rollers along said length of said predetermined fold lines.   
     
     
         9 . A system for low-force roll folding of a two-dimensional sheet material having one or more predetermined fold lines into three-dimensional article, said system comprising:
 a sheet material with bend-facilitating structure extending along a length one or more of said predetermined fold lines;   a stand of rollers configured to effect bending of said sheet metal along said bend-facilitating structure; and   a driver to move said stand of folding rollers relative to the sheet material along said length of one or more of said predetermined fold lines to effect bending of the sheet material along said bend-facilitating structure.   
     
     
         10 . A system for low-force roll folding according to  claim 9 , further comprising:
 a plurality of stands of folding rollers, each stand configured to effect and incremental cross-sectional profile upon the sheet material.   
     
     
         11 . A system for low-force roll folding according to  claim 9 , wherein said sheet material includes bend-facilitating structure along a link of diverging predetermined fold lines. 
     
     
         12 . A system for low-force roll folding according to  claim 9 , wherein said sheet material includes bend-facilitating structure along a nonlinear length predetermined fold lines. 
     
     
         13 . A system for low-force roll folding according to  claim 9 , wherein said folding rollers are substantially cylindrical and roll line the sheet material adjacent to but removed from said fold lines.