Three-dimensional structure formed with precision fold technology and method of forming same

Abstract

A three-dimensional structure formed with precision fold technology includes a first sheet section having a first edge formed with a first joinder structure proximate the first edge, a second sheet section having a second edge formed with a second joinder structure proximate the second edge for interlocking engagement with said first joinder structure, and a plurality of folding structures formed in the sheet of material along a plurality of desired fold lines which divide the sheet of material into said first and second sheet sections, the folding structures being formed to produce sufficiently precise folding of the sheet of material along the fold lines to position the first and second edges together such that said first and second joinder structures interengage with one another and retain the sheet of material in a folded condition.

1 . A sheet of material formed for bending or folding into a three-dimensional structure, the sheet of material comprising:
 a first sheet section having a first edge formed with a first joinder structure proximate the first edge;   a second sheet section having a second edge formed with a second joinder structure proximate the second edge for interlocking engagement with said first joinder structure; and   a plurality of folding structures formed in the sheet of material along a plurality of desired fold lines which divide the sheet of material into said first and second sheet sections, the folding structures being formed to produce sufficiently precise folding of the sheet of material along the fold lines to position the first and second edges together such that said first and second joinder structures interengage with one another and retain the sheet of material in a folded condition.   
     
     
         2 . The sheet of material as defined in  claim 1  wherein,
 the first joinder structure is a joinder tab extending out of the plane of the first sheet section forming a slot extending toward the first edge, and the second joinder structure is a registration flange, a portion of which is dimensioned and configured to extend into the slot upon folding. 
 
     
     
         3 . The sheet of material as defined in  claim 2 , wherein the joinder tab has a J-shaped cross-section. 
     
     
         4 . The sheet of material as defined in  claim 2 , wherein the joinder tab is formed by stamping. 
     
     
         5 . The sheet of material as defined in  claim 4 , wherein the first sheet section has an aperture formed by stamping the joinder tab out of the plane of the first sheet. 
     
     
         6 . The sheet of material as defined in  claim 5 , wherein the portion of the registration flange received in said slot includes a locking protrusion extending out-of-plane and dimensioned and configured to extend into the aperture to prevent disengagement of the first and second joinder structures. 
     
     
         7 . The sheet of material as defined in  claim 6  wherein,
 the locking protrusion has a ramp-shaped profile to facilitate insertion of the portion of the registration flange into the slot. 
 
     
     
         8 . The sheet of material as defined in  claim 1  wherein,
 the folding structures are provided by one of slits, grooves and displacements formed in the sheet of material to define a plurality of folding straps having center lines extending obliquely across the fold lines. 
 
     
     
         9 . A sheet of material folded and secured to form a three-dimensional corner structure, the sheet of material comprising:
 a first sheet portion folded along a first fold line to produce a first corner, the first sheet portion including an inwardly projecting coupling shoulder displaced out-of-plane forming a receiving slot, the coupling shoulder spaced from the first fold line, the first sheet further including an aperture formed by the out-of-plane displacement of the coupling shoulder; and   a second sheet portion folded along a second fold line to produce a second corner member, the second sheet portion having a registration flange, a portion of which is received in the slot of the coupling shoulder, the registration flange portion having an outwardly projecting latch member spaced from the second fold line and extending into the aperture of the first sheet portion producing an interference fit between the coupling shoulder and the registration flange portion.   
     
     
         10 . The assembly as defined in  claim 9  wherein,
 the first fold line and the second fold line are each formed by a plurality of folding structures provided by one of slits, grooves and displacements defining a plurality of spaced apart folding straps having center lines extending obliquely across the fold lines to produce precise location of the coupling shoulder and latch member relative to the first fold line and precise location of the registration flange portion and the coupling shoulder slot.