Foldable physical structures

Abstract

Physical structures having kinematic compatibility are disclosed. One example of a physical structure includes walls that are connected together such that the physical structure is moveable between a flat-folded state and an expanded state. In the expanded state, the physical structure at least partially encloses a volume. One or more of the walls may include two or more panels. The structure may include locking mechanism(s) to stabilize the structure in the expanded state. The structure may include mechanical assistance component(s) that reduce the force that need be applied to move the structure from the flat-folded state to the expanded state. Physical structures that are moveable between a flat unfolded state and a folded state are also disclosed Such physical structures may include connected panels that are moveable between the flat unfolded state and the folded state. In the folded state, a physical structure may at least partially enclose a volume.

What is claimed is: 
     
         1 . A physical structure having kinematic compatibility, the structure comprising walls connected together such that the walls are moveable between a flat-folded state and an expanded state, wherein (i) each of at least two of the walls comprises two or more panels and (ii) the walls at least partially enclose a volume when in the expanded state. 
     
     
         2 . The structure of  claim 1 , comprising one or more actuators, wherein the walls are moveable between the folded state and the expanded state by the one or more actuators. 
     
     
         3 . The structure of  claim 2 , wherein the one or more actuators is a single actuator. 
     
     
         4 . The structure of  claim 2 , wherein the one or more actuators comprises two actuators disposed at different locations in the structure (e.g., corresponding to different hinge lines) (e.g., to apply force to different panels). 
     
     
         5 . The structure of  any one of the preceding claims , wherein the structure is moveable between the folded state and the expanded state by moving with a single degree of freedom (e.g., by applying an expansion force to only one panel of one of the walls at a time) (e.g., wherein the structure comprises a roof and moving with the single degree of freedom does not close the roof) (e.g., wherein the structure comprises a roof that is one of the walls and moving with the single degree of freedom closes the roof). 
     
     
         6 . The structure of  any one of the preceding claims , wherein the walls comprise a front wall and an opposing back wall, wherein the front wall of the walls comprises panels disposed and connected such that the panels fold and unfold away from the back wall when moving between the folded state and the expanded state (e.g., wherein the panels are disposed and connected to have a fold with a vertex having a degree of four or more). 
     
     
         7 . The structure of  claim 6 , wherein the back wall comprises only one panel. 
     
     
         8 . The structure of  any one of the preceding claims , wherein at least one of the walls comprises panels that are disposed and connected so that the wall folds with both one or more mountain folds and one or more valley folds. 
     
     
         9 . The structure of  any one of the preceding claims , wherein the at least two walls comprises a first wall and an opposing and identically foldable second wall (e.g., side walls). 
     
     
         10 . The structure of  claim 9 , wherein the first wall has a top edge and comprises a hinge line along which the first wall folds that intersects the top edge at a non-corner location. 
     
     
         11 . The structure of  claim 10 , wherein the first wall has a bottom edge and a front edge adjacent to the bottom edge and the hinge line also intersects a corner of the bottom edge away from the front edge and the non-corner location is at least 0.2*H away from the front edge, where H is a height of the first wall. 
     
     
         12 . The structure of any one of  claims 9-11 , wherein the two or more panels of the first wall comprises a trapezoidal panel and a triangular panel. 
     
     
         13 . The structure of  claim 12 , wherein the trapezoidal panel has two parallel edges and a shorter one of the two parallel edges has a length of at least 0.2*H, where His a height of the first wall. 
     
     
         14 . The structure of any one of  claims 9-13 , wherein the first wall comprises a triangular panel that forms less than half of the first wall. 
     
     
         15 . The structure of any one of  claims 9-14 , wherein the at least two walls further comprises a third wall that is adjacent to the first wall and to the second wall and the third wall comprises three panels. 
     
     
         16 . The structure of  any one of the preceding claims , wherein the two or more panels are connected with an offset crease method, an offset panel technique, a hinge shift technique, or a combination thereof. 
     
     
         17 . The structure of  any one of the preceding claims , wherein the two or more panels comprises a panel having a non-uniform thickness (e.g., partial cutout) that corresponds to a different one of the two or more panels (e.g., such that the two or more panels are nested in the flat-folded state). 
     
     
         18 . The structure of  any one of the preceding claims , wherein the panels are non-deformable. 
     
     
         19 . The structure of  any one of the preceding claims , wherein at least one of the two or more panels (e.g., at least one panel of each of the at least two walls) comprises a tab extending along a hinge line and another panel (e.g., of the two or more panels) is connected to the at least one of the two or more panels at the tab. 
     
     
         20 . The structure of  any one of the preceding claims , comprising a roof (e.g., comprising one or more panels). 
     
     
         21 . The structure of  claim 20 , wherein the roof is one of the walls. 
     
     
         22 . The structure of  claim 20 or claim 21 , wherein the roof is a flat roof (e.g., an extended height roof), a gable roof, or a shed roof. 
     
     
         23 . The structure of  any one of the preceding claims , wherein the walls comprise a front wall and at least some of (e.g., each of) the walls except the front wall is an extended height wall. 
     
     
         24 . The structure of  any one of the preceding claims , wherein the walls comprise a back wall and at least some of (e.g., each of) the walls except the back wall comprises two or more panels. 
     
     
         25 . The structure of  any one of the preceding claims , comprising a floor. 
     
     
         26 . The structure of  claim 25 , wherein the floor comprises a single panel. 
     
     
         27 . The structure of  claim 25 or claim 26 , wherein the floor is one of the walls. 
     
     
         28 . The structure of  any one of the preceding claims , wherein the walls are connected together by hinges each of which connects adjacent ones of the walls. 
     
     
         29 . The structure of  any one of the preceding claims , wherein at least one (e.g., each) adjacent pair of the two or more panels is connected by one or more hinges. 
     
     
         30 . The structure of  claim 28 or claim 29 , comprising one or more molded hinges each formed at least partially in one of the walls. 
     
     
         31 . The structure of  any one of the preceding claims , further comprising locking mechanisms disposed to lock the two or more panels of each of the at least two panels in position in the expanded state. 
     
     
         32 . The structure of  any one of the preceding claims , further comprising one or more locking mechanisms disposed to lock the walls in the expanded state. 
     
     
         33 . The structure of  any one of the preceding claims , wherein the at least two walls comprises two adjacent walls that are not parallel in the expanded state. 
     
     
         34 . The structure of  any one of the preceding claims , wherein the panels do not deform between the flat-folded state and the expanded state. 
     
     
         35 . The structure of  any one of the preceding claims , wherein, for at least one pair of adjacent ones of the walls, the adjacent ones are not directly connected (e.g., a back wall of the walls is not directly connected to a floor) [e.g., wherein one wall of the pair of adjacent walls moves (e.g., horizontally and vertically) and rotates when the physical structure moves from the flat-folded state to the expanded state]. 
     
     
         36 . The structure of  any one of the preceding claims , wherein the walls are disposed and constructed to have two symmetric corner folds corresponding to one of the walls (e.g., the back wall). 
     
     
         37 . The structure of  any one of the preceding claims , wherein the walls are disposed and connected to have at least one water bomb fold. 
     
     
         38 . The structure of  any one of the preceding claims , wherein the walls comprise at least one window, at least one door, or at least one window and at least one door (e.g., wherein at least one of the walls comprises at least a portion of a window, at least a portion of a door, or at least a portion of a window and at least a portion of a door) (e.g., wherein at least one of the two or more panels for at least one of the at least two walls comprises at least a portion of a window and/or at least a portion of a door). 
     
     
         39 . The structure of  any one of the preceding claims , comprising one or more mechanical assistance components (e.g., one or more active components and/or one or more passive components) (e.g., torsion springs) (e.g., each disposed at a hinge line, e.g., between two of the walls or two of the two or more panels of one of the at least two walls). 
     
     
         40 . The structure of  any one of the preceding claims , wherein the walls comprise a rigid frame and soft shell. 
     
     
         41 . The structure of  any one of the preceding claims , wherein the walls comprise a hard shell. 
     
     
         42 . The structure of  any one of the preceding claims , wherein the walls comprise a sandwich composite. 
     
     
         43 . The structure of any one of  any one of the preceding claims , wherein the walls have been constructed using additive manufacturing. 
     
     
         44 . The structure of  any one of the preceding claims , wherein the structure is wider than the structure is tall. 
     
     
         45 . The structure of  any one of the preceding claims , wherein the volume is at least 10 m 3  (e.g., at least 15 m 3 , at least 20 m 3 , at least 30 m 3 , at least 40 m 3 , at least 50 m 3 , at least 60 m 3 , or at least 100 m 3 ). 
     
     
         46 . The structure of  any one of the preceding claims , wherein the structure is habitable. 
     
     
         47 . The structure of  any one of the preceding claims , wherein the structure is a shelter. 
     
     
         48 . The structure of  any one of the preceding claims , wherein the structure entirely encloses the volume [e.g., in combination with a floor surface (e.g., bare earth or a floor included in the physical structure)]. 
     
     
         49 . The structure of  any one of the preceding claims , wherein the walls comprise at least (e.g., and no more than) four walls. 
     
     
         50 . The structure of  any one of the preceding claims , wherein at least two (e.g., at least three) of the walls have a polygonal shape having at least four (e.g., at least 5) sides. 
     
     
         51 . The structure of  any one of the preceding claims , wherein the physical structure is a rectangular structure or a hexagonal structure. 
     
     
         52 . The structure of  any one of the preceding claims , wherein the physical structure is modular (e.g., has at least one open side to facilitate connection to another modular physical structure). 
     
     
         53 . The structure of  any one of the preceding claims , wherein each of the two or more panels has a thickness of at least 1 mm (e.g., at least 2 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 8 mm, at least 1 cm, at least 1.5 cm, or at least 2 cm) and no more than 50 cm (e.g., no more than 40 cm, no more than 30 cm, no more than 20 cm, no more than 15 cm, no more than 10 cm, no more than 8 cm, no more than 6 cm, no more than 5 cm, no more than 4 cm, no more than 2 cm, or no more than 1 cm). 
     
     
         54 . The structure of  any one of the preceding claims , wherein the physical structure comprises seals disposed along edges of the walls and of the two or more panels such that the physical structure is sealed in the expanded state. 
     
     
         55 . The structure of  any one of the preceding claims , wherein the physical structure has a lateral extent in the flat-folded state that is less than a total area of the walls (e.g., including any roof and/or floor) of the physical structure in the expanded state (e.g., the lateral extent is no more than 75%, no more than 50%, no more than 33%, no more than 25%, or no more than 20% of the total area). 
     
     
         56 . The structure of  any one of the preceding claims , wherein the physical structure has a lateral extent in the flat-folded state that is no more than an area of a largest wall of the physical structure in the expanded state. 
     
     
         57 . A method of unfolding a physical structure, the method comprising moving connected walls from a flat-folded state to an expanded state, wherein at least two of the walls comprise panels that are folded in the flat-folded state and unfolded in the expanded state and the walls at least partially enclose a volume in the expanded state. 
     
     
         58 . The method of  claim 57 , wherein moving the connected walls to the expanded state comprises moving with a single degree of freedom. 
     
     
         59 . The method of  claim 58 , wherein moving with the single degree of freedom comprises applying an expansion force to (e.g., pushing) only one of the panels at a time [e.g., at least partially with one or more mechanical assistance components (e.g., actuator(s))]. 
     
     
         60 . The method of any one of  claims 57-59 , wherein moving the walls into the expanded state comprises applying an expansion force to the walls in a first location along a first direction for a first period of time and then applying an expansion force to the walls in a second location along a second direction for a second period of time after the first period of time. 
     
     
         61 . The method of  claim 60 , wherein moving the walls into the expanded state comprises applying the expansion force in the first location along the first direction until a torque threshold is met or exceeded and then applying the expansion force in the second location along the second direction. 
     
     
         62 . The method of any one of  claims 57-61 , wherein moving the walls into the expanded state comprises applying an expansion force to a first panel of one of the walls for a first period of time and then applying an expansion force to a different second panel of one of the walls for a second period of time after the first period of time. 
     
     
         63 . The method of any one of  claims 60-62 , wherein an end of the first period of time and a beginning of the second period of time are determined based on a torque applied to the system. 
     
     
         64 . The method of  claim 62 or claim 63 , wherein moving the walls into the expanded state comprises applying the expansion force to the first panel until a torque threshold is met or exceeded and then applying the expansion force to the second panel. 
     
     
         65 . The method of any one of  claims 57-64 , wherein moving the walls to the expanded state comprises actuating one or more actuators. 
     
     
         66 . The method of  claim 65 , wherein the one or more actuators is a single actuator. 
     
     
         67 . The method of  claim 66 , wherein the one or more actuators is a plurality of actuators. 
     
     
         68 . The method of  claim 67 , wherein moving the connected walls comprises actuating only one of the plurality of actuators at a time. 
     
     
         69 . The method of  claim 68 , comprising changing which actuator of the plurality of actuators is actuating based on a torque applied to the structure. 
     
     
         70 . The method of  claim 68 or claim 69 , comprising changing which actuator of the plurality of actuators is actuating when a threshold torque is met or exceeded. 
     
     
         71 . The method of any one of  claims 57-70 , wherein the structure is comprised in (e.g., is) a habitable shelter when the structure is in the expanded state. 
     
     
         72 . The method of any one of  claims 57-71 , comprising folding the walls from the expanded state to the flat-folded state [e.g., by applying a folding force to the walls (e.g., with one or more mechanical assistance components (e.g., actuator(s)))]. 
     
     
         73 . The method of any one of  claims 57-72 , wherein the physical structure comprises one or more torsion springs and moving the connected walls from the flat-folded state to the expanded state comprises providing force from the one or more torsion springs. 
     
     
         74 . The method of any one of  claims 57-73 , wherein moving the connected walls from the flat-folded state to the expanded state comprises translating (e.g., horizontally and vertically) and rotating at least one of the walls (e.g., only one of the walls) (e.g., wherein each of the at least one of the walls comprises only a single panel) (e.g., wherein translating and rotating each of the at least one of the walls comprises unfolding along two symmetric corner folds for the wall). 
     
     
         75 . The method of any one of  claims 57-74 , wherein the structure is the structure of any one  claims 1-56 . 
     
     
         76 . A thick-walled physical structure, comprising connected panels that are movable between a flat unfolded state and a folded state, wherein the panels at least partially (e.g., entirely) enclose a volume in the folded state. 
     
     
         77 . The structure of  claim 76 , wherein at least some of the panels fold inward into the volume when the structure is moved from the flat unfolded state to the folded state (e.g., wherein the at least some of the panels are disposed at corners of one or more walls of the structure in the folded state). 
     
     
         78 . The structure of  claim 76 or claim 77 , wherein, for at least one (e.g., at least two) pairs of adjacent ones of the panels, the adjacent ones of the panels are connected together only at ends of abutted edges of the adjacent ones of the panels. 
     
     
         79 . The structure of  claim 76 or claim 77 , wherein, for each pair of adjacent ones of the panels, the adjacent ones of the panels are connected together along at least a central portion of abutted edges of the adjacent ones of the panels (e.g., entirely along abutted edges of the adjacent ones of the panels) [e.g., with one or more hinges (e.g., comprising fabric)]. 
     
     
         80 . The thick-walled structure of any one of  claims 76-79 , comprising one or more energy storage hinges that each connect adjacent ones of the panels. 
     
     
         81 . The structure of  claim 80 , wherein each of the one or more energy storage hinges comprises an elastomeric material (e.g., that is in an energetic state when the structure is in the folded state) (e.g., that is adhesively or mechanically fastened to the adjacent ones of the panels). 
     
     
         82 . The structure of claim  82 , wherein the elastomeric material is a barrier material (e.g., to water). 
     
     
         83 . The structure of any one of  claims 76-82 , wherein the thick-walled structure is a single degree-of-freedom system. 
     
     
         84 . The structure of any one of  claims 76-83 , wherein the panels comprise roof panels (e.g., of a pyramid hip roof). 
     
     
         85 . The structure of  claim 84 , wherein at least two of the roof panels comprise a hole for a pin (e.g., a quick-release pin). 
     
     
         86 . The structure of any one of  claims 76-85 , comprising a pin (e.g., a quick-release pin) that is insertable (e.g., inserted) into ones of the panels to maintain the panels in the folded state. 
     
     
         87 . The structure of any one of  claims 76-86 , wherein each of at least two of the panels comprises a respective hole disposed in the panel shaped to accommodate a pin (e.g., a quick-release pin). 
     
     
         88 . The structure of any one of  claims 76-87 , wherein the structure has kinematic compatibility. 
     
     
         89 . The structure of any one of  claims 76-88 , wherein at least some of the panels comprise a chamfered edge (e.g., wherein the at least some of the panels that fold inward into the volume comprise a chamfered edge). 
     
     
         90 . The structure of any one of  claims 76-89 , wherein each of the panels has a thickness of at least 1 mm (e.g., at least 2 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 8 mm, at least 1 cm, at least 1.5 cm, or at least 2 cm) and no more than 50 cm (e.g., no more than 40 cm, no more than 30 cm, no more than 20 cm, no more than 15 cm, no more than 10 cm, no more than 8 cm, no more than 6 cm, no more than 5 cm, no more than 4 cm, no more than 2 cm, or no more than 1 cm). 
     
     
         91 . The structure of any one of  claims 76-90 , wherein the physical structure has a blooming construction (e.g., an angled blooming construction or a blooming 90 degree construction). 
     
     
         92 . The structure of any one of  claims 76-91 , wherein the physical structure has a chamfered construction. 
     
     
         93 . The structure of any one of  claims 76-92 , wherein the panels comprise a panel that rotates about an axis when moving between the unfolded state and the folded state and the panel comprises a hole for a pin and the hole is not aligned with the axis. 
     
     
         94 . The structure of any one of  claims 76-93 , wherein each of at least two of the panels comprises a hole disposed therethrough, wherein the at least two of the panels rotate about different axes when moving between the unfolded state and the folded state and the holes of the at least two of the panels are disposed such that a common pin can be inserted through the holes. 
     
     
         95 . The structure of any one of  claims 76-94 , wherein each of two or more of the panels comprise a hole sized and shaped to have a pin inserted therethrough. 
     
     
         96 . The structure of  claim 95 , wherein the hole is disposed at an angle relative to a thickness dimension of the panel. 
     
     
         97 . The structure of  claim 95 or claim 96 , wherein the hole is disposed such that when a pin is inserted therethrough the pin and the panel are not orthogonal. 
     
     
         98 . A method of erecting the physical structure of any one of  claims 1-75 , comprising using a winch to move the structure between the folded state and the expanded state. 
     
     
         99 . A method of erecting the physical structure of any one of  claims 76-97 , comprising using a winch to move the structure between the unfolded state and the folded state.