The present invention relates to panels for use in building lightweight structures.
A panel made of a planar and simpler material is ideal for building a lightweight structure such as a geometric puzzle, model, and ornament. The panel is light, compact, easily manufactured, and convenient for assembly and disassembly without requirement of tools or other elements. Thinner panels reduce the weight of the structure and are suitable for creating different shapes with flat or curved surfaces by curving or bending. However, the shape and usage of the assembled structure have been largely limited due to their joints. The joints are relatively fragile and the structures easily come apart when dropped. Curvature generates significant strains and makes the structure even more unstable or unable to form. Practically, closed geometric structures are useful for many applications, but they are mostly polyhedra with flat surfaces and also vulnerable to impacts.
According to one aspect of the present invention, a panel for use in building a geometric structure is provided. The panel is made of a substantially planar and flexible material, namely, a film or a sheet having a thickness of from 0.10 to 0.75 mm and a weight per area of from 0.01 to 0.15 g/cm2 and capable of being curved and bent with human fingers. The panel includes: a body having a geometric shape circumscribed by a plurality of edges, each of the edges being either a line segment or an arc; and at least one joint formation placed along some of or all of the edge. The joint formation has of a plurality of tabs spaced apart by at least one gap. Each of the tabs is integral with the body, has its base along the edge, protrudes out from the body at the base, expands bilaterally and proximally from the base at an angle of more than 0 and less than 75 degree, and has no overlaps between the tabs. Each of the gaps is a part of the edge and also an interval between the adjacent bases. A length of the base and a length of the gap along an outline of the edge are substantially equal within ±10%. A position of the gap along the outline of the edge inversely corresponds to a position of one of the bases along the outline of the edge when inverted relative to a midpoint of the edge. Therefore, the joint formations along the edges of varied curvatures are alignedly, hingedly, and detachably interlocked with each other by twisting the panels to individually hook the tabs at the gaps. The flat, curved, or bent panel is used to build the structure.
According to another aspect of the present invention, a system for use in building a two- or three-dimensional geometric structure is provided. The system includes at least one panel, made of a substantially planar and flexible material, namely, a film or a sheet capable of being curved and bent with human fingers. The panel include: a body having a geometric shape circumscribed by a plurality of edges, each of the edges being either a line segment or an arc; and at least one joint formation placed along some of or all of the edges. The joint formation has a plurality of tabs spaced apart by at least one gap. Each of the tabs is integral with the body, has a base along the edge, protrudes out from the body at the base, expands bilaterally and proximally from the base at an angle of more than 0 and less than 75 degree, and has no overlaps between the tabs. Each of the gaps is a part of the edge and also an interval between the adjacent bases. A length of the base and a length of the gap along an outline of the edge are substantially equal within ±10%. A position of the gap along the outline of the edge inversely corresponds to a position of one of the bases along the outline of the edge when inverted relative to a midpoint of the edge. Therefore, the joint formations along the edges of varied curvatures are alignedly, hingedly, and detachably interlocked with each other by twisting the panels with the fingers to individually hook the tabs at the gaps. The flat, curved, or bent panel is used to build the structure.
The panels of this invention allow one to build a variety of lightweight geometric structures. The structure is assembled without requirement of tools or connecting elements. The panel is made of a substantially planar and flexible material, which can be curved or bent with human fingers to form flat or curved surfaces of the structure. The panels are joined by twisting with the fingers. The joint formations along straight or curved edges mediate panel connection in alignment. A resulting hinge enables angle adjustments around the straight or curved edge as a rotation axis. Each tab is manipulated individually, serving as a fundamental unit of connection. Therefore, the edge is joined gradually with a light force of fingers, enabling to make a difficult connection that requires a substantial force. This system increases the relative strength of panel connection, improves tolerance against strains of curved surfaces or impacts of falling, and expands buildable shapes of geometric structures with well-defined faces, edges, and vertices. Connected panels are readily separated by twisting with the fingers, and will be reused.
Panel connection is made by twisting, not by inserting the panels. As illustrated in
As illustrated in
As illustrated in
As illustrated in
It is easy to separate the panels with the fingers, by twisting the panels in the opposite direction. The interlocked tabs will be sequentially disjoined from one end to the other without being torn apart. The separated panels are reusable.
The tab expands bilaterally and proximally from its base so as to hook each other via press-contacts at their bases. And, the tabs do not overlap each other so as to ease manufacturing. Therefore, the tab is not limited to a round shape. The gap is a part of the edge and an interval between the adjacent bases. Since the edge serves as a rotation axis to adjust panel angles, the edge so as the gap must be straight or smoothly curved, without a sudden change in the edge curvature. A length of the base (A) and a length of the gap (B) must be measured along the outline of the edge.
The length of the base (A) along the outline of the edge is a length between two adjacent base points D along the outline of the edge. The length of the gap (B) along the outline of the edge is a length between two adjacent base points D along the outline of the edge. The length of the base (A) and the length of the gap (B) along the outline of the edge are substantially equal within ±10%, so as to tightly fit the base at the gap. This is required for making edge-to-edge connections without forming a noticeable space, even if two edges are different in shapes (see also
For the straight edge, θ and condition 1 are as follows (Math 1, 2, and 3). If r is 3 to 30 mm, A will be 3 to 57.9 mm from condition 1. If W is 50 mm, A will be 3 to 12.5 mm with condition 2. Find a preferable A by considering the size and usage of the structure, as it affects the number of the tabs per edge. Note that placing more tabs per edge improves tolerance against strains or impacts (e.g. four tabs per edge).
θ=(180°/π)arcsin(A/2r) [Math 1]
30°<θ<75° [Math 2]
r<A<1.932r [Math 3]
For the edge of convex arc, θ and condition 1 are as follows (Math 4, 5, and 6).
θ=(180°/π)arccos[(Z2−r2−R2)/2rR] [Math 4]
(180°/π)arccos[½ sin(A/2R)−R/r]<θ<75° [Math 5]
R arcsin[r/(r+R)]<A<2R arctan(r/R) [Math 6]
For the edge of concave arc, θ and condition 1 are as follows (Math 7, 8, and 9).
θ=(180°/π)arccos[(r2+R2−Z2)/2rR] [Math 7]
(180°/π)arccos[R/r−½ sin(A/2R)]<θ<75° [Math 8]
R arcsin[r/√{square root over ((r2+R2))}]<A<2R arcsin(r/R) [Math 9]
The position of the gap along the outline of the edge inversely corresponds to the position of one of the bases along the outline of the edge when inverted relative to a midpoint of the edge. By this, two edges of the same length should join perfectly in alignment regardless of straight or smoothly curved edges. This also allows a partial or full arrangements of tabs along the edge. Furthermore, symmetric and uniform arrangements of joint formations enhance versatility in connections.
The size and shape of the tabs are designed freely, as long as the tabs have a constant base length, bilateral and proximal expansion from the base, and no overlaps with each other. To ease handling and to minimize steric hindrance, horizontal and vertical sizes of the tab are preferably more than 5 mm and less than one-third of the edge length. The shape of the tab may be bilaterally symmetric and smooth-edged (e.g. circular and elliptical shapes). Face-to-face connections, being less affected by steric hindrance, give more freedom in the size and shape of the tabs (see also
The tabs facilitate handling with the fingers and also serve for decoration. In case of steric hindrance, the tabs may be bent along the edge, positioned inside or outside of the structure, or cut off by removing the upper portion while leaving the bottom portion for hook (keep the length about 5 to 10 times of the panel thickness from the edge). Placing the tab at the edge terminal is optional, as it is prone to steric hindrance (see
The panels are either unit- or net-types. The unit-type panel has a basic geometrical shape, and a plurality of such panels are used to build the structure. The net-type panel has a net-like shape, which is curved or bent to build the structure. The unit-type panels are capable of creating a variety of shapes, while the net-type panels facilitate to form predetermined shapes.
The body is a closed two-dimensional geometrical shape. The body of unit-type panels may be a polygon from a triangle to a dodecagon, in which each of the edges is either a line segment or an arc. A combination of such geometrical shapes may serve as the body of net-type panels. The unit-type panels with higher symmetry are more versatile. Mirror-symmetric shapes allow overlaid connections (see
The panel may have crease lines to facilitate bending. The crease lines are one-dimensional shape consisting of line segments or an arcs.
The panel may have apertures or slits. Apertures and slits are useful in approximating non-developable surface, fastening, hanging, or decorating the structures.
Curved surfaces formed are mostly developable surfaces such as cylinders, cones, and tangent developables. Non-developable surfaces are only roughly approximated (see
The panel is made of a substantially planar and flexible material. It should be hard enough to hold the assembled structure, as well as soft enough to allow curving or bending with the fingers. Avoid using brittle materials. Papers may be used. For repeated use, plastics are preferable. Plastics may be processed (e.g. compounding, physical finishing, metalizing, printing, and coating), or combined with other materials (e.g. paper, wood slice, thin fabric or leather, and metal foil) by means of lamination or adhesive bonding. Synthetic papers and functional films (e.g. color films, fluorescence films, phosphorescence films, vapor-deposited films, mirror films, dichroic films, polarizing films, holographic films, lenticular films, and liquid crystal films) significantly change the texture and appearance of the structure.
The panel is preferably 0.10 to 0.75 mm in thickness, when common plastics are used. Thicker panels are harder to bend or curve with the fingers, while excessively thinner panels yield frail structures. Some plastics (e.g. polyethylene) are very flexible, but, as they thicken, soon it becomes hard to manipulate with the fingers. In one experiment, an icosahedron made of polyethylene terephthalate films (0.10 mm in thickness, 20 regular triangular panels of 3 cm in edge length) was 1.3 g in weight (60 cm3 in volume, 6 cm in diameter), standing still, squashable with a finger, but tolerant to ten trials of 1-m free fall to a wooden floor, and withstood a suspension when loaded with 80 g of glass beads. An icosahedron made of polypropylene sheets (0.75 mm in thickness, 20 regular triangular panels of 40 cm in edge length) was 1,180 g in weight (140,000 cm3 in volume, 76 cm in diameter), standing still, and tolerant to ten trials of 1-m free fall. The structures made of thinner panels retain sufficient stability relative to the weight.
To obtain lightweight structures, a weight per area of the panel is preferably 0.01 to 0.15 g/cm2. Although specific gravities of plastics are generally 0.9 to 1.7 g/cm3, lamination with a metal foil, for example, adds weight. Lighter panels are compact, portable, and also economical. For manufacturing, the body and joint formation of the panel may be integrally processed. Depending on applications, employ suitable methods including die-cutting, punching, laser-processing, and injection molding.
The panel serves different applications. The panels are assembled into different shapes, which may be used as a construction toy, an educational material of geometry, a model for designing or art, and a decorative ornament. The structure is lightweight and stable, which may be used as a container, a package, and a hanging ornament. It may be also used as a lampshade for a LED lighting apparatus. The panels are connected in layers and allow insertion of a planar material (e.g. a flattened flower), which may be used as an accessory, bookmark, and coaster.
The panels may be provided in the form of a kit for the convenience of users. The kit includes a set of panels in combinations. For example, a kit for regular polyhedra may include the panels of regular polygons. The kit may also include other elements or apparatuses depending on applications.
According to one aspect of the invention, a joint system is provided. The system comprises at least one panel made of a substantially planar and flexible material capable of being curved or bent with human fingers. The system allows one to build two- or three-dimensional lightweight structures having flat or curved surfaces. The joint formations on straight or curved edges enable edge-to-edge connections in alignment with sufficient stability. The tabs are individually manipulated by applying a light force with the fingers. The panels are readily separated by twisting and may be reused.
The following embodiments of the present invention include but are not limited to the described material, configuration, method, and application. The panels were primarily made of a polyethylene terephthalate film at about 0.2 mm in thickness. The panel shape, including the body and joint formation, was designed by a computer. The material was processed with a laser cutting device. The tab used were mostly circular at 3.5 mm in radius, and the lengths of the base and gap were 5 mm along the outline of straight or curved edges. For regular polygons, the edge length was 50 mm and had 4 or 5 tabs per edge (with or without the terminal tab). The arc curvature was mostly 50 mm in radius. Under these conditions, an included angle at the base and a percentage of the tab overlaps were 45.6° and 19.3% for the straight edge, 48.4° and 16.2% for the convex arc edge, and 42.7° and 22.9% for the concave arc edge, respectively. The weight per area was 0.023 g/cm2, which was about one-sixth of commercially available panels with similar sizes. An icosahedron assembled from 20 regular triangular panels having 5 cm in edge length was 7 g in weight (9.5 cm in circumspheric diameter, 273 cm3 in volume). The structure remained intact after 10 trials of 1-m free fall to a wooden floor, and also withstood a load of 420 g glass beads when suspended. Similarly, a truncated dodecahedron assembled from 20 regular triangular panels and 12 regular decagonal panels having 5 cm in edge length was 63 g in weight (30 cm in circumspheric diameter, 10,630 cm3 in volume). The structure did not come part even after 10 trials of 1-m free fall, although an easily fixable dent was formed at the vertex twice.
The provided embodiments include examples of 1) structures assembled from the panels having straight or curved edges, 2) structures assembled from the panels having same or different edge lengths and angles, 3) structures assembled from the panels having joint formations along some of or all of the edges, 4) structures of convex or concave polyhedra, 5) structures having flat or curved faces, 6) structures built with the unit-type or net-type panels, 7) structures assembled from the panels by bending or curving, and 8) two- or three-dimensional structures.
Convex polyhedra were assembled from regular polygonal panels.
The unit-type panels having different interior angles or edge lengths were used to construct convex or concave polyhedral structures.
The unit-type panels having concave or convex arcs were used to construct structures having curved faces. The edges of varied curvatures are joined in alignment.
Rectilinear or curvilinear bending of the panels creates flat or curved faces of the structure. Bending across the edge is possible.
The net-type panels are useful to build structures in predetermined shapes. This is an example of building the curved structures.
The unit-type panels were used to build two-dimensional structure. The panel enables both horizontal and layered connections to create a variety of geometric patterns. As an example of horizontal connection,
Number | Date | Country | Kind |
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JP2017-130736 | Jul 2017 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2017/047122 | 12/27/2017 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2019/008796 | 10/1/2019 | WO | A |
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20200215425 A1 | Jul 2020 | US |