Abstract: A method for precision bending of a sheet of material (41, 241, 341, 441) along a bend line (45, 245, 345, 445) and the resulting sheet are disclosed. A method includes a step of forming longitudinally extending slits (43, 243, 343, 443) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441) along the bend line (45, 245, 345, 445) with edges (257, 457) engaged and supported on faces (255, 455) of the sheet material on opposite sides of the slits. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line (45, 245, 345, 445). Several slit embodiments (43, 243, 343, 443) suitable for producing edge-to-face engagement support and precise bending are disclosed, as is the use of the slit sheets to enhance various fabrication techniques.

Abstract: A two-dimensional sheet material is provided that is suitable for bending along a bend line to form a three-dimensional object. The sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one side of the bend line. A portion of the displacements shear adjacent the bend line and define an edge and an opposed face. The edge and opposed face configured to produce edge-to-face engagement of the sheet material during bending. Alternatively, sheet material is provided with a plurality of displacements in a thickness direction of the sheet material on one or both sides of the bend line, and with a plurality of corresponding and cooperating protrusions to improve structural integrity and/or to improve electromagnetic and radio frequency shielding. The sheet material may also be provided with a self-latching structure. A method of preparing and using these sheet materials is also described.

Abstract: A sheet of material formed for bending along a bend line including a sheet of material (30) includes a plurality of dividing slits (37) and a plurality of strap slits (39) formed therethrough. The dividing slits extending substantially along a desired bend line (35) and divide the sheet of material into first and second planar regions (32, 33). The strap slits intersect the desired bend line and adjacent pairs of strap slits form a bending strap therebetween. The bending strap has a longitudinal strap axis intersecting the desired bend line. The sheet of material may be formed of composite materials. A method of forming and using the sheet of material is also disclosed.

Abstract: A card guide for mounting printed circuit boards, electronic pathway or component carrying cards, or the like, to an electronic equipment housing having a wall with a pair of openings formed to receive mounting feet provided on the card guide. The card guide body includes a card-receiving guideway on an inwardly facing side of the body and a card mounting structure on the outwardly facing side of the body. The card mounting structure preferably includes L-shaped posts or feet having longitudinally extending portions which enable the card guide to be inserted through an opening in a housing wall to a position in which the L-shaped feet interlock with the housing wall adjacent to the openings. Most preferably the card guide body is resiliently flexible and can be bowed to allow insertion into pairs of mounting openings and will spring back once inserted to secure the card guide to the housing wall.

Abstract: A apparatus for forming a three-dimensional (3D) object from a sheet material preferably includes a sheet material, a shaping die defining a cavity adapted to receive at least a portion of the sheet material, a portion of the cavity having a shape corresponding to a desired surface of the 3D object, and a forming member positioned relative to the sheet material opposite the cavity and having a rigid edge having a shape corresponding to a desired small-radii event of the 3D object. When force is applied to the sheet material and to the forming member, the sheet material is forced against the portion of the cavity to form the desired surface, and the rigid edge is forced against the sheet material to form the desired small-radii event. A method of using the apparatus for spline bending of sheet material is also disclosed.

Abstract: A method of preparing a sheet of material for bending along a bend line includes the step of forming at least one displacement in the thickness direction of the sheet of material, the displacement including a flat zone substantially parallel to the sheet of material with a portion of the periphery of the flat zone extending along and adjacent to the bend line, and including an angled transition zone interconnecting the flat zone with a remainder of the sheet of material. The forming step is preferably accomplished using one of a stamping process, a punching process, a roll-forming process and an embossing process. A sheet of material suitable for bending using the process also is disclosed, as are the use of coatings, shin guards and displacing the area of the sheet between bending inducing slits.

Abstract: A sheet of material (21, 61, 81) formed for control bending along a bend line (23, 63) while maintaining a continuous web of material (26) across the bend line (23, 63). The sheet has at least one groove (22, 62, 82) formed therein with a central groove portion (24, 64, 84) extending in the direction of and positioned proximate to a desired bend line (23, 63). The groove is formed with a continuous web of material (26) at a bottom of the groove (22, 62, 82) and has a configuration defining at least one bending strap (27, 67) extending across the bending line (23, 63) at the end of the groove with a centerline (28) of the bending strap (27, 67) oriented obliquely across the bend line (23, 63) so that a balancing of the forces during bending of the web along the central portion (24, 64, 84) of the grooves and bending of the oblique bending strap occur and control the location of bending of the sheet.

Abstract: A method and apparatus for imparting compound folds on sheet materials includes a tool base for receiving and supporting the sheet material, a locator for positioning the sheet material relative to the work base, and a bend actuator mounted on the tool base. The bend actuator has an actuator member movable between an initial retracted position and a deployed extended position for applying a force against an unsecured portion of sheet material to effect bending of the sheet material about the first fold line as the actuator member moves from the initial retracted position and contacts the unsecured portion. The bend actuator also has a contact member positioned to abut against an outer portion of the unsecured portion as the actuator member continues to bend the sheet material about the first fold line, wherein the contact member effects bending of the sheet material along the second fold lines as the actuator member continues moving toward the deployed extended position.

Abstract: A process of forming bend-controlling structures, such as slits, grooves or displacements (22), in a sheet of material (21, 121, 221, 321, 421, 521, 621, 721). The bend-controlling structures (22) have central portions (26) extending substantially parallel to a desired bend line (23) on the sheet and end portions (27) which diverge away from the bend line (23). In one embodiment the process includes the step of forming the bending straps (24) between pairs of slit end portions (27) at a desired spaced apart distances along the bend line (23) with the straps (24) having a desired configuration, and the step of forming central portions (26) which connect the end portions (27) to complete the slits (22) using a separate die set. A plurality of end portion dies (51/54) can be used to produce end portions (27) of various shapes and straps (24) of various widths, and a single set of central portion forming dies (71/74) are used to connect the end portions (27).

Abstract: A bending tool system is provided for forming a three-dimensional structure from a two-dimensional sheet material which includes a predetermined fold line. The system includes a tool base for receiving and supporting the sheet material in a work plane, a clamp for engaging against the sheet material to secure a portion of the sheet material relative to the tool base, a locator for positioning the sheet material relative to the tool base such that the clamp extends through the clamping aperture, and a bending arm located adjacent the clamp, the bending arm movable from an initial position located below the work plane to an upper position in order to apply an upward force against an unsecured portion of the sheet metal to effect bending of the sheet material about the fold line. A method of using the tool system for bending sheet materials is also described.

Abstract: A sheet material is provided for forming a precision folded structural and aesthetic component of a contoured three-dimension. The sheet material may include a forward-panel bend line separating a forward panel and a fold panel, the forward-panel bend line may be curved to impart contour on at least the fold panel upon bending of the sheet material about the forward-panel bend line, and a fold line extending along the fold panel, the fold line may be substantially straight to impart the contour of the fold panel to the upper panel upon bending of the sheet material about the fold line.

Abstract: A sheet of material (21, 61, 81) formed for control bending along a bend line (23, 63) while maintaining a continuous web of material (26) across the bend line (23, 63). The sheet has at least one groove (22, 62, 82) formed therein with a central groove portion (24, 64, 84) extending in the direction of and positioned proximate to a desired bend line (23, 63). The groove is formed with a continuous web of material (26) at a bottom of the groove (22, 62, 82) and has a configuration defining at least one bending strap (27, 67) extending across the bending line (23, 63) at the end of the groove with a centerline (28) of the bending strap (27, 67) oriented obliquely across the bend line (23, 63) so that a balancing of the forces during bending of the web along the central portion (24, 64, 84) of the grooves and bending of the oblique bending strap occur and control the location of bending of the sheet.

Abstract: A sheet of material, suitable for bending along a bend line to a predetermined angle, includes one planar segment on one side of the bend line, another planar segment on another side of the bend line, one displacement extending in the thickness direction of the sheet of material from the one planar segment, and another displacement extending in the thickness direction of the sheet of material from the another planar segment. The displacements are dimensioned and configured such that they engage one another during bending and limit the angular displacement of the one side relative to the another side. As such, the displacements self-key the resulting corner at the predetermined angle and provide structural integrity to the corner.

Abstract: A process of forming bend-controlling structures, such as slits, grooves or displacements (22), in a sheet of material (21, 121, 221, 321, 421, 521, 621, 721). The bend-controlling structures (22) have central portions (26) extending substantially parallel to a desired bend line (23) on the sheet and end portions (27) which diverge away from the bend line (23). In one embodiment the process includes the step of forming the bending straps (24) between pairs of slit end portions (27) at a desired spaced apart distances along the bend line (23) with the straps (24) having a desired configuration, and the step of forming central portions (26) which connect the end portions (27) to complete the slits (22) using a separate die set. A plurality of end portion dies (51/54) can be used to produce end portions (27) of various shapes and straps (24) of various widths, and a single set of central portion forming dies (71/74) are used to connect the end portions (27).