Expandable Panel
A lightweight, compressible panel structure can include a collapsible portion that includes outer facing sections and inner core sections connected by hinge points and/or hinge assemblies. One or more longitudinal support structures can be included to hold the expandable panel structure in its expanded configuration. Methods and apparatus are described.
The current application claims priority under 35 U.S.C. §119(e) to U.S. Provisional patent application Ser. No. 62/107,955 filed on Jan. 26, 2015 and entitled “Expandable Panel” and U.S. Provisional patent application Ser. No. 62/187,193 filed on Jun. 30, 2015 and entitled “Expandable Panel,” which are both incorporated by reference herein in their entirety.
TECHNICAL FIELDThe subject matter described herein relates to an expandable panel structure that includes a collapsible portion and, in some implementations, can further include one or more longitudinal support structures.
BACKGROUNDThere may be instances where robust structures, such as for example shelters, temporary bridges, support platforms, or the like, need to be constructed quickly and inexpensively.
SUMMARYAspects of the current subject matter can include a compressible panel that has a collapsible portion and, in some implementations, can further include one or more longitudinal support structures.
In a first aspect, an apparatus includes a collapsible panel structure configured to form an expanded configuration and a collapsed configuration. The collapsible panel structure includes outer facing sections forming a first side and a second side of the collapsible panel structure, and inner core sections arranged in a zig-zag manner between the first side and the second side with vertex hinge points pivotally coupling adjoining inner core sections. The first and second sides include facing pair hinge points that pivotally couple adjoining outer facing sections. The inner core sections and the outer facing sections form a series of adjoining triangular prisms when the collapsible panel structure is in the expanded configuration, and the inner core sections and outer facing sections form a series of adjoining quadrilateral prisms when the collapsible panel structure is transitioning into the collapsed configuration.
In a second, interrelated aspect, an apparatus includes a collapsible panel structure configured to form an expanded configuration and a collapsed configuration. The collapsible panel structure includes outer facing sections forming a first side and a second side of the collapsible panel structure, inner core sections arranged in a zig-zag manner between the first side and the second side with inner core hinge points that pivotally couple adjoining inner core sections, extensions that extend between each coupling of an inner core section and an inner core hinge point thereby offsetting the inner core hinge point from a longitudinal length of the inner core section, and supplemental hinge points that pivotally couple adjoining outer facing sections and inner core sections. The first and second sides include facing pair hinge points that pivotally couple adjoining outer facing sections. The inner core sections, the extensions, and the outer facing sections form a series of adjoining quadrilateral prisms when the collapsible panel structure is in the expanded configuration, and wherein the inner core sections, the extensions, and the outer facing sections form a series of adjoining six-sided prisms when the collapsible panel structure is transitioning into the collapsed configuration.
In a third interrelated aspect, a method includes expanding a collapsible portion of a collapsible panel structure along an axis perpendicular to faces of a plurality of inner core sections of the collapsible panel structure; and completing the expanding of the collapsible portion upon planar alignment of two outer facing sections of the collapsible panel structure joined at a facing pair hinge point that is disposed opposite a vertex hinge point joining two of the inner core sections. The inner core sections are arranged in a zig-zag manner between a first side of outer facing sections and a second side of outer facing sections with vertex hinge points pivotally coupling adjoining inner core sections. A method can optionally include joining a longitudinal support structure to the expanded collapsible portion, subsequently removing the longitudinal support structures, and re-collapsing the collapsible portion.
In a fourth interrelated aspect, a method includes expanding a collapsible portion of a collapsible panel structure along an axis perpendicular to faces of a plurality of inner core sections of the collapsible panel structure and completing the expanding of the collapsible portion upon planar alignment of two outer facing sections of the collapsible panel structure joined at a facing pair hinge point that is disposed opposite an inner core hinge point joining two of the inner core sections. The inner core sections are arranged in a zig-zag manner between a first side of outer facing sections and a second side of outer facing sections with inner core hinge points pivotally coupling adjoining inner core sections and are offset from longitudinal lengths of the adjoining inner core sections by extensions. Supplemental hinge points pivotally couple adjoining outer facing sections and inner core sections. A method can optionally include joining a longitudinal support structure to the expanded collapsible portion, subsequently removing the longitudinal support structures, and re-collapsing the collapsible portion.
In optional variations, one or more of the following features can be included or incorporated into the aforementioned aspects in any feasible combination. A support structure can be included to extend along a length of the collapsible panel structure in the expanded configuration. The support structure can include one or more of an open channel that is configured to cap a first end of the collapsible panel structure, a telescoping segment that allows the support structure to at least partially collapse, and a plurality of joinable segments. The support structure can extend through openings located along the inner core sections. The support structure can be curved.
In at least the first aspect, the vertex hinge points can optionally be located at an apex of each triangular prism of the series of adjoining triangular prisms when the collapsible portion is in the extended configuration. Two outer facing sections jointed at a facing pair hinge point can be aligned with an opposite vertex hinge point joining two inner core sections. When the collapsible panel structure is transitioning into the collapsed configuration, a facing pair hinge point of the facing pair hinge points is located at a top or a bottom of each quadrilateral prism of the series of adjoining quadrilateral prisms.
In at least the second aspect, two outer facing sections can optionally be in an alignment and jointed at a facing pair hinge point that is disposed opposite an inner core hinge point when the collapsible portion is in the extended configuration. When the collapsible panel structure is transitioning into the collapsed configuration, the facing pair hinge points and inner core hinge points can be alternately located at a top and a bottom of each hexagonal prism of the series of adjoining quadrilateral prisms.
The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings,
When practical, similar reference numbers denote similar structures, features, or elements.
DETAILED DESCRIPTIONThe descriptions herein include methods, approaches, techniques, articles, and systems relating to light-weight structural panels or other structures that can be compacted into a small volume when not in use. In some aspects, implementations of the current subject matter can include a compactable part and one or more support parts, which can also be referred to as longitudinal support parts. Implementations of the current subject matter can be useful in many applications, including but not limited to situations involving assembling structures in areas where it would be prohibitive or unwieldy to bring in conventional building materials, as well as where it may be time intensive to construct shelters using conventional materials. Convenience of assembly, disassembly, transportation, and storage can all be improved relative to existing approaches.
The above-noted aspects and features may be implemented in systems, apparatus, methods, and/or articles depending on the desired configuration. The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.
The longitudinal support structures 130 can in some implementations of the current subject matter have a fixed geometry (e.g. they need not be collapsible like the collapsible portion 110). In other implementations of the current subject matter, a longitudinal support structure 130 can include one or more telescoping segments or segments that are combinable in other manners such that the longitudinal support structure 130 can be at least partially collapsed for transportation and storage. In one example, a longitudinal support structure 130 can be formed of two or more segments that are joinable by any feasible mechanism (e.g. threaded connections, an insertable feature of a first segment that slides into a receiving feature of a second segment, etc.)
As seen in
The inner core sections 115 can be shaped as rectangles as in the example shown in
The pattern of inner core sections 115 can bear loads applied perpendicular to the outer facing sections 120 as well as provide some torsional rigidity to a completed panel 100. The bracing provided by the inner core sections 115 to the outer facing section 120 when the collapsible portion 110 is extended, combined with the added rigidity of the support structures 130 allow the panel 100 to be load bearing. The collapsible portion 120 extends out along a direction, labeled as the X-axis in
In still other implementations of the current subject matter, the collapsible portion 110 can slide onto the longitudinal support structures 130. In other words, rather than the open channel configuration of a longitudinal support structure 130 discussed above, in which longitudinal support structures 130 are configured to attach over outer ends of the collapsible portion 110 once it is extended, one or more longitudinal support structures 130 can be formed as members that pass through holes or the like formed in the inner core sections 115.
While the explanation of the example implementation presented in reference to
As seen in
The parts of a panel as described herein may be constructed of one or more materials, which can be selected according to the intended use and/or desired properties of the panel. For example the outer facing sections of the collapsible portion may include a first material selected for compatibility with an external environment in which the panel will be placed as well as tensile strength, while the inner core sections may include a second material that is chosen for compressive strength with less concern for the external environment. The longitudinal support structures may be formed of even another material that is perhaps more rigid than the outer facing sections. Alternatively, any or all of the parts of a panel may be constructed of the same material.
In addition, the collapsible portion 110 of the panel 700 can also include supplemental hinge points 710 that connect an outer facing section 120 to an adjacent inner core section 115. As such, a first inner core section 115 can be linked to a second inner core section 115 via an inner core hinge point 740, as well as linked to an outer facing section 120 via the supplemental hinge point 710. Therefore, an inner core section 115 can have a total of four linking points, with two separate links disposed near each end of the inner core section: one to an outer facing section 120 via a supplemental hinge point 710 and a second to another inner core section 115 via an inner core hinge point 740.
As shown in
As shown in
The joints 915a-915d can be positioned relative to each other such that they allow the collapsible portion 110 to form a compact collapsed configuration. For example, in a collapsed configuration, at least the inner core sections 115 can be positioned approximately parallel to each other and spaced apart from each other by a distance defined by the space between two joints, such as the third joint 115c and fourth joint 115d of an adjacent vertex hinge link 910. The collapsible portion 110 of the panel 900 can also include facing pair hinge points 235 that link two outer facing sections, such as described above.
As shown in
In this implementation, the vertex hinge links 910 can allow for improved simplicity in manufacturing and assembly. As discussed above, a single vertex hinge link 910 can allow for the independent pivoting of four separate sections of the collapsible portion 110. As such, reductions in materials use as well manufacturing and assembly complexity can be realized. Additionally, this implementation can allow for greater structural loads and larger applications such as bridges, ramps, temporary piers and docks, and other uses.
Non-limiting examples of materials that may be used for the outer facing sections 120 include carbon fiber, polymers, fiber reinforced polymers, plastics, metal, ceramics, polymer reinforced ceramics, metal reinforced ceramics, composite materials, platelet material, chain link or chain mail material, mesh, woven fabric, wood, cardboard, paper, woven natural materials, honeycombed and other cored composites, and the like, including any combination thereof. Polymers may include natural polymers, such as rubber, cellulose, and silk, and synthetic polymers, such as polyethylene, polystyrene, phenol formaldehyde resin, nylon, polyvinyl chloride, polylactic acid, acrylonitrile butadiene styrene, polypropylene, polyacrylonitrile, and the like. Fiber reinforced polymers may include polymers reinforced with glass fibers, aramid fibers, graphite fibers, carbon fibers, polymer fibers, boron fibers, hemp fibers, natural material fibers, and the like. Metals may include aluminum, aluminum alloys, nickel, nickel alloys, steel, iron, titanium alloys, cobalt-chromium alloys, and any other metal or metal alloy sufficiently strong and/or resistant to the environment in which the panel will be used. A treatment may be applied to the outer facing sections, particularly the portions of the outer facing sections that will be exposed to the environment. Exemplary treatments include paint or a coating that may allow the panel to blend in with its surroundings, a reflective coating, and the like. In some implementations of the current subject matter, one or more outer facing sections can include elements or the like applied or attached to the outer facing sections, such as for example, one or more electronic components (e.g. solar cells, antenna elements, LED screen components, lighting sources, sensor arrays, touch screens, sound generating devices, transducers, or the like), printed material (e.g. signs, fabrics, wall coverings, or the like), etc. When used as a support for a display screen, an expandable panel consistent with implementations of the current subject matter can be rapidly deployable (e.g. to provide a display screen of a desired scale—which can vary from screens sized for personal computer displays or smaller to theater-sized or larger—merely by expanding panel structure as described herein from a fully collapsed configuration to a fully expanded configuration and affixing one or more longitudinal support structures 130).
Materials used for the inner core sections 115 may also include those used for the outer facing sections, described above. The inner core sections may require that the material selected also be strong in compression, so that the inner core sections resist collapse, buckling, or other failure when the panel is fully extended and a load is applied perpendicular to the outer facing sections. Similarly, the longitudinal support structures may be made from the same materials as those listed above for the outer facing sections. However, the longitudinal support structures may require additional characteristics, such as, for example, increased rigidity compared to the outer facing sections, increased friction against the ground, and/or malleability to enable the edges of the panel to conform to a roof or ceiling layer.
The outer facing sections, inner core sections, and longitudinal support structures may be made by conventional machining, hot-pressing, injection molding, extrusion, roller-pressing, conventional reinforced polymer composite lay-up, foaming, 3D printing, spraying, and the like. The components of a panel may be made as lattices or as solid bodies with strategically placed openings (e.g. holes or voids) to reduce weight while maintaining strength. For example, the components may include foamed materials, including foamed polymers, ceramics, and/or metals. Other possible materials can include honeycomb core composites, foam core composites, and optionally “built-up” structures for larger assemblies. For example, a welded truss assembly can be used for the inner core components for larger-scale panels (e.g. for use in temporary bridges, ramps, or the like). The outer facing sections, inner core sections, and longitudinal support structures may or may not have reinforcing shapes to provide additional stiffness as required by applications (e.g. ribbed or corrugated sections, or the like).
The vertices of the panel sections, optionally including but not limited to the vertex hinge points, the facing pair hinge points, the supplemental hinge points, the inner core hinge points, and the vertex hinge links, and the like, may be of any suitably strong and pliable material. For example, thin flexible hinges such as fabric or living hinges may be used at the hinge points or hinge links to connect inner core and/or outer facing sections depending on application loads. In other implementations of the current subject matter, the hinge points or hinge links can be joined by molded or machined polymer hinges, machined metal hinges, metal injection molded hinge components, combinations thereof, or by any suitable hinging material or design consistent with the other teachings herein. The vertex hinge points 240, the facing pair hinge points 235, the supplemental hinge points 710, the inner core hinge points 740, and/or the vertex hinge links 910 may be simple hinges or assemblies of one or more hinges, hinging mechanisms, jointed assemblies, or other combinations thereof which connect two or more adjacent inner core sections 115 and/or outer facing sections 120 such that the centers of the hinge points or assemblies retain their arrangement as described above.
In use, a panel may be transported to and/or from its use destination with the collapsible portion fully compressed and the longitudinal support structures separate from the collapsible portion. In this way, when transporting more than one panel at a time, multiple collapsible portions may be stacked upon or against each other, and the longitudinal support structures may be bundled together in an efficient manner, as well.
At its destination location, a collapsible portion of a panel may be fully extended then held rigid with the longitudinal support structures. The volume between the inner core sections may be left empty. Alternatively, some or all of the volume between the inner core sections may be filled with material found at the destination location or with material transported with the panel for that purpose. For example, if the destination location is a desert or beach, the volume between the inner core sections may be filled with sand before completing the panel with the addition of the longitudinal support structures. In another example, an insulating material, such as for example a foaming insulating material, may be inserted into the volume between the inner core sections. At a destination location, a panel may be constructed and used in conjunction with other panels and/or other construction materials to build a structure. Panels may be connected to each other and/or other construction materials using adhesives, tape, physical joining methods, or any combination thereof. In some example implementations, interlocking clips can be included as part of (or add-on components to) the longitudinal support structures. Alternatively or in addition, panels of straight and curving sections can be combined to form walls and roofs. Temporary or portable shelters, shade structures, walkways, bridges, or the like may be constructed which are light, easily portable, and reusable.
The subject matter described herein can be embodied in systems, apparatus, methods, and/or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claim.
Claims
1. An apparatus comprising:
- a collapsible panel structure configured to form an expanded configuration and a collapsed configuration, the collapsible panel structure comprising; outer facing sections forming a first side and a second side of the collapsible panel structure, the first and second sides comprising facing pair hinge points that pivotally couple adjoining outer facing sections; and inner core sections arranged in a zig-zag manner between the first side and the second side with vertex hinge points pivotally coupling adjoining inner core sections;
- wherein the inner core sections and the outer facing sections form a series of adjoining triangular prisms when the collapsible panel structure is in the expanded configuration, and wherein the inner core sections and outer facing sections form a series of adjoining quadrilateral prisms when the collapsible panel structure is transitioning into the collapsed configuration.
2. The apparatus of claim 1, further comprising a support structure that extends along a length of the collapsible panel structure in the expanded configuration.
3. The apparatus of claim 2, wherein the support structure comprises at least one of an open channel that is configured to cap a first end of the collapsible panel structure, a telescoping segment that allows the support structure to at least partially collapse, and a plurality of joinable segments.
4. The apparatus of claim 2, wherein the support structure extends through openings located along the inner core sections.
5. The apparatus of claim 2, wherein the support structure is curved.
6. The apparatus of claim 1, wherein in the extended configuration, the vertex hinge points are located at an apex of each triangular prism of the series of adjoining triangular prisms.
7. The apparatus of claim 6, wherein two outer facing sections jointed at a facing pair hinge point are aligned with an opposite vertex hinge point joining two inner core sections.
8. The apparatus of claim 1, wherein when the collapsible panel structure is transitioning into the collapsed configuration, a facing pair hinge point of the facing pair hinge points is located at a top or a bottom of each quadrilateral prism of the series of adjoining quadrilateral prisms.
9. An apparatus comprising:
- a collapsible panel structure configured to form an expanded configuration and a collapsed configuration, the collapsible panel structure comprising; outer facing sections forming a first side and a second side of the collapsible panel structure, the first and second sides comprising facing pair hinge points that pivotally couple adjoining outer facing sections; inner core sections arranged in a zig-zag manner between the first side and the second side with inner core hinge points that pivotally couple adjoining inner core sections, extensions that extend between each coupling of an inner core section and an inner core hinge point thereby offsetting the inner core hinge point from a longitudinal length of the inner core section; and supplemental hinge points that pivotally couple adjoining outer facing sections and inner core sections;
- wherein the inner core sections, the extensions, and the outer facing sections form a series of adjoining quadrilateral prisms when the collapsible panel structure is in the expanded configuration, and wherein the inner core sections, the extensions, and the outer facing sections form a series of adjoining six-sided prisms when the collapsible panel structure is transitioning into the collapsed configuration.
10. The apparatus of claim 9, further comprising a support structure that extends along a length of the collapsible panel structure in the expanded configuration.
11. The apparatus of claim 10, wherein the support structure comprises at least one of an open channel that is configured to cap a first end of the collapsible panel structure, a telescoping segment that allows the support structure to at least partially collapse, and a plurality of joinable segments.
12. The apparatus of claim 10, wherein the support structure extends through openings located along the inner core sections.
13. The apparatus of claim 10, wherein the support structure is curved.
14. The apparatus of claim 9, wherein in the extended configuration, two outer facing sections are in an alignment and jointed at a facing pair hinge point that is disposed opposite an inner core hinge point.
15. The apparatus of claim 9, wherein when the collapsible panel structure is transitioning into the collapsed configuration, the facing pair hinge points and inner core hinge points are alternately located at a top and a bottom of each hexagonal prism of the series of adjoining quadrilateral prisms.
16. A method comprising:
- expanding a collapsible portion of a collapsible panel structure along an axis perpendicular to faces of a plurality of inner core sections of the collapsible panel structure;
- completing the expanding of the collapsible portion upon planar alignment of two outer facing sections of the collapsible panel structure joined at a facing pair hinge point that is disposed opposite a vertex hinge point joining two of the inner core sections, wherein the inner core sections are arranged in a zig-zag manner between a first side of outer facing sections and a second side of outer facing sections with vertex hinge points pivotally coupling adjoining inner core sections.
17. The method of claim 16, further comprising joining a longitudinal support structure to the expanded collapsible portion.
18. The method of claim 17, further comprising removing the longitudinal support structures.
19. The method of claim 18, further comprising re-collapsing the collapsible portion.
20. A method comprising:
- expanding a collapsible portion of a collapsible panel structure along an axis perpendicular to faces of a plurality of inner core sections of the collapsible panel structure;
- completing the expanding of the collapsible portion upon planar alignment of two outer facing sections of the collapsible panel structure joined at a facing pair hinge point that is disposed opposite an inner core hinge point joining two of the inner core sections, wherein the inner core sections are arranged in a zig-zag manner between a first side of outer facing sections and a second side of outer facing sections with inner core hinge points pivotally coupling adjoining inner core sections and are offset from longitudinal lengths of the adjoining inner core sections by extensions, and wherein supplemental hinge points pivotally couple adjoining outer facing sections and inner core sections.
Type: Application
Filed: Aug 13, 2015
Publication Date: Aug 17, 2017
Inventor: Michael M. Stevenson (San Diego, CA)
Application Number: 14/826,152