Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A solar panel rack may comprise one or more sheet metal brackets configured to attach solar panels to the solar panel rack. The sheet metal brackets may include clinching tabs configured to be clinched to features on the solar panels to attach the solar panels to the solar panel rack. The sheet metal brackets may further include protrusions configured to facilitate electrical contact between the brackets and the solar panels when the clinching tabs are clinched to features on the solar panels. The sheet metal brackets may additionally or alternatively include positioning tabs configured to contact features on the solar panels to position the solar panels in desired locations on the solar panel rack.

Abstract: A solar panel rack may comprise a vertical support, a transverse support, brackets attaching hollow beams to the transverse support, and brackets configured to attach solar panels or solar panel assemblies to the hollow beams. Internal splices may couple collinearly arranged hollow beams in the solar panel rack. Some or all of these components may be formed from folded sheet metal blanks comprising bend lines predefined by bend-inducing features formed in the blanks. Preformed slots, holes, or other openings in the sheet metal blanks may predefine the relative positions of various components in the solar panel rack and predefine the positions of solar panels or solar panel assemblies to be supported by the solar panel rack. Individual components of the solar panel rack may be useful in other structures and applications apart from solar panel racks.

Abstract: A load-bearing three-dimensional structure including a skeletal structure formed by a sheet of material having a plurality of bend lines, each bend line including a plurality of folding displacements, wherein the sheet of material is bent along the bend lines into a box-section; and a reinforcing member configured for substantially surrounding a portion of the skeletal structure when bent into a box-section to reinforce the structural integrity of the skeletal structure. A method of manufacturing the three-dimensional structure is also disclosed.

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: Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material formed with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line.

Abstract: A sheet of material formed for bending along a bend line comprises a plurality of slits positioned proximate and along the bend line. The slits each have opposite end portions which diverge away from the bend line. The slits are configured and positioned to produce bending of the sheet of material along the bend line. The diverging slit end portions reduce stress in the sheet of material during bending.

Abstract: A method of preparing a sheet of material for bending along a bend line comprising the step of forming of at least one displacement in the thickness direction of the sheet of material with a portion of the periphery of the displacement closest to the bend line providing an edge and opposed face configured in position to produce edge-to-face engagement of the sheet on opposite sides of the periphery during bending. 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: Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material formed with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line.

Abstract: Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material formed with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line.

Abstract: Precision-folded, high strength, fatigue-resistant structures and a sheet therefore are disclosed. To form the structures, methods for precision bending of a sheet of material along a bend line and a sheet of material fowled with bending strap-defining structures, such as slits or grooves, are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves through the sheet of material in axially spaced relation to produce precise bending of the sheet when bent along the bend line. The bending straps have a configuration and orientation which increases their strength and fatigue resistance, and most preferably slits or arcs are used which causes edges to be engaged and supported on faces of the sheet material on opposite sides of the slits or arcs. The edge-to-face contact produces bending along a virtual fulcrum position in superimposed relation to the bend line.

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 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.

Abstract: A two-dimensional sheet of material for bending along a bend line to form a three-dimensional article having a load-bearing bend line, the sheet including at least one bend-controlling displacement. The displacement includes a displaced portion displaced from the sheet of material in a thickness direction defined by a sheared face, the displaced portion further including a central portion extending along the bend line and opposing end portions at opposite ends of the central portion; and a stem portion interconnecting the displaced portion to the remainder of the sheet of material. The stem portion is located inwardly of the end portions and defined by opposing termini of the sheared face. In various aspects, the displacements are formed in opposite thickness directions and configured to promote bi-directional precision folding. Methods of forming and using the sheet of material are also described.

Abstract: A sheet of material (111) having a plurality of bend-inducing structures (113) configured and positioned to produce bending along a bend line (115). The bend-inducing structures (113) have arcuate return portions (122) extending from opposite ends (121) back along the bend-inducing structures (113) toward the other return portion (122) and each return portion (122) has a length dimension and a radius of curvature reducing stress concentrations. Preferably, the length dimension of the arcuate return portion (122) is in excess of twice the thickness. The lateral distance, LD, to which the bend-inducing structures (113) is formed in the sheet away from the bend line (115) is preferably minimized by small radius arcs (125) which connect the return portions (122) to the remainder of the bend-inducing structures (113).

Abstract: A substantially two-dimensional sheet material is configured for bending along a bend line to form a three-dimensional article. The sheet material includes a sheet of elastically and plastically deformable material, one portion of the sheet material located on one side of the bend line and another portion located on the opposing side of the bend line, one portion being displaced relative to the another portion in the direction of the thickness of the sheet material, and/or a plurality of shear lengths extending along the bend line separating the one and another portions of the sheet material. At least a pair of adjacent shear lengths define a strap interconnecting the one and another portions of the sheet material.

Abstract: A sheet of material formed for folding into a three-dimensional structure. The sheet has edges formed with joinder structures, such as dovetails, and a plurality of folding structures, such as slits, grooves or displacements, that control folding of the sheet in a manner causing the joinder structures to be folded into interlocking interengagement. The folding structures are configured for very precise folding of the sheet so that the folding structures will be in precise registered juxtaposition. Additionally, the sheet of material includes a retention structure, such as a retention fold or a retention deformation, which will prevent unfolding of the sheet. A method for fastener-free joining of sheet edges together also is disclosed, as are the resulting three-dimensional structures.