Foldable composite structures

Patent metadata

Field	Value
Publication number	US-10994468-B2
Application number	US-201916381653-A
Country	US
Kind code	B2
Filing date	Apr 11, 2019
Priority date	Apr 11, 2018
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

Foldable composite structures and methods for fabricating foldable composite structures are provided. For example, a method comprises selectively applying a rigidifying substance to a sheet of composite material to define a plurality of hinges; allowing the rigidifying substance to cure; and folding the sheet of composite material along the hinges to form the composite structure. As another example, a method comprises laying out flat a sheet of composite material; masking a plurality of hinges on the sheet; applying a polymer to a sheet face; curing the polymer; removing the masking; and folding the sheet along the hinges to form the composite structure. An exemplary foldable composite structure comprises a planar sheet of composite material folded to define a plurality of surface segments and a plurality of hinges. A portion of the hinges form peaks and the remainder of the hinges form valleys. The hinges are defined between adjacent surface segments.

First claim

What is claimed is:

1. A method for fabricating a composite structure, comprising:
selectively applying a rigidifying substance to a sheet of composite material to define a plurality of hinges;
allowing the rigidifying substance to cure;
folding the sheet of composite material along the hinges to form a planar flat pack; and
unfolding the planar flat pack into the composite structure, the composite structure being three-dimensional,
wherein unfolding the planar flat pack into the composite structure comprises folding the sheet of composite material along the hinges to form the three-dimensional composite structure.

2. The method of claim 1 , wherein the composite material is a textile-based composite.

3. The method of claim 1 , wherein the composite material is a fiber-reinforced-polymer (FRP).

4. The method of claim 3 , wherein the composite material is a dry fiber reinforcement fabric.

5. The method of claim 1 , further comprising:
applying a masking material to the sheet of composite material before applying the rigidifying substance; and
removing the masking material before folding the sheet of composite material.

6. The method of claim 1 , wherein allowing the polymer to cure comprises curing the rigidifying substance over time at ambient temperature.

7. The method of claim 1 , further comprising:
applying a coating to the hinges after the planar flat pack is unfolded to form the composite structure.

8. The method of claim 1 , wherein the rigidifying substance is selectively applied using a printer.

9. The method of claim 1 , wherein the rigidifying substance is selectively applied by a robotic arm of an automated machine.

10. The method of claim 1 , wherein unfolding the planar flat pack comprises defining a plurality of surface segments with the hinges between adjacent surface segments, the plurality of surface segments forming the composite structure.

11. The method of claim 1 , further comprising:
returning the three-dimensional composite structure to the planar flat pack.

12. A method for fabricating a composite structure, comprising:
laying out flat a sheet of composite material;
masking a plurality of locations of hinges on the sheet of composite material using a masking material;
applying a polymer to a face of the sheet of composite material;
curing the polymer;
removing the masking material; and
folding the sheet of composite material along the hinges to form the composite structure,
wherein the composite structure is a structural building component,
wherein the hinges are curved, and
wherein the composite structure has a non-zero Gaussian curvature.

13. The method of claim 12 , further comprising:
folding the composite structure into a flat pack configuration to transport the composite structure.

14. The method of claim 12 , further comprising:
joining the sheet of composite material with a second sheet of composite material.

15. The method of claim 12 , further comprising:
applying a coating to the composite structure after the sheet of composite material is folded to form the composite structure.

16. The method of claim 12 , wherein the composite structure is a reusable framework for a concrete structure.

17. The method of claim 12 , wherein the composite structure is a stay-in-place framework for a concrete structure.

18. The method of claim 12 , further comprising:
spraying one or more surfaces of the composite structure with concrete.

19. A method for fabricating a composite structure, comprising:
laying out flat a sheet of composite material;
masking a plurality of locations of hinges on the sheet of composite material using a masking material;
applying a polymer to a face of the sheet of composite material;
curing the polymer;
removing the masking material;
folding the sheet of composite material along the hinges to form the composite structure; and
spraying one or more surfaces of the composite structure with concrete,
wherein the composite structure is a structural building component.

Assignees

• Univ Clemson
• Univ Clemson Res Foundation

Inventors

• Choma Joseph

Classifications

• B29C70/30

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title

• B29C53/06 Primary

  Forming folding lines by pressing or scoring · CPC title

• B29C53/04 Primary

  of plates or sheets {(B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00)} · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B27/08

  of synthetic resin · CPC title