MULTI-MATERIAL FOLDABLE PRODUCT

Field of the invention

The invention relates to the field of material science and engineering with relations to a multi-material foldable product and its production process wherein the multi-material foldable product is suitable for various decorative and functional purposes, such as for partitioning or decorating a room or any indoor or outdoor space in a unique way that is foldable or compactable like a conventional curtain system with a connectable hanger system.

Background of the invention

Most conventional partitioning products are single-material products such as curtains, blinds, or fixed partitions. When they are combined with certain designs for fitting, they can be rearranged and adapted to the future space needs, but their shapes and forms cannot be changed from their originally produced forms so they can either divide or open the space. Their usage focuses only on function, not aesthetic. This poses a limitation in using a space creatively.

Considering existing solutions such as decorated laminated glass, it usually incorporates varied materials in between two sheets of glasses before lamination. This creates aesthetic and decorative point of view in using this glass as partitioning products. But it still lacks flexibility in changing its size, shape, form, reflectance. The purpose of this invention is to give that flexibility to the conventional partition by combining several materials. When combined designated properties from several materials, it transforms flat rigid partition panels into foldable ones. This does not only give limitless possibilities in adapting its shape, size, and form but also creates the uniqueness to the space and memorable experience to the audience.

Summary of the invention

A multi-material foldable product according to this invention generally comprising at least a set of solid sheet as its first outermost layer, a polymer film as its second layer, a reliable sheet as its third layer, a second polymer film as its fourth layer, and a second solid sheet as its fifth outermost layer. The solid sheets that form the outermost first and fifth layers of the multi- material foldable product can be chosen from glass sheets, plastic sheets, or combination of glass and plastic sheets. Optionally or in combination with the glass sheets, the plastic sheets can be utilized wherein the plastic sheets can be chosen from acrylic, polycarbonate, or corrugated plastic sheets. The above solid sheets may be in different shapes and sizes or comparable shape and size depending on user's will. The rollable sheet of the multi-material foldable product according to this invention is preferably a sheet of fabric wherein said fabric is chosen from woven fabric, non-woven fabric, knitted fabric, netting fabric, technical fabric, or a combination of these fabrics. The reliable sheet shall exhibit good tensile strength in order withstand the gravitational forces from solid sheets that are hung on or attached to its surface. Thus, it is preferable that the user conducts a tensile test of the product before choosing the most appropriate solid sheets for the reliable sheets that will be deposited on. After choosing the right materials should the user then carry out the design and production of the actual multi- material foldable product that best fits to the particular function or task.

Further, the multi-material foldable product may comprise a set of metal sheets placing along at least one side of the product or are in proximity to least one edge of the product for anchoring to the hanger system which is connectable to the rail like a curtain system or may, optionally, comprise a set of metal stands placing along at least one bottom side of the product for holding the multi-material foldable product in place like a partition. The metal sheets and metal stand can be chosen from aluminum, steel, titanium, copper, stainless steel, silver, gold, or platinum sheets, or a combination of at least two of the metal sheets.

Brief description of the drawings

FIG. 1A illustrates a front or back view of one embodiment of the multi-material foldable product according to this invention;

FIG. IB illustrates an exploded view of one detailed embodiment of the hanger system of the multi-material foldable product as illustrated in FIG. 1 A;

FIG. 2A illustrates a front or back view of one embodiment of the multi-material foldable product according to this invention; FIG.2B illustrates an exploded view of one detailed embodiment of the hanger system of the multi-material foldable product as illustrated in FIG.2A;

FIG.3 illustrates a front or back view of one embodiment of the multi-material foldable product according to this invention;

FIG. 4A illustrates a front or back view of one embodiment of the multi-material foldable product according to this invention;

FIG.4B illustrates an exploded view of one detailed embodiment of the hanger system of the multi-material foldable product as illustrated in FIG. 4A;

FIG. 5A illustrates a front or back view of one embodiment of the multi-material foldable product according to this invention;

FIG. 5B illustrates an exploded view of one detailed embodiment of the hanger system of the multi-material foldable product as illustrated in FIG.5A;

FIG. 6A illustrates a front of back view of one embodiment of the multi-material foldable product according to this invention;

FIG.6B illustrates an exploded view of one embodiment of the support structure of the multi- material foldable product as illustrated in FIG.6B;

FIG. 7A illustrates an eye-level, side view showing layers of materials of one embodiment of the multi-material foldable product according to this invention;

FIG. 7B illustrates an eye-level, side view showing layers of materials at one edge or one side of one embodiment of the multi-material foldable product according to this invention;

FIG.7C illustrates an eye-level, side view showing layers of materials at one edge or one side of one embodiment of the multi-material foldable product according to this invention; and

FIG.7D illustrates an eye-level, side view showing layers of materials at one edge or one side of one embodiment of the multi-material foldable product according to this invention. Detailed description of the invention

FIGS. 1 A, 2A, 3, 4A, 5A, and 6A represent some possible embodiments of a multi- material foldable product (1) according to this invention wherein said product (1)— in its most fundamental form— comprise the following sequential set of layers as depicted in FIG.7 A: - At least one solid sheet (3) as a first outermost layer (2);

At least one ethylene- vinyl acetate (EVA) films (5) wherein each film (5) is preferably positioned on each solid sheet (3) as a second layer (4);

- A rollable sheet (9) as a third layer (8);

- At least one EVA film (11) as a fourth layer (10) wherein each film (11) corresponds to the EVA film (5) of the second layer (4); and

- At least one solid sheet (13) as a fifth outermost layer (12) which is located on an opposite side of the first layer (2).

The layers of materials which made up the multi-material foldable product (1) according to FIG. 7A may further comprise a set of silicone fillings (7) inside the gaps between the solid sheets (3) of the first outermost layer and a set of silicon fillings (15) inside the gaps between the solid sheets (13) of the fifth outermost layer (12) wherein the silicon fillings (7, 15) may optionally be of equivalent height as the solid sheets (3, 13) or having filled at 0.5 mm thinner than the width of the gaps between the solid sheets (3, 13). Further, each of the EVA films (5, 11) is preferably at least 0.5 mm smaller than each side of each of the solid sheets (3, 13) that it positions on.

The solid sheets (3, 13) that form the outermost layers (2, 12) of the multi-material foldable product (1) can be chosen from glass sheets, plastic sheets, or combination of glass and plastic sheets wherein the glass sheets are preferably chosen from clear, mirror, or combination of clear and mirror glass sheets or fragments. Optionally or combinatorially with the glass sheets, the plastic sheets can be employed wherein the plastic sheets can be chosen from acrylic, polycarbonate, or corrugated plastic sheets. The above solid sheets (3, 13) may be in different shapes and sizes or comparable shape and size depending on users will.

The Tollable sheet (9) of the multi-material foldable product (l) is preferably a sheet of fabric wherein said fabric is chosen from woven fabric, non-woven fabric, knitted fabric, netting fabric, technical fabric, or a combination of these fabrics. The rollable sheet (9) shall exhibit good tensile strength in order withstand the solid sheets (3, 13) that are hung on or attached to its surface; thus, it is preferable that the user conducts a tensile test of the product (1) before choosing the most appropriate solid sheets (3, 13) for the rollable sheets (9) that will be deposited on. After choosing the right materials (3, 13, 9) should the user carry out the design and production of the actual multi-material foldable product (1) that fits to the function it provides. The EVA films (5, 11) are also important interlayer materials that can enable the solid sheets (3, 13) to be adhered to the rollable sheet (9) once the films (5, 11) are melted and compressed by some form of pressurization and heat; thus, the chosen EVA films (5, 11) shall exhibit certain quality and thickness to produce a desirable outcome, but shall not be longer or larger than the solid sheets (3, 13) which can cause stains or undesired damages to the product

(1).

Further, the multi-material foldable product (1) may comprise, in one embodiment, a set of metal sheets (18) and metal sheets (21) placing along at least one side of the product (1) or are in close proximity to at least one edge of the product (1) between the two solid sheets (3 and 13) wherein, as illustrated in FIG.7B:

- The metal sheets (18) are positioned between the EVA films (5) on the second layer (4) and a first metal facing set of EVA films (17) on a first metal sheet facing layer (16); and

- The metal sheets (21) are positioned between the EVA films (11) on the fourth layer (10) and a second metal facing set of EVA films (20) on a second metal sheet facing layer (19); - Wherein, the metal sheets (18 and 21) may be of comparable shape and size or maybe of different shapes and sizes depending on the design and utility.

In relation to the metal sheets (18 and 21) as depicted in FIG.7B, each metal sheet (18, 21) may further comprise an inlet (27, 28) for fitting a hanger (29) into wherein the hanger (29) comprises an extended body (30) for fitting through the inlets (27 and 28) and securing with a fastener (32) on one end and anchoring to a downward facing C-shaped rail (40) on an opposite hook-end (31). FIG. IB illustrates an exploded view of the hanger system in one of this invention's embodiments.

In another embodiment of the hanger system of the multi-material foldable product (1) as illustrated in FIG.2B, each metal sheet (18 or 21 ) comprises a hole (32, 33) for fitting a hanger (34, 35) into wherein:

- one hanger (34) fits through the hole (32) of the metal sheet (18) and secures with a fastener (36) on one end, and anchors to a downward facing C-shaped rail (40) on an opposite hook-end (37); and - another hanger (35) fits through the hole (33) of the metal sheet (21) and secures with a fastener (38) on one end, and anchors to the downward facing C-shaped rail (40) on an opposite hook-end (39).

In the two embodiments of the multi-material foldable product (1) in FIG. 4 A and FIG. 5A, at least one metal sheet (22) as illustrated in FIG.4B and FIG.5B is placed on at least one part or on at least one side of the product (1) or is in close proximity to at least one edge of the product (1) and is laid in-between the two solid sheets (3 and 13) wherein, as shown in FIG.7C, a first surface (25) of said metal sheet (22) is positioned on or next to the EVA films (5) on the second layer (4) and a second surface (26) is positioned on or next to the EVA films (11) on the fourth layer (10). If the metal sheet (22) is placed horizontally along a top edge (45) of the product (1) as illustrated in FIG.4B, a horizontal pole (46) is then placed directly underneath said metal sheet (22) and is connectable to a set of hangers (47) through their set of bottommost holes (48) and a set of fasteners (49) on at least two ends. The hangers (47) are further anchorable, on their uppermost hook ends (50), to a downward facing C-shaped rail (40).

If the metal sheets (22), preferably two, are placed vertically along at least two side edges (51) of the product (1) as illustrated in FIG. 5B, at least two vertical poles (52) with their uppermost outward facing horizontally curved ends (53) shall then be placed on the external sides of the metal sheets (22) to connect to a set of hangers (47) through their set of bottommost holes (48) and a set of fasteners (49) on at least two ends. The hangers (47) are further anchorable, on their hook ends (50), to a downward facing C-shaped rail (40) and the vertical poles (52) are further tightened to the product (1) with a set of fasteners (70) at the bases (71).

In one embodiment of the multi-material foldable product (1) according to FIG. 6 A wherein no metal sheets (18, 21, 22) are presented, the product (1) may be set up to stand on a ground by having— at or along its bottom side— at least one metal stand (75) placing between the two solid sheets (3 and 13) wherein— as shown in FIG.7D— a first surface (76) of said metal stand (75) is positioned on or next to the EVA films (5) on the second layer (4), a second surface (77) is positioned on a or next to the EVA films (11) on the fourth layer (10), and a central holding portion (80) provides a space for holding the reliable sheet (9) in place. The metal sheets (18, 21, 22) and metal stand (75) are preferably chosen from aluminum, steel, titanium, copper, stainless steel, silver, gold, or platinum sheets, or a combination of at least two of the metal sheets, but most preferably is stainless steel.

One example of the method of producing a multi-material foldable product ( 1 ) according to this invention may comprise the following steps: - Step 1: placing a template on a vacuum tray; - Step 2: placing a polypropylene (PP) wrap on the template;

- Step 3: placing at least one solid sheet (3) on top wherein the solid sheet (3) corresponds to the template;

- Step 4: placing at least one ethylene-vinyl acetate (EVA) film (5) on top of the solid sheet (3);

- Step 5: placing a reliable sheet (9) on top;

- Step 6: placing at least one EVA film (11) on top of the reliable sheet (9) so that each film (11) corresponds to the EVA film (5) layer;

- Step 7: placing at least one solid sheet (13) on top of the EVA film (11) so that the solid sheet(13) corresponds to the film (11) underneath;

- Step 8: placing the vacuum tray into a vacuum pump or sealing system and setting a pressure gage at -0.5 to -1.5 bar;

- Step 9: vacuuming the pre-vacuumed product at room temperature for 75-200 minutes, increasing the temperature to 60-90 °C for 70-110 minutes, increasing the temperature to 90-120 °C for 40-70 minutes, increasing the temperature to 120-140 °C for 20-40 minutes, then maintaining the temperature at 120-140 °C for 75-100 minutes, and reducing the temperature until it reaches 40 °C before shutting down the vacuum system; and

- Step 10: taking the product (1) out of the vacuum system. The method above may further include in steps 4 and 7, sequentially, the act of filling in silicone fillings (7, 15) inside the gaps between the solid sheets (3, 13) of the outermost layers

(2, 12), preferably, the silicon fillings (7, 15) inside the gaps are of the equivalent height as the height of the solid sheets (3, 13), and are at least 0.5 mm thinner than the width of the gaps between the solid sheets (3, 13). Further in step 4, one embodiment as depicted in FIG. 7B requires that the metal sheets (18) are positioned between the EVA films (5) on the second layer (4) and a first metal facing set of EVA films (17) on a first metal sheet facing layer (16). In step 6, the metal sheets (21) are then positioned between the EVA films (11) on the fourth layer (10) and a second metal facing set of EVA films (20) on a second metal sheet facing layer (19).

The embodiments as depicted in FIG. 7C and FIG. 7D which show the layers of materials on one end of the product (1). The embodiments similarly comprise the act of placing a metal sheet (22) on or next to EVA films (5) in step 4 wherein the first surface (25, 76) is touched upon the EVA films (5) and wherein the Tollable sheet (9) is touched upon one end as illustrated in FIG.7C or is partly inserted into the holding portion (80) as illustrated in FIG. 7D so that the metal stand (77) can hold the reliable sheet (9) in place. In step 6, the second surface (26, 77) is then touched upon the EVA films (11) on the fourth layer (10) accordingly.

Although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while several variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.