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Systems, tools, and methods for forming corrugated structures and apparatuses including corrugated structures

  • US 9,023,265 B1
  • Filed: 01/28/2013
  • Issued: 05/05/2015
  • Est. Priority Date: 01/28/2013
  • Status: Active Grant
First Claim
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1. A tool for forming a corrugated structure from a pliable blank, the tool comprising:

  • a plurality of forming blocks laterally and movably supported relative to each other;

    wherein the tool defines a pre-formed configuration and a post-formed configuration;

    wherein when the tool is in the pre-formed configuration, the forming blocks are spaced laterally further away from each other than when the tool is in the post-formed configuration;

    wherein when the tool is in the post-formed configuration, the plurality of forming blocks collectively defines a corrugated form; and

    wherein the plurality of forming blocks includes;

    at least one ridge forming block having an upper surface configured to at least partially define a respective ridge of the corrugated structure; and

    at least two valley forming blocks separate from the at least one ridge forming block positioned on opposite lateral sides of the at least one ridge forming block, wherein each valley forming block has an upper surface that is lower than the upper surface of the at least one ridge forming block and that is configured to at least partially define a respective valley of the corrugated structure;

    a compaction mechanism configured to selectively conform the pliable blank to the corrugated form; and

    block translating mechanisms positioned between each of the at least two valley forming blocks and the at least one ridge forming block configured to reconfigure the tool from the pre-formed configuration to the post-formed configuration by selectively translating the at least two valley forming blocks laterally relative to and toward the at least one ridge forming block while the compaction mechanism operatively conforms the pliable blank to the corrugated form.

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