Patent Abstract:
An expandable panel includes a generally planar panel portion, penetrated by several pluralities of spaced parallel cuts. The cuts include aligned sets of apertures and aligned sets of transverse gaps. The panel is expandable by pulling the sides apart, separating the panel along the cuts. The positioning of the apertures and gaps causes the panel portions defined between the parallel cuts to bend apart, defining front and back planes, to which sheathing, surface panels, or “skins,” can be attached. The panel can be locked in its open position by inserting connectors in adjacent aligned gaps.

Full Description:
RELATED APPLICATION 
   This application claims priority to U.S. Provisional Patent Application No. 60/789,871, filed on Apr. 7, 2006, which is incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   I. Field of the Invention 
   The present invention relates generally to expandable panel structures and methods of manufacturing such structures. Although not limited to a single field of use, expandable panel structures are particularly well-suited for use in the architecture and construction industries. 
   II. Description of the Prior Art 
   Conventional structural approaches in the architecture and construction industries generally include rectangular frames, each frame having generally horizontal upper and lower beams, and generally vertical end beams connecting respective distal ends of the upper and lower beams. A plurality of substantially vertical studs may be fixed to the upper and lower beams, provided at spaced intervals between the two vertical end beams. Panels or sheathing, such as sheet rock, drywall, and gypsum board, are then fixed to the combination of upper and lower beams, end beams, and studs to define an internal wall. Alternatively, materials such as siding, brick, or the like are fixed to the frame to define an external wall. 
   Conventional materials and construction, however, suffer from many drawbacks. For instance, construction of each frame and attachment of the studs thereto generally must be performed at the construction site. This process is slow, labor-intensive, and often subject to weather and labor problems. The process also is subject to relative imprecision in comparison to prefabricated methods. As a result, conventional construction approaches are relatively slow, expensive, and inefficient. Moreover, the volume of materials that must be shipped to the job site to build according to standard practices occupies a relatively significant amount of space in transport vehicles used for the job. The resulting number of trips required to transport all of the necessary materials to the job site further adds to the overall job time, complexity, and cost. 
   It would be advantageous to provide, for instance, an expandable panel construction approach that can be easily manufactured and assembled, in a modular and cost-effective manner, in any one of a limitless variety of different configurations. 
   SUMMARY OF THE INVENTION 
   The advantages and purposes of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the advantages and purposes of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. 
   One aspect of the invention provides a panel structure including a sheet of material configured to move between a nonexpanded position, where the sheet of material forms a substantially flat shape, and an expanded position, where the sheet of material forms a substantially stepped shape. The panel structure includes a first side segment formed in the sheet of material and having an outer leg and an inner leg configured to allow the first side segment to bow when the sheet of material moves from the nonexpanded position to the expanded position. The panel structure further includes a second side segment formed in the sheet of material and having an outer leg and an inner leg configured to allow the second side segment to bow when the sheet of material moves from the nonexpanded position to the expanded position. The panel structure still further includes at least one inner segment formed in the sheet of material and having a first leg and a second leg configured to allow the inner segment to bow when the sheet of material moves from the nonexpanded position to the expanded position. The panel structure still further includes at least one spacer configured to maintain the sheet of material in the expanded position. 
   Another aspect of the invention provides a method of forming a wall structure including providing a panel having a substantially planar portion having front and rear surfaces, right and left side edges, and first and second distal ends, with a central portion defined midway. The method includes forming a plurality of spaced parallel apertures through the panel portion from the front surface to the rear surface so as to define a pair of first and second panel surfaces facing each other. The method further includes pulling the panel in opposite directions by the right and left side edges, thereby spreading apart the panel along each cut, with the panel portions between the cuts bending apart to define front and rear planes. The method still further includes securing the panel in its expanded position and affixing sheathing to at least one of the front and rear planes of the panel. 
   Another aspect of the invention provides an expandable panel structure comprising a substantially planar portion having front and rear surfaces, right and left side edges, and first and second distal ends, with a central portion. The expandable panel structure includes a plurality of spaced parallel cuts penetrating the panel portion from the front surface to the rear surface. The plurality of spaced parallel cuts includes a first plurality of cuts spaced a predetermined distance apart, each cut of the first plurality of cuts extending from the first distal end to an aperture provided in the panel at a position spaced away from the central portion toward the first distal end, thereby defining a first plurality of apertures aligned with one another. The plurality of spaced parallel cuts further includes a second plurality of spaced parallel cuts, each cut of the second plurality of cuts extending from the second distal end to an aperture provided in the panel at a position spaced away from the central portion toward the second distal end, thereby defining a second plurality of apertures aligned with one another, each respective cut in the second plurality of cuts being substantially aligned with a corresponding cut in the first plurality of cuts. The plurality of cuts further includes a third plurality of cuts spaced from one another between the aligned first and second pluralities of cuts, each cut of the third plurality of cuts extending between an aperture of a third plurality of apertures and an aperture of a fourth plurality of apertures, the third and fourth pluralities of apertures being spaced inward from the first and second distal ends toward the central portion, each of the cuts defining a pair of edges that face each other. The expandable panel structure is configured to expand by moving the right and left side edges in opposite directions so as to spread apart portions of the panel along each cut and bend the panel portions between the cuts apart to define front and rear planes. 
   Another aspect of the invention provides a panel structure including a panel assembly having a pattern of cuts, a pattern of grooves, and a pattern of apertures. The pattern of cuts, pattern of grooves, and pattern of apertures are configured to move the panel assembly between a nonexpanded position, where the panel assembly forms a substantially flat shape, and an expanded position, where the panel assembly forms a substantially stepped shape. The panel structure further includes a support structure configured to fit within at least one of the pattern of grooves of the panel assembly and maintain the panel assembly in the expanded position. 
   It is to be understood that both the foregoing general description and the following detailed description are only exemplary, and are intended to provide further explanation of the invention as claimed. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings, 
       FIG. 1  is a front view of an expandable panel consistent with the present invention in a nonexpanded position, displaying the pattern of cuts; 
       FIG. 2A  is a front view depicting the expandable panel of  FIG. 1  in a partially expanded position, displaying the pluralities of segments; 
       FIG. 2B  is a front view depicting the expandable panel of  FIG. 1  in an expanded position, displaying the pluralities of segments; 
       FIG. 3A  is a front view of an embodiment of a connector for fixing the expandable panel of  FIG. 1  in a preferably expanded position; 
       FIG. 3B  is a perspective view of the expandable panel having a plurality of the connectors of  FIG. 3A  fixed therein; 
       FIG. 3C  is a perspective view of the expandable panel having a plurality of the connectors of  FIG. 3A  fixed therein; 
       FIG. 4A  is a front view of the expandable panel having a plurality of the connectors of  FIG. 3A  fixed therein; 
       FIG. 4B  is a front view of the expandable panel having a plurality of the connectors of  FIG. 3A  fixed therein; 
       FIGS. 5A-5F  depict a method of assembly of an expandable panel in accordance with the present invention; 
       FIG. 6A  is a front view of an alternative embodiment of a connector for fixing the expandable panel in an expanded position; 
       FIG. 6B  is a front view of the expandable panel having a plurality of the connectors of  FIG. 6A  fixed therein; 
       FIG. 7A  is a front view of another alternative embodiment of a connector for fixing the expandable panel in an expanded position; 
       FIG. 7B  is a front view of the expandable panel having a plurality of the connectors of  FIG. 7A  fixed therein; 
       FIG. 8A  is a front view depicting the expandable panel in a nonexpanded position, along with a single skin panel; 
       FIG. 8B  is a front view depicting the expandable panel in an expanded position, with a plurality of skin panels affixed therein; 
       FIG. 9  is a perspective view of the expandable panel in an expanded position, with a plurality of skin panels having apertures affixed therein; 
       FIG. 10A  is a perspective view of an expandable panel in accordance with the present invention in the expanded position and having tabs for supporting sheathing; 
       FIG. 10B  is a perspective view of an expandable panel in accordance with the present invention in the expanded position and sandwiched between sheathing; 
       FIG. 11A  is a front view of an expandable panel in accordance with the present invention, being in the nonexpanded position and having a generally horizontal crease; 
       FIG. 11B  is a front view of an expandable panel in accordance with the present invention, being in the nonexpanded position and having a generally diagonal crease; 
       FIG. 11C  is a perspective view of an expandable panel in accordance with the present invention, being in the expanded position, and having a crease and roof support members that are bent about the crease; 
       FIG. 12A  is a front view of an alternative embodiment of an expandable panel in accordance with the present invention, being in the nonexpanded position and having a plurality of curved cuts; 
       FIG. 12B  is a perspective view of the alternative embodiment of  FIG. 12A , being in the expanded position and forming an arched canopy; 
       FIG. 13A  is a front view of an alternative embodiment of an expandable panel in accordance with the present invention, being in the nonexpanded position and having a plurality of arched cuts; 
       FIG. 13B  is a perspective view of the alternative embodiment of  FIG. 13A , being in the expanded position and forming an arch support; 
       FIGS. 14A-14C  are front views of alternative embodiments of expandable panels in accordance with the present invention in nonexpanded positions; and 
       FIGS. 15A-15E  are perspective views depicting fixing means in distal ends of the expandable panels used to fix expandable panels together. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference will now be made in detail to the present embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
   As broadly embodied herein and referring to  FIG. 1 , an exemplary expandable panel  50  may preferably include a substantially planar front surface  52 , a substantially planar rear surface  53  (not shown in  FIG. 1 ), right and left side edges  54  and  56 , and first and second distal ends  58  and  59 . A central portion  57  may be defined midway between the first and second distal ends  58  and  59 . Tab portions  55  may extend from either end of the central portion  57 . In one embodiment, the tab portions  55  extend from the right and left side edges  54  and  56 . 
   The panel  50  may preferably include a pattern of cuts  60 , a pattern of apertures  63 ,  65 ,  69 ,  70 , and a pattern of gaps  66 ,  72 . Each pattern may penetrate through the front and rear surfaces  52 ,  53  of the panel  50 . The pattern of cuts  60  may include a first series of generally parallel cuts  62  that may extend along a longitudinal direction of the panel  50 . Each cut  62  may be spaced apart from one another by any suitable spacing so long as the panel  50  can be moved between a nonexpanded position and an expanded position. 
   The pattern of apertures may include a first series of apertures  63  that are spaced upward away from the central portion  57  of the panel  50 . Each cut  62  may extend downward from the first distal end  58  of the panel  50  to be connected with a respective one of the first series of apertures  63 . The first series of apertures  63  may be generally aligned with one another in a line parallel to the distal ends  58  and  59 , and generally transverse to the side edges  54  and  56 . 
   The pattern of cuts further may include a second series of generally parallel cuts  64 , and the pattern of apertures may include a second series of apertures  65  that are spaced downward away from the central portion  57  of the panel  50 . Each cut  64  may extend upward from the second distal end  59  to be connected with a respective one of the second series of apertures  65 . The second series of apertures  65  may be aligned with one another in a line generally parallel to the distal ends  58  and  59 , and transverse to the side edges  54  and  56 . 
   The pattern of cuts further may include a third series of generally parallel cuts  68 . Each cut  68  may be located between one of the cuts of the first and second series of cuts  62 ,  64 . In other words, the first, second, and third series of generally parallel cuts  62 ,  64 , and  68  may be interposed relative to one another. Each of the third series of generally parallel cuts  68  may extend between a respective one of a third series of apertures  69  and a respective one of a fourth series of apertures  70 . Each of the third series of apertures  69  may be inwardly spaced away from the first distal end  58  toward the central portion  57 . The third series of apertures  69  may define a row of spaced apart apertures  69  extending along a direction generally parallel to the first distal end  58  and transverse to the side edges  54  and  56  of the panel  50 . Similarly, the fourth series of apertures  70  may be inwardly spaced away from the second distal end  59  toward the central portion  57 . The fourth series of apertures  70  may define another row of spaced apart apertures  70  extending along a line generally parallel to the second distal end  59  and transverse to the side edges  54  and  56 . 
   The pattern of gaps  66 ,  72  may include a first series of gaps  66  and a second series of gaps  72 . Each of the first and second series of gaps  66 ,  72  may extend along a direction that is generally traverse to the longitudinal direction of the panel  50 . The first and second series of gaps  66 ,  72  may form three rows of gaps that extend along a direction generally parallel to the distal ends  58  and  59  and a direction generally transverse to the side edges  54  and  56  of the panel  50 . The first series of gaps  66  may be located at a position that is spaced inward from the distal ends  58 ,  59  of the panel  50  toward the central portion  57 , respectively. The first series of gaps  66  also may be connected to the first series of cuts  62  and the second series of cuts  64 . The second series of gaps  72  may be located in the central portion  57  of the panel  50 . The second series of gaps  72  also may be connected to the third series of cuts  68 . In the illustrated embodiment, each of the second series of gaps  72  is connected at a midpoint of each of the third series of cuts  68 . 
   As will be understood by one of skill in the art, the expandable panel  50  may include any variety of additional reinforcements or cut-out features for mitigating the effects of stress, and thereby increasing the load-bearing capabilities of the panel  50 . For instance, the expandable panel  50  may include reinforcing plates or reinforcing ribs located at points of relatively high stress. The expandable panel  50  also may include rounded edges, filleted interior corners, drilled apertures, or any other feature known for use in preventing fracture at points of high stress propagation, or impeding the formation of fold lines that may impede the structural integrity of the panel  50 . In one embodiment, the expandable panel  50  may include stress-mitigating structures located adjacent to or around the pattern of cuts  60 , the pattern of apertures  63 ,  65 ,  69 ,  70 , and/or the pattern of gaps  66 ,  72 . For example, in one embodiment, the expandable panel  50  may be affixed to another expandable panel  50  in a layered configuration for the purpose of providing additional load-bearing functionality. The expandable panel  50  also may be manufactured to have any particularly suitable size or shape, such as a relatively larger or smaller panel than illustrated, and may include a greater or lesser number of spaced generally parallel cuts  60 , depending on the expected use and loading. For instance, the thickness of the panel  50  can be selectively increased at certain locations (e.g., adjacent to or around the pattern of cuts  60 , the pattern of apertures  63 ,  65 ,  69 ,  70 , and/or the pattern of gaps  66 ,  72 ) to improve the structural integrity of the panel  50 . Moreover, the shapes and orientations of the spaced generally parallel cuts  60  may be optimized based on various stress profiles, as desired. 
     FIG. 2A  illustrates an exemplary embodiment of the panel  50  after it has been moved to a partially expanded position. In particular, given the patterns of cuts, apertures, and gaps described with respect to  FIG. 1 , the exemplary expandable panel  50  may include a first side segment  110 , a second side segment  112 , and one or more inner segments  114  disposed therebetween. Each of the segments  110 ,  112 , and  114  may include a first distal end joint  116  and a second distal end joint  118 . Each of the first distal end joints  116  and second distal end joints  118  may include at least one groove  67  that is formed by an end portion of a respective one of the first series of gaps  66 . Each of the first and second side segments  110  and  112  may include an inner leg  121  extending from a respective first distal end joint  116  to a respective second distal end joint  118 , and an outer leg  123  extending from a respective first distal end joint  116  to a respective second distal end joint  118 . Each of the inner segments  114  may include a first leg  120  extending from a respective first distal end joint  116  to a respective second distal end joint  118 , and a second leg  122  extending from a respective first distal end joint  116  to a respective second distal end joint  118 . Each of the inner and outer legs  121 ,  123  and first and second legs  120 ,  122  may include a midpoint portion  124 . Each of the midpoint portions  124  may be disposed along the central portion  57  and may have formed therein a groove  73  that is formed by an end portion of a respective one of the second series of gaps  72 . 
   According to the embodiment of  FIG. 2A , the outer leg  123  and inner leg  121  of the first side segment  110  may be joined at their ends by the corresponding first distal end joint  116  and a second distal end joint  118 , respectively. The outer leg  123  and inner leg  121  of the second side segment  112  may be joined at their ends by the corresponding first distal end joint  116  and second distal end joint  118 , respectively. The first leg  120  and the second leg  122  of each inner segment  114  may be joined at their ends by first and second distal end joints  116 ,  118 , respectively. 
   Moreover, the inner leg  121  of the first side segment  110  may be joined to the first leg  120  of an adjacent inner segment  114  by their respective midpoint portions  124 . Similarly, the second leg  122  of the adjacent inner segment  114  may be joined to the first leg  120  of a still further adjacent inner segment  114  by their respective midpoint portions  124 . Finally, the second leg  122  of the inner segment that is adjacent to the second side segment  112  may be joined to the inner leg  121  thereof by their respective midpoint portions  124 . This pattern of joints can be applied to virtually any number of segments. 
   Each of the cuts  60  of the expandable panel  50 , and thus, each of the first and second legs  120 ,  122 , and inner and outer legs  121 ,  123 , may form at least a part of a first panel surface  76  and at least a part of a second panel surface  78 . When the expandable panel  50  is in a nonexpanded position, as depicted in  FIG. 2A , the first panel surfaces  76  may substantially face the adjacent second panel surfaces  78 . 
     FIG. 2B  depicts an exemplary embodiment of the panel  50  in an expanded position. The panel  50  may be expanded by pulling the first side segment  110  and the second side segment  112  away from each other. During assembly, the left side edge  56  of the first side segment  110  may be pulled away from the right side edge  54  of the second side segment  112  along a direction transverse to the longitudinal direction of the cuts  60 . For instance, the panel  50  may be expanded by pulling the tab portions  55  in opposite directions transverse to the direction of cuts  60 . Alternatively, the inner segments  114  may be sequentially pulled away from the first side segment  110 , the second side segment  112 , and each other inner segment  114 . Accordingly, the panel  50  may expand and separate along each of the cuts  60 . Because of the location and aligned orientation of the various apertures  63 ,  65 ,  69 , and  70 , and of the gaps  66  and  72 , the first side segment  110 , the second side segment  112 , and the at least one inner segment  114  may each bow outward. And when the segments  110 ,  112 ,  114  bow outward, the midpoints of the two legs of each segment may separate from each other. Because the two legs of each segment are joined at their ends by respective first and second distal end joints  116 ,  118 , and because the midpoints of the two legs of each segment bend or bow in opposite directions, the first and second distal end joints  116 ,  118  may be subjected to bending, compression, and/or torsional forces. Similarly, because legs between adjacent sections are joined by their midpoint portions  124 , and because adjacent legs are configured to bend in opposite directions, each of the midpoint portions  124  may be subjected to bending, compression, and/or torsional forces. 
   As illustrated in  FIG. 2B , the panel  50  in its expanded position may resemble a generally stepped configuration. In other words, each segment may appear to be stepped, one upon another. Because adjacent segments  110 ,  112 , and  114  may be connected only at their midpoint portions  124 , the resulting structure may result in previously adjacent first distal end joints  116  and previously adjacent second distal end joints  118  being spaced apart. Still further, as the segments  110 ,  112 , and  114  bow outward, each of the transversely adjacent legs is spread apart, so as to separate the first panel surfaces  76  and second panel surfaces  78 . According to some embodiments, the overall effect of the expansion of the panel  50  also may include a twisting of segments  110 ,  112 , and  114 , such that the now spread apart first and second panel surfaces  76  and  78  form front and rear planes to which sheathing and/or other inserts may be attached. In one exemplary embodiment, the resulting expandable panel  50  may be referred to as a “double zig-zag,” “accordion,” or “stepped” variation of the exemplary expandable panel  50 . In other exemplary embodiments, connectors, spacers, or the like may be inserted into the panel  50 , such as into adjacently aligned gaps, to provide structural support and/or to maintain the panel  50  in its expanded position. These assembly steps may be performed in any suitable manner, such as by hand and without the use of heavy tools or machinery. 
     FIG. 3A  depicts an exemplary embodiment of a connector  80  (alternatively referred to as a “spacer”) that includes two L-shaped tabs  82 . Each of the two L-shaped tabs  82  may be disposed on opposite ends and opposite faces of the connector  80 .  FIGS. 3B ,  3 C,  4 A, and  4 B depict additional embodiments of the connectors  80  as they are incorporated into the expandable panel  50 . The connectors  80  may be fitted within different locations of the panel  50 . For instance, the two L-shaped tabs  82  of a connector  80  each may be formed to fit within a respective groove  67 ,  73  defined by the first and second series of gaps  66 ,  72  in the panel  50 . In one embodiment of the invention, the L-shaped tabs  82  and grooves  67 ,  73  may together form a mating engagement without the use of screws, fasteners, or the like. For instance, the L-shaped tabs  82  of the connectors  80  may be relatively locked into the grooves  67  and/or  73  of the panel  50 . Thus, the connectors  80  may be configured to maintain the panel  50  in its expanded position and to provide rigidity and strength to the panel  50 . As will be understood by one of skill in the art, each connector  80  may be made of any suitable material and configured in any suitable manner so long as it is able to withstand a plurality of compression and/or tension forces while maintaining the panel  50  in the expanded position. 
     FIGS. 5A-5F  depict a method of assembling an exemplary expandable panel  50 . Specifically, a method is depicted for expanding the panel  50  into the exemplary expanded configuration illustrated in  FIG. 4B . For instance, the panel  50  may be assembled by inserting one or more connectors  80  at a time into two adjacent grooves of the grooves  67  and/or  73  until the panel  50  is fully expanded. As will be understood by one of skill in the art, specific methods for assembly relating to the sequencing of assembly, and particular methods of inserting connectors  80  into mating and/or locking engagement with the expandable panel  50  will become apparent upon practice of the invention. For instance, in one embodiment, connectors  80  may be installed into adjacent grooves  67  and then into adjacent grooves  73 . Alternatively, connectors  80  may be installed into adjacent grooves  73  and then into adjacent grooves  67 . In some embodiments, the connectors  80  may be further secured to gaps of panel  50  by adhesives, such as glue or solder, or by other mechanisms, such as dowel pins, hooks, or the like. 
     FIG. 6A  depicts another exemplary embodiment of a connector  80  that has T- or H-shaped tabs  82 .  FIG. 6B  depicts an embodiment of the expandable panel  50  in which the panel  50  may be expanded by the embodiment of connectors  80  depicted in  FIG. 6A . 
     FIG. 7A  depicts yet another exemplary embodiment of a connector  80  that has protruding tabs  82 .  FIG. 7B  depicts an embodiment of the expandable panel  50  in which the panel  50  may be expanded by the embodiment of connectors  80  depicted in  FIG. 7A . 
     FIG. 8A  depicts another embodiment of the expandable panel  50  in its nonexpanded position.  FIG. 8A  also depicts a single detachable skin panel  84  having U-shaped tabs  85 . The skin panel  84  may be formed in any suitable shape so long as it is compatible with openings formed in an expanded panel  50 . In the embodiment of  FIG. 8A , the skin panel  84  may be substantially in the shape of a vesica piscis. The skin panel  84  also may be made of any suitable material known in the art. In one embodiment, skin panel  84  may be a relatively rigid panel made of wood, plastic, or metal. Alternatively, the skin panel  84  may be made of glass or another transparent material. In any of these exemplary embodiments, the U-shaped tabs  85  may be used to hold the expandable panel  50  in its expanded position. Specifically, the U-shaped tabs  85  may interlock (e.g., by tongue and groove mechanism) surfaces of the panel  50 , such as the first and second panel surfaces  76  and  78 , the first, second, third, or fourth apertures  63 ,  65 ,  69 ,  70 , and/or the grooves  67 ,  73 . In another embodiment, skin panel  84  may be a relatively flexible panel made of plastic or cloth, such as canvas. In this embodiment, a flexible skin panel  84  may be secured to expandable panel  50  by any suitable means, such as hooks, ties, adhesives, or the like. In certain embodiments, skin panel  84  may include aesthetic designs, such as pictures, manufacturers&#39; logos, advertisements, and/or other indicia. 
     FIG. 8B  depicts the expandable panel  50  as expanded by a relatively rigid embodiment of the skin panels  84 . Moreover, the expandable panel  50  further includes alternative relatively rigid skin panels  86  that may be specially configured to be accommodated in partial openings of the panel  50 . In this embodiment, because the skin panels  84  and  86  are relatively rigid, they may both expand and provide structural support to panel  50 . Furthermore, because the skin panels  84 ,  86  may be formed in a suitable geometric configuration, they may be nested together in adjacent locations of a sheet of stock material, prior to manufacture, in order to minimize material waste and to ease production. 
     FIG. 9  depicts an embodiment of expandable panel  50  having disposed therein alternative embodiments of the skin panels  84 . In particular, the skin panels  84  may include one or more apertures  104 . According to one embodiment, apertures  104  may be purely aesthetic in nature. In another embodiment, apertures  104  may function to accommodate wires, pipes, insulation, plumbing, or any other structures or materials preferably extended through an interior or exterior wall. In a further embodiment, scrap material cut from the apertures  104  may be used to manufacture components, such as the connectors  80 . The apertures  104  also may allow for interweaving of components, such as connectors  80 , through the skin panels  84 . 
     FIG. 10A  depicts another exemplary embodiment wherein an expanded panel  50  is provided with one or more tabs  94  (alternatively referred to as “protrusions”). The tabs  94  may be used for attaching sheathing to the panel  50 . The tabs  94  may be cut from the same material as that of the panel  50 . For instance, the tabs  94  may extend from portions of the panel  50 , such as the first panel surface  76  or second panel surface  78 . The tabs  94  also may be disposed in locations of the panel  50  corresponding to mechanisms for attaching the sheathing. As a result of the change in geometry caused by the tabs  94 , the pattern of cuts  60 , the pattern of apertures  63 ,  65 ,  69 ,  70 , and the pattern of gaps  66 ,  72  may be altered. For example, the apertures resulting between legs of adjacent segments may be wider in view of the space required for the tabs  94  to extend from the adjacent first panel surfaces  76  and second panel surfaces  78 . 
     FIG. 10B  depicts the exemplary embodiment wherein the expanded panel  50  is provided between sheathing  90 . In this embodiment, sheathing  90  may be mounted to the expanded panel  50  by inserting the plurality of tabs  94  of the panel  50  through correspondingly disposed apertures  95  in sheathing  90 . In lieu of tabs  94 , the panel  50  may include another type of hook, dowel pin, clip, or other mechanism by which sheathing  90  may be sufficiently supported. For instance, in one embodiment, sheathing  90  may be mounted to the panel  50  by the tab portions  55  illustrated in  FIGS. 1 and 2 . 
   Sheathing consistent with the present invention may be manufactured from one or more of any suitable type of material. In one embodiment, sheathing  90  may include one or more of plywood, drywall, sheet rock, gypsum board, metal, cloth, foam, insulation, honeycomb, steel, or any composite material. In another embodiment, sheathing  90  may be manufactured from a transparent or translucent material, including but not limited to glass, frosted glass, and plastics such as acrylic. By this embodiment, elements of the expanded panel  50  may be angled or louvered in consideration of the directional orientation of the panel  50  relative to the sun. Accordingly, sunlight into a corresponding structure may be at least partially controlled, as desired. 
   Alternatively, the embodiment of  FIG. 10B  may be particularly suitable for constructing concrete load-bearing walls. For example, after attachment of suitably disposable sheathing  90  to the expanded panel  50 , cement may be poured into a gap  92  defined between two panels of sheathing  90  and allowed to set. In one embodiment, the interior faces of sheathing  90  may be embossed or otherwise three-dimensionally disposed with indicia, such as patterns, corporate names, logos, advertisements, or specifications. Accordingly, concrete set therein may include such indicia upon removal of the sheathing  90 . If desired, segments of the panel  50  may function as built-in reinforcement for the concrete form, if so designed. Moreover, sheathing  90  may be left in place around concrete forms rather than used purely as a preform structure. Sheathing  90  also may be reusable for other cast concrete applications. 
   In yet another embodiment, insulation may be incorporated into gap  92  by one of several embodiments. For example, insulation may be a spray-in foam variety, such as Icynene®, which expands to fill the gap  92 . Insulation may alternatively include loose fill insulation, which is installed to fill specific voids between the expandable panel  50  and sheathing  90 . In one preferred embodiment, insulation may be custom, batt insulation, which is preformed to infill the particular shape created upon expansion of the expandable panel  50 . Insulation may also include sheets of insulation which are installed, such as by adhesive, to the outer or inner face of sheathing  90 . By such embodiments, installation of insulation may be substantially easier and more cost effective in terms of reduced man-hours. 
     FIG. 11A  depicts yet another exemplary embodiment of the expandable panel  50  that has a horizontal crease (alternatively referred to as a “fold line”)  74  intermediate the central portion  57  and the first distal end  58 .  FIG. 11B  depicts yet another exemplary embodiment of the expandable panel  50  wherein the crease  74  may be diagonal instead of horizontal. Horizontal or diagonal creases  74  may allow the expandable panel  50  to be expanded into a desired overhanging panel configuration. In one embodiment, the horizontal and/or diagonal creases  74  may be staggered from one segment of the panel  50  to another in order to generate a desired form of the expanded panel  50 . 
     FIG. 11C  depicts an embodiment of the expandable panel  50  in which an upper portion of the panel  50  has been bent, such as along a crease  74 , to define a plurality of generally right-angle roof support members  88 . As shown in  FIG. 11C , the roof support members  88  may be expanded in a manner consistent with expansion of the rest of the panel  50 . As will be described below, the roof support members  88  may include fixing means at distal ends of each segment for the purpose of being joined to another expandable panel  50 . Alternatively, the roof support members  88  may be configured to accept any other conventional roof truss members or flooring. 
   As an alternative to bending a portion of the expandable panel  50  about a crease, the panel  50  may be manufactured to naturally form an arched canopy or roof support portion. For example, as depicted in  FIG. 12A , the expandable panel  50  may be manufactured to include a curved shape having curved cuts  105 . The overall shape of the expandable panel  50  and the curved cuts  105  may be particularly designed using a computer. The actual curved cuts  105  may be manufactured using conventional machines, such as computer numerical controlled (“CNC”) milling machines, or more preferably by advanced manufacturing techniques such as water-jet machining or laser cutting. Accordingly, such an expandable panel  50  may be expanded to create an arched canopy  106 , as shown in  FIG. 12B . 
     FIG. 13A  depicts yet another embodiment of the expandable panel  50  that includes a generally arch-shaped panel having a plurality of arched cuts  107 . Accordingly, such an expandable panel  50  may be expanded to create an arch support  108 , as shown in  FIG. 13B . In one embodiment, the arch support  108  may be disposed in a horizontal orientation to function as a roof support, such as a barrel vault. As will be appreciated by one of skill in the art, such variations in shape of the expandable panel  50  and the plurality of spaced cuts  60 ,  105 , or  107  therein may be altered to create the desired architectural, aesthetic, and/or load-bearing structures. 
     FIGS. 14A-C  depict still further alternative embodiments of the expandable panel  50 . For example,  FIG. 14A  illustrates an embodiment of the expandable panel  50  in which only two alternating series of generally parallel cuts  126 ,  127  may be disposed in the panel  50 . Moreover, only two series of gaps  128  may be incorporated, with one line of gaps  128  being disposed at each distal end of the panel  50 . Accordingly, as will be appreciated by one of skill in the art, the resulting expanded panel may be a simply alternating, stepped panel, which may be held in its expanded position by a line of connectors at each of its distal ends. This embodiment may be referred to as a “single zig-zag” expandable panel. 
     FIG. 14B  illustrates an embodiment of the expandable panel  50  in which an additional series of generally parallel cuts  130  may be included, relative to the expandable panel  50  illustrated in  FIG. 1 . The expandable panel  50  also may include an additional series of gaps  132 . In this embodiment, the resulting expanded panel may be similar in nature to the expanded panel of  FIG. 2B  but may effectively include an additional half of the panel  50  protruding from one of its distal ends. Thus, the so-called “triple zig-zag” expandable panel  50  may either be longer than those of previous embodiments, or it may have shorter parallel cuts and segments. 
     FIG. 14C  illustrates an embodiment of the expandable panel  50  in which the expandable panel of  FIG. 1  may be essentially doubled (i.e., mirrored about a distal end, such as the first distal end  58 , of the panel). Therefore, the expandable panel may include two additional series of generally parallel cuts  134 ,  136 , as well as five overall lines of gaps  138 . The resulting “quadruple zig-zag” expandable panel  50  may be either longer than those of previous embodiments, or it may have shorter parallel cuts and segments. These and other variations on the particularly disclosed expanded panels  50  will become apparent to one of ordinary skill in the art upon study of the present disclosure. That is, alternative arrangements of cuts, apertures, and segments are not limited to the embodiments recited herein, and are contemplated within the scope of the present invention. 
     FIGS. 15A-E  depict fixing means in distal ends of the expandable panels  50  for connecting expandable panels  50  together. Specifically, referring back to  FIG. 2A , each first distal end joint  116  and/or second distal end joint  118  of each segment  110 ,  112 ,  114  may include a fixing means for connecting various modular expanded panels  50  together by their first and/or second distal ends  58 ,  59 . As illustrated in  FIG. 15A , each segment of the panel  50  may include at least one of a male connector  100  and a female receptor  102 . As illustrated, the male connectors  100  and the female receptors  102  may be tongue and groove mechanisms that form mating engagements between the respective distal ends of the panels  50 .  FIGS. 15B-E  illustrate embodiments in which the panels  50  are joined by the male connectors  100  and the female receptors  102 . The panels  50  also may be joined to each other in various configurations by use of the tab portions  55 . In these embodiments, already expanded and assembled panels  50  may be in modular form and therefore suitable for interconnection between themselves and other building components. Accordingly, the presently disclosed expandable panel  50  may become one component of a comprehensive and mass-produced modular building system. 
   The expandable panel  50 , consistent with the present invention, may be manufactured from one or more of any suitable type of material. For example, expandable panels may be made out of plywood, such as birch, fir, meranti, or bamboo plywood. Plywood may be selected depending on various levels of quality, taking into consideration factors such as knots, gap widths between plys, glue quality, and supplier. Plywood may be selected having relatively thinner plys and high-quality glue in the interest of increased panel flexibility. Plywood that has a thickness of approximately 0.25″ to 0.75″ may be used depending on the nature of its use (e.g., interior versus exterior wall). In some embodiments, several sheets of thinner plywood may be layered to increase its load-bearing functionality. Moreover, plywood may be selected depending on grain orientation. In a preferred embodiment, plywood may be selected having wood grain running in a longitudinal axis of the expandable panel, in order to strengthen the panel against transverse bending. 
   Expandable panels also may be made from plastics such as polyethylene, polycarbonate, and the like. Expandable panels may, in some embodiments, be made from metals or metal alloys, including steel, stainless steel, and aluminum. In another embodiment, expandable panels may be made from composite materials, such as fiberglass, carbon fiber, or composites of plastics or wood. In a still further embodiment, expandable panels may be made from recycled materials of one or more of the aforementioned materials. 
   Methods for manufacturing expandable panels consistent with the present invention may include conventional and/or relatively advanced techniques. For example, any suitable technique may be selected depending on factors such as materials, costs, blank size, and time constraints. Expandable panels may be initially designed using a computer. For example, software operating on a computer, such as computer aided drafting (“CAD”) software, may be used to create drawing files of preferable shapes for expandable panels. In some embodiments, CAD software may be used in combination with computer aided manufacturing (“CAM”) software. Cutting paths and speeds may be input by a user on the computer or the cutting machine, or automatically generated by software operating on either device. In one embodiment, particularly designed cuts may be programmed using CAD modeling software. Resulting drawing files may be transferred to a cutting machine. 
   In one embodiment, expandable panel  50  may be manufactured by a CNC milling machine. By this embodiment, well-tested methods may be used to program and cut slots into the expandable panel  50 . However, due to substantial material loss from a saw, sometimes as much as 0.5 inches, more advanced techniques may be desired. For example, in other embodiments, expandable panel  50  may be manufactured with a water jet-cutting machine or laser-cutting machine, both of which offer material loss approximately one-tenth (e.g., approximately 0.032″ in certain water jet-cutting machines) of that experienced with CNC machines. Such precise manufacturing may be advantageous in embodiments of the present invention in which cuts and gaps approach relatively small dimensions. Moreover, reduced material loss may be desired when forming precise stress-propagation inhibiting features, such as at apertures  63 ,  65 ,  69 , and  70 . Expandable panel  50  also may be manufactured in mass-production by one or more radial dies. 
   Once manufactured and assembled, the exemplary expandable panel  50  may be oriented such that the cuts  60  extend either vertically or horizontally. For example, the expandable panel  50  may form a large wall section that extends from floor to ceiling. The expandable panel  50  may have formed therein spaces for elements such as windows and doors. In certain embodiments, the expandable panel  50  may be expanded by varying amounts at distinct locations along the length of the panel  50  to account for these features. 
   The characteristics and features of the presently disclosed exemplary expandable panel and assembly provide numerous advantages. For instance, in their unassembled (i.e., nonexpanded) position, numerous expandable panels  50  may be stacked in relatively lesser volume due to the initially flat sheet configuration of the panels  50 . Accordingly, storage and shipping costs are reduced, and fewer trips are required for transporting building materials to the job site. 
   In addition, because the exemplary expandable panels  50  may be mass-produced in a machine shop or factory, and because they require little further assembly, relatively unskilled labor may be employed in the final stages of panel assembly and installation. For example, assembly may include a relatively simple method of snapping together panels and connectors without the need for material removal processes. Furthermore, use of the expandable panel  50  may be advantageous in applications requiring eventual un-installation since the panel  50  may be retracted and re-stored in its nonexpanded position. Therefore, the disclosed expandable panel  50  may be particularly well-suited for use in structures, such as emergency shelters, low-income housing, temporary barriers, signage, tents, stages, and pavilions. For example, a structure formed from the expandable panels  50  may be covered by a canvas tarpaulin or additional sheets of plywood with relative ease and cost-efficiency. 
   Moreover, because an assembly including the expandable panel  50  may be relatively flexible, a wall or other support including it may be particularly well-suited in applications subject to substantial vibrations, such as those in construction and earthquake zones. For example, upon selection of the appropriate materials and inclusion of particular stress-mitigating features, an earthquake-proof structure may be formed by assembly of one or more of the expandable panels  50 . 
   Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true spirit and scope of the invention being indicated by the following claims. Thus, it should be understood that the invention is not limited to the illustrative examples in this specification. Rather, the invention is intended to cover all modifications and variations that come within the scope of the following claims and their equivalents.

Technology Classification (CPC): 8