KASANE hinge
the fold that seals, stops and locks itself
Two membranes and a gasket replace taped seams: a tight membrane on the axis face of each crease and a slack bellows on the face that opens carry air, rain and vapour across the fold, a structural edge closeout takes bearing, and a thermally broken latch carries the tension side of the crease moment.
- BYU membrane-fold surrogate hinge
- One thickness method per article: Tachi tapered…
- Tight axis-face membrane plus slack bellows or…
- Pultruded GFRP or hardwood edge closeouts as the…
- +5
How it works · 12 steps · 7 parts
- Facet panels are glass-FRP sandwiches with a PIR core: 80-120 mm for temperate sites; polar sites need 200-250 mm PIR-equivalent (U about 0.09-0.11 W/m2K at panel centre). A mycelium core is an option only where mass and U targets allow (it adds 7-24 kg/m2 at 120 mm).
- Every panel edge carries a structural closeout of pultruded GFRP or hardwood, 15-25 mm deep. This closeout, not the core, is the bearing surface; a 10-20 mm aerogel strip sits behind it to keep the thermal line continuous.
- Each test article uses one thickness method. The Miura wall uses Tachi tapered panels, which have a limited fold range, so its folded thickness is taken from the fold geometry. The vault uses Chen/You offset panels, which fold flat but need stack depth for the offset hinge lines. No packing figure assumes both at once.
- Rigid-foldability is checked before tooling: the crease pattern is run in a kinematic simulator (MERLIN or Origami Simulator) and must show zero facet strain through the whole fold. Patterns that need facet bending or snap-through (for example the classic Yoshimura) are not used for rigid thick panels.
- At each crease the rotation axis sits on one face, and that face alternates between mountain and valley creases. A tight vacuum-laminated PVDF-coated polyester membrane spans the crease on the axis face. On the opposite face the edge gap changes by about t x dTheta, so the membrane there is a slack loop or bellows of at least 1.2 x t x dTheta (about 230 mm for t = 120 mm and a 90 degree fold change; about 150 mm for t = 80 mm), or a bonded EPDM or silicone strip with at least 300% elongation.
- The inner layer is the vapour control layer and the outer layer the rain screen; at each valley the space between them drains to the sill gutter, with a heat-traced or self-draining outlet at cold sites.
- The offset or taper geometry lets each crease close only to its design dihedral; faces meet and stop it, so a wall cannot over-rotate even if a winch is mis-operated.
- At the design dihedral the edge closeouts bear on each other in compression. Under wind reversal the tension side of each crease moment passes through the latch, so the latch is a primary structural member: latch tension T is about M_crease / (0.8 t), and it is sized for fatigue as well as preload.
- The latch is thermally broken: a GFRP or polyamide body with a bronze cam only at the bearing point, mounted on the inside face behind the vapour layer so it does not pierce the membrane.
- An EPDM bulb gasket inside the membrane is compressed by the same latch preload as a second air barrier.
- Each latch carries a Hall-effect position sensor and a strain gauge; the module passport records engaged or not, and TSURU verifies every latch after deployment.
- A failed membrane or bellows strip is cut out over 300 mm and re-laminated with a field vacuum kit as an obi patch (target 30 minutes).
| Part | Material | Spec |
|---|---|---|
| Facet panel | Glass-FRP faces, PIR core (mycelium optional), aerogel strip behind edge closeout | 80-120 mm temperate, 200-250 mm PIR-equivalent polar; 10-12 kg/m2 at 120 mm PIR (calculated) |
| Edge closeout | Pultruded GFRP channel or hardwood | 15-25 mm deep bearing surface; allowable bearing stress from closeout datasheet, not from the core (PIR about 0.15-0.3 MPa) |
| Axis-face membrane | PVDF-coated polyester, vacuum laminated | tight across crease; target 2,000 fold cycles |
| Opening-face bellows | Slack PVDF-polyester loop, or EPDM/silicone sheet (>= 300% elongation) bonded to membrane | length >= 1.2 x t x dTheta (150 mm at 80 mm, 230 mm at 120 mm, 90 degree fold) |
| Over-centre latch | GFRP or polyamide body, bronze cam at bearing point only, stainless pin | primary tension member; T = M_crease / (0.8 t); 910 mm pitch; inside face behind vapour layer; Hall sensor |
| Backup gasket | EPDM bulb | compressed 30-40% at preload (target) |
| Obi repair kit | Membrane roll, adhesive, portable vacuum pump | 300 mm patch, 30 min (target) |
12-month prototype 2.4 m thick-panel Miura wall section (Tachi tapered panels) and a 3.64 m span x 1.82 m long rigid-foldable quadrilateral-panel vault strip (Chen/You offset panels; pattern verified at zero facet strain), both with axis-face membranes, opening-face bellows, edge closeouts, thermally broken latches and gaskets; a 2 x 2 x 2 m sealed test box built from the same facets; hinge coupons for ageing.
Pass No water penetration in the spray sequence; box q50 <= 1.5 m3/(h.m2); membrane and bellows intact and leakage rise < 25% after 2,000 cycles; latch preload retained within 10%; coupons pass ageing blocks; cone-calorimeter results consistent with a target of Euroclass B-s2,d0 (EN 13501-1), with NFPA 285 as the US route.
Kill Membrane delamination before 500 cycles, box q50 > 3.0 m3/(h.m2) with gasket, or water penetration at any opening-side crease (bellows): occupied enclosures revert to the v2 rule (fixed insulated rooms, origami only on unoccupied canopies and wings).
BOM USD 70,000-150,000 including rigs, chamber rental and lab fees (materials only about 18,000-35,000)
Risks UV and abrasion ageing of the coated fabric and bellows at outside creases · Ice formation in valley drainage channels and condensation at crease lines in cold climates · Fire performance of FRP and foam cores (no code route proven yet) · Thermal bridging at latches and edge closeouts · Latch fatigue under wind reversal · PFAS regulation of fluoropolymer coatings
EXPERIMENTAL: each ingredient is a prototype or lab result; the weathertight, insulated building hinge with an opening-face bellows is unbuilt and is the single most important risk in ORIJO.













