Blow-molded unitary structure with enhanced strength

Patent metadata

Field	Value
Publication number	US-11524812-B2
Application number	US-202117193421-A
Country	US
Kind code	B2
Filing date	Mar 5, 2021
Priority date	Apr 28, 2020
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

A blow-molded unitary structure includes a panel having first and second panel walls and a generally hollow interior between the first and second panel walls. The structure also includes a plurality of depressions, or at least one ridge, or both the depressions and ridge to enhance the strength of the structure. The plurality of depressions is monolithically formed with the panel, recessing from the second panel wall toward the first panel wall. A depression has a side wall composed of first and second segments. Cross-sectional-wise, the first and second segments have different widths and thus collectively forms a step between the first and second segments. A ridge is also monolithically formed with the panel and includes a section, at which the width of the ridge varies along the height direction of the ridge.

First claim

What is claimed is:

1. A blow-molded unitary structure comprising:
a panel comprising:
a first panel wall; and
a second panel wall spaced apart from the first panel wall in a first direction; and

a plurality of depressions monolithically formed with the first or second panel wall, each recessing from the second panel wall toward the first panel wall to enhance a strength of the panel, wherein each depression in the plurality of depressions comprises:
an open top at the second panel wall;
a closed bottom opposite to the open top; and
a depression side wall connecting the open top and the closed bottom,
wherein the depression side wall comprises a first depression side wall segment adjacent to the open top and a second depression side wall segment adjacent to the closed bottom,
wherein the first and second depression side wall segments have different lateral widths or diameters measured on planes substantially perpendicular to the first direction, and
wherein the first and second depression side wall segments are connected to each other by a step formed between the first and second depression side wall segments.

2. The blow-molded unitary structure of claim 1 , wherein the closed bottom is formed monolithically at the first panel wall or is part of the first panel wall.

3. The blow-molded unitary structure of claim 1 , wherein cross-sectional-wise, the first depression side wall segment is wider than the second depression side wall segment.

4. The blow-molded unitary structure of claim 3 , wherein the second depression side wall segment is tapered toward the first panel wall.

5. The blow-molded unitary structure of claim 1 , wherein on a cross section substantially coincident with the second panel wall, the open top of each depression in the plurality of depressions has a substantially polygonal shape.

6. The blow-molded unitary structure of claim 1 , wherein on a cross section substantially coincident with the second panel wall, the open top of each depression in the plurality of depressions has a substantially square shape, and the plurality of depressions is arranged in a pattern such that each edge of the substantially square shaped open top is oriented at an angle of substantially 45 degrees with respect to a panel side edge of the panel.

7. The blow-molded unitary structure of claim 1 , wherein a depression is separated from its adjacent depression in the plurality of depressions by a distance that is from substantially 3 times to substantially 7 times a distance separating the first and second panel walls.

8. The blow-molded unitary structure of claim 7 , wherein the distance separating adjacent depressions is measured from a center of the depression to a center of its adjacent depression, and the distance separating the first and second panel walls is measured from an exterior surface of the first panel wall to an exterior surface of the second panel wall.

9. The blow-molded unitary structure of claim 1 , wherein a distance separating the first and second panel walls is from substantially 4 times to substantially 7 times a thickness of the first or second panel wall.

10. The blow-molded unitary structure of claim 1 , further comprising:
a ridge monolithically formed with the panel, protruding beyond the second panel wall on a side opposite to the first panel wall.

11. A blow-molded unitary structure comprising:
a panel comprising a first panel wall, and a second panel wall spaced apart from the first panel wall in a first direction; and
a ridge monolithically formed with the panel and extended from the panel in the first direction beyond the second panel wall, the ridge comprising:
a first ridge side wall comprising a first ridge base edge and a first ridge top edge, the first ridge base edge joined with the first panel wall;
a second ridge side wall spaced apart from the first ridge side wall in a second direction, the second ridge side wall comprising a second ridge base edge and a second ridge top edge, the second ridge base edge joined with the second panel wall; and
a ridge top wall connecting the first ridge top edge of the first ridge side wall and the second ridge top edge of the second ridge side wall,

wherein at a first ridge section of the ridge, a distance measured from the second ridge side wall to the first ridge side wall varies along the first direction.

12. The blow-molded unitary structure of claim 11 , wherein at the first ridge section of the ridge, the distance measured from the second ridge top edge of the second ridge side wall to the first ridge side wall is from about 35% to about 70% of the distance measured from the second ridge base edge of the second ridge side wall to the first ridge side wall.

13. The blow-molded unitary structure of claim 11 , wherein at the first ridge section of the ridge, the first ridge side wall is substantially perpendicular to the first or second panel wall and the second ridge side wall is oblique with respect to the second panel wall.

14. The blow-molded unitary structure of claim 11 , wherein at the first ridge section of the ridge, the second ridge side wall includes a first segment joined with the ridge top wall and a second segment joined with the second panel wall, wherein one segment in the first and second segments is substantially perpendicular to the second panel wall and the other segment in the first and second segments is oblique with respect to the second panel wall.

15. The blow-molded unitary structure of claim 14 , wherein at the first ridge section of the ridge, the one substantially perpendicular segment has a height measured along the first direction that is less than about 70%, less than about 50%, less than about 30%, or less than about 10% of a distance measured along the first direction from the ridge top wall to the second panel wall.

16. The blow-molded unitary structure of claim 11 , wherein the first ridge section of the ridge forms a corner, and the second direction at the first ridge section is a radial direction of the corner.

17. The blow-molded unitary structure of claim 16 , wherein the corner formed by the first ridge section of the ridge is disposed at or adjacent to a corner of the panel.

18. The blow-molded unitary structure of claim 11 , wherein at a second ridge section adjacent to the first ridge section of the ridge, the distance measured from the second ridge top edge of the second ridge side wall to the first ridge side wall is substantially the same as the distance measured from the second ridge base edge of the second ridge side wall to the first ridge side wall.

19. The blow-molded unitary structure of claim 18 , wherein at least one depression is formed at the second ridge section to enhance a strength of the ridge.

20. A blow-molded unitary structure comprising:
a panel comprising a first panel wall, and a second panel wall spaced apart from the first panel wall in a first direction; and
a ridge monolithically formed with the panel and extended from the panel in the first direction beyond the second panel wall, the ridge comprising:
a first ridge side wall comprising a first ridge base edge and a first ridge top edge, the first ridge base edge joined with the first panel wall;
a second ridge side wall spaced apart from the first ridge side wall in a second direction, the second ridge side wall comprising a second ridge base edge and a second ridge top edge, the second ridge base edge joined with the second panel wall; and
a ridge top wall joined with the first ridge top edge of the first

Assignees

• Inno Sports Co Ltd

Inventors

• Choi Kwan Jun

Classifications

• B29C49/4812

  and welding opposite wall parts of the parisons or preforms to each other · CPC title

• A47B2200/001

  Manufacture of table tops · CPC title

• A47B13/08

  Table tops; Rims therefor (not restricted to table tops A47B95/04) · CPC title

• B29C49/0031

  Making articles having hollow walls · CPC title

• B29L2022/007

  integrally moulded or formed · CPC title