Patent Application
20240398119
The present invention relates to the field of supporting furniture, such as table, desk, shelf, rack, and the like, and more particularly to supporting furniture constructed with hollow fusion panel.
It is very common to use plastic to produce articles, such as plastic made furniture, toys and sports equipment. U.S. Pat. No. 6,112,674 discloses a banquet table which comprises a tabletop is made by blow molding and a pair of support pedestals pivotally attached thereto. U.S. Pat. Nos. 7,140,308, 7,100,519 and 8,677,912 disclose a foldable banquet table which comprises a tabletop made by injection molding and a pair of support pedestals pivotally attached thereto, as shown in
Different supporting furniture, such as desks as shown in
It would be environmental friendly and appreciated that if the tabletop or support panel can be made of plastic that not only reduces the weight of the products as well as their manufacturing cost and transportation cost, but also provides much longer life span especially plastic products are completely recyclable nowadays. For adjustable table, as shown in
Plastic made panel and manufacturing method thereof have many advantages that other materials cannot match, such as light weight, low cost, and easy shaping, while it also has some disadvantages, such as lower structural strength. In order to make up for the shortcomings of low structural strength of plastic panel, manufacturers generally design plastic panel structurally, for example designing additional reinforcing ribs or using improved materials, so as to strengthen the strength of plastic made supporting furniture.
Additional reinforcing ribs usually increase the overall weight of the plastic product, and the reinforcing ribs are generally provided on the underside of the plastic product to bear load and weight. If the plastic product is a tabletop board, the ribs may adversely affect the installation of the table legs, because the ribs may occupy the installation locations of the table legs.
To strengthen the strength of plastic products by means of various material properties usually requires a higher cost. For example, for larger tabletop boards, they require more materials and higher manufacturing costs, resulting in difficult to promote the use. Moreover, it is currently difficult to find a perfect plastic material that overcome the above shortcomings thereof while maintaining the advantages of plastic.
At present, there is a kind of plastic panel on the market, which has a hollow structure surrounded by upper and lower surfaces, wherein the lower surface and the upper surface are spaced apart and the lower surface extends toward the upper surface to support the upper surface. In this way, a plastic panel with lighter weight and higher structural strength is provided. However, due to the performance limitation of the plastic itself, the structural strength of this kind of plastic product is still relatively low, and that the upper surface may collapse due to long load bearing times during long periods of use. Additionally, during the manufacturing process of this kind of plastic panel, it is also necessary to pay attention to the spacing and separation of the upper and lower opposing surfaces that, if they are accidentally stuck together, it may cause uneven heat dissipation on the upper surface and produce defective products.
In order to solve the above-mentioned technical problems of the conventional art, the present invention provides a technical solution for a supporting furniture with blow-molded hollow fusion panel having a stable and strong structure while having good impact resistance and light in weight.
The present invention provides another technical solution for producing a compound structure of a supporting furniture with double-layer blow-molded hollow fusion panel having a good impact resistance, strong and stable structure, but light weight.
The present invention provides another technical solution for producing a compound structure of a three-layer hollow fusion panel having a good impact resistance, strong and stable structure.
The present invention provides another technical solution of a hollow fusion panel and producing method thereof, wherein the hollow fusion panel is made of a combination of new and recycled materials.
The present invention provides another technical solution of a hollow fusion panel and producing method thereof, wherein the hollow fusion panel is made of new material and at least 30% by mass of recycled material.
The present invention provides another technical solution of a hollow fusion panel and producing method thereof, wherein at least an outer layer of the upper panel member of the hollow fusion panel is made of new material and at least an inner layer of the hollow fusion panel is made of recycled material, up to 90% by mass of the hollow fusion panel.
The present invention provides another technical solution for providing a blow-molded hollow fusion panel for supporting furniture, comprising an upper panel member and a lower panel member, wherein the upper panel layer and the lower panel member are formed by blow-molding to form a hollow structure between the upper panel member and the lower panel member, wherein each of the upper panel member and the lower panel member includes an outer layer and an inner layer, wherein the lower panel member has a predetermined number of portions recessed in a direction toward the upper panel member until the inner layer of the lower panel member is fused with the inner layer of the upper panel member to form a predetermined number of joint supporting structures respectively.
The present invention provides another technical solution for providing a blow-molded hollow fusion panel for supporting furniture, comprising a first panel member and a second panel member, wherein the first and second panel members are made of different materials and formed by blow-molding to form a hollow structure between the first panel member and the second side panel member, wherein each of the first and second panel members includes one or more layers.
In one embodiment, the first panel member is an outer panel member and the second panel member is an inner panel member of the blow-molded hollow fusion panel, wherein the second panel member has a predetermined number of portions recessed in a direction toward the first panel member until an inner layer of the one or more layers of the second panel member is fused with an inner layer of the one or more layers of the one or more layers of the first panel member to form a predetermined number of joint supporting structures respectively.
In one embodiment, the first panel member is one of a right side panel member and a left side panel member and the second panel member is another one of the right side panel member and the left side panel member of the blow-molded hollow fusion panel, wherein the second panel member has a predetermined number of portions recessed in a direction toward the first panel member until an inner layer of the one or more layers of the second panel member is fused with an inner layer of the one or more layers of the one or more layer of the first panel member to form a predetermined number of joint supporting structures respectively.
In one embodiment, the first panel member is a top panel member and the second panel member is a bottom panel member of the blow-molded hollow fusion panel, wherein the second panel member has a predetermined number of portions recessed in a direction toward the first panel member until an inner layer of the one or more layers of the second panel member is fused with an inner layer of the one or more layers of the one or more layer of the first panel member to form a predetermined number of joint supporting structures respectively
In one embodiment, a portion of the inner or lower panel member is recessed in a direction toward the outer or upper panel member until the inner layer of the lower panel member is fused with the inner layer of the upper panel member to form a plurality of supporting structures.
In one embodiment, each of the upper (outer) panel member and the lower (inner) panel member includes an outer layer, an intermediate layer and an inner layer, wherein the lower panel member has a predetermined number of portions of the lower panel member is recessed in a direction toward the upper panel member until the inner layer of the lower panel member is fused with the inner layer of the upper panel member to respectively form a predetermined number of joint supporting structures distributed in a predetermined manner.
In one embodiment, at least one of the intermediate layer and the inner layer of the upper panel member and the lower panel is made of recycled material.
In one embodiment, at least the outer layer of each of the upper panel member and the lower panel member is made of nylon or new material of high density polyethylene, and at least one of the intermediate layer and the inner layer of the upper panel member and the lower panel is made of recycled material of high density polyethylene.
In one embodiment, the mass percentage of the outer layer is approximately 5-6%, the mass percentage of the intermediate layer is approximately 2-3% and the mass percentage of the inner layer is approximately 90%.
In order to improve the strength of an edge structure of the hollow fusion panel, the upper panel member has an outer bending wall downwardly bent from an outer edge thereof, and the lower panel member has an inner bending wall downwardly bent from an outer edge thereof, wherein a bottom of the inner layer of the outer bending wall and a bottom of the inner layer of the inner bending wall are fused and integrated with each other.
In order to improve the structural strength of the hollow fusion panel, the joint supporting structure can be embodied a point structure or an elongated strip structure.
In one embodiment, at least one reinforcing rib is provided at the joint supporting structure.
In one embodiment, the joint supporting structure is constructed to have two reinforcing ribs and, correspondingly, three contact peak points which are arranged at intervals with the two reinforcing ribs.
The present invention provides another technical solution for providing the layer of the raw material structure of a double-layer blow-molded hollow fusion panel, wherein the outer layer of each of the upper (outer) panel member and the lower (inner) panel member are made of high density polyethylene, and the inner layer of the upper (outer) panel member and the lower (inner) panel member both use a mixture selected from high density polyethylene, metallocene polyethylene and calcium carbonate, or that both the upper panel member and the lower panel member use a mixture selected from high density polyethylene, metallocene polyethylene and glass fiber.
In one embodiment, for the inner layer, the mass percentage of the metallocene polyethylene is 10-15%, the mass percentage of the calcium carbonate is 15-20%, and the rest is high density polyethylene. Alternatively, the mass percentage of the metallocene polyethylene is 10-15%, the mass percentage of the glass fiber is 15-25%, and the rest is high density polyethylene.
The present invention provides another technical solution that: according to the compound material structure of a double-outer single-inner three-layer blow-molded hollow fusion panel of each of the upper panel members and lower panel members, the outer layers of the upper panel member and the lower panel member are both made of high density polyethylene, and the intermediate layers of the upper panel member and the lower panel member are both made of a mixture selected from high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber, and the inner layers of the upper panel member and the lower panel member are both made of metallocene polyethylene.
In one preferred embodiment, for the intermediate layer, the mass percentage of high density polyethylene is 70-85% and the mass percentage of calcium carbonate is 15-30%.
In another preferred embodiment, for the intermediate layer, the mass percentage of high density polyethylene is 60-85% and the mass percentage of the glass fiber is 15-40%.
In one embodiment, the metallocene polyethylene, the calcium carbonate, glass fiber, and the high density polyethylene for producing the inner layer and/or the intermediate layer are recycled materials.
Compared with the conventional art, the advantage of the present invention is that the multi-layer blow-molded hollow fusion panel only utilizes the blow-molded hollow structure of the upper (outer) and lower (inner) panel members to construct a lightweight, rigid, and impact-resistant hollow fusion panel structure, wherein a predetermined number of portions of the lower panel member is recessed in the direction toward the upper panel member until the inner layer of the lower panel member and the inner layer of the upper panel member are fused with each other to respectively form a predetermined number of joint supporting structures distributed in a predetermined manner to improve the structural strength of the hollow fusion panel. The outer layer can be made of materials with high surface strength, scratch resistance and oil resistance. The inner layer can be made of materials with low thermoplastic shrinkage ratio to provide a frame support effect. When the intermediate layer is made of materials with high toughness, elasticity and energy absorption, the intermediate layer is able to provide a buffering effect to effectively alleviate the damage to the panel due to impact and drop, thereby further improving the overall structural strength of the hollow fusion panel.
An advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the hollow fusion panel has a structure that has excellent properties, such as excellent structural strength performance while being manufactured to have a thinner thickness.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the hollow fusion panel includes a first panel member and a second panel member arranged opposing with each other correspondingly, wherein one or more portions of the second panel member extend toward the first panel member to be fused with one or more portions of the first panel member respectively to form a predetermined number of supporting structure, which can be conducive to enhancing the structural strength of the hollow fusion panel.
In one embodiment, at least the outer layer of at least one of the first panel member and the second panel member is made of nylon or new material of high density polyethylene, and at least one of the intermediate layer and the inner layer of the upper panel member and the lower panel is made of recycled material of high density polyethylene.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the fusion of the supporting structure and the first panel member enables a thickness of the entire hollow fusion panel can be reduced.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein due to the fusion of the supporting structure and the first panel member, a thickness of the joint between the supporting structure and the first panel member can be smaller than the sum of the thickness of the supporting structure and the thickness of the first panel member. In other words, the thickness at this joint position can be reduced in comparison with the condition without or before the fusion, that facilitates heat dissipation during the manufacturing process.
Another advantage of the invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the hollow fusion panel has better impact resistance.
Another advantage of the invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein at least a portion of the blow fusion panel can be made of recycled plastic, and the surface color of the hollow fusion panel can be selected in different colors according to the requirement and actual need.
Another advantage of the invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the hollow fusion panel is constructed to have a hollow structure that the upper panel member and lower panel member are spaced apart from each other to achieve a lightweight feature and to enhance the structural strength.
Another advantage of the invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the hollow fusion panel is constructed to have the first member and the second member each being configured to have two or more layer structure, wherein different layers are made of different materials to provide different performances so as to enhance the overall performance of the hollow fusion panel.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof, wherein the first panel member can be a double-layer or multi-layer structure, and the supporting structure can be fused with at least one layer of the first panel member, thereby facilitating a bonding strength of the first panel member and the second panel member.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof. In the conventional art, a certain distance is required to be maintained between the first panel member and the second panel member to prevent unwanted occurrence of melting collapse at the surface of the first panel member caused due to incorrect contact between the first panel member and the second panel member. In the present invention, since the first panel member can be a double-layer or multi-layer structure, the choice of materials with different properties to manufacture the first panel member can minimize the occurrence of melting collapse that may be caused at the interconnection of the first panel member and the second panel member.
Another advantage of the present invention is to provide a hollow fusion panel for supporting furniture and producing method thereof. In the conventional art, any possible contact area between the first panel member and the second panel member should be reduced as much as possible in order to reduce the occurrence of melting collapse caused by uneven heat dissipation due to the thicker thickness of the contacting position. In the present invention, since the first panel member and the second panel member of the hollow fusion panel can be fused at the joint position thereof, a thickness at such contacting position is reduced, thereby reducing the possibility of melting collapse occurrence.
According to one aspect of the present invention, the present invention provides a blow-molded hollow fusion panel for supporting furniture, which includes:
In one embodiment, the hollow integral structure of the hollow fusion panel comprises a first layer and a second layer, wherein the first layer and the second layer are at least partially overlapped and composited, the first panel member including one or two selected from at least a portion of the first layer, at least a portion of the second layer and at least a combining portion of at least a portion of the first layer and at least a portion of the second layer, the second panel member including one or two selected from at least a portion of the first layer, at least a portion of the second layer and at least a combining portion of at least a portion the first layer and at least a portion the second layer, wherein a plurality of portions of the second panel member is recessed in a direction toward the first panel member to form a predetermined number of supporting structures distributed in a predetermined manner, wherein each of the supporting structures forms a recessed cavity, wherein a plurality of the supporting structures and the first panel member are at least partially fused, such that a fusing area of the first panel member being fused and occupied by a corresponding supporting structure of the predetermined number of supporting structures is s and a thickness of the portion of the first panel member respective to the second panel member opposing arranged is t, where s/t2 is greater than 0.1.
According to one aspect of the present invention, the present invention provides a hollow fusion panel for supporting furniture, which includes:
According to one embodiment of the present invention, the hollow fusion panel is made of a combination of new and recycled materials.
According to one embodiment of the present invention, the hollow fusion panel is made of new material and at least 30% by mass of recycled material.
According to one embodiment of the present invention, at least an outer layer of the upper panel member of the hollow fusion panel is made of new material and at least an inner layer of the hollow fusion panel is made of recycled material, up to 90% by mass of the hollow fusion panel.
According to one embodiment of the present invention, each of the supporting structures is provided with at least one reinforcing rib which is positioned in the recessed cavity and extended integrally with the supporting structure.
According to one embodiment of the present invention, the second panel member extends toward the cavity to form at least one contact peak point, wherein each contact peak point is recessed in a direction toward the first panel member until being connected with the first panel member.
According to one embodiment of the present invention, the reinforcing rib is a U-shape wave-like structure formed from at least portion of the corresponding supporting structure protruding and extending toward the first panel member, wherein the reinforcing rib is transversally extended across a bottom of the recessed cavity to form at least one contact peak point correspondingly, and the contact peak point is recessed toward the first panel member until connecting with the first panel member.
According to another aspect of the present invention, the present invention provides a hollow fusion panel for supporting furniture, which includes:
According to one embodiment of the present invention, multiple portions of the second panel member are recessed toward the first panel member to form a predetermined number of supporting structures distributed in a predetermined manner, wherein each of the supporting structures forms a recessed cavity.
According to one embodiment of the present invention, each of the supporting structures is provided with at least one reinforcing rib positioned in the recessed cavity and integrally extended with the supporting structure.
In accordance with another aspect of the invention, the present invention comprises a method of manufacturing a hollow fusion panel for supporting furniture, which comprises the steps of:
According to one embodiment of the present invention, at least one of the first polymer material and the second polymer material has a first polymer and a second polymer which are heated to fluid state and extruded to form a first layer and a second layer fused with each other, wherein the first layer is located at an outer side of the corresponding first or second side polymer layer.
According to one embodiment of the present invention, each of the first polymer material and the second polymer material has a first polymer and a second polymer which are heated to fluid state and extruded to form a first layer and a second layer fused with each other, wherein the first layer of the first side polymer layer is located at an outer side of the first panel member and the first layer of the second side polymer layer is located at an outer side of the second panel member.
According to one embodiment of the present invention, at least one of the first polymer and the second polymer includes recycled material of thermoplastic polymer.
In accordance with another aspect of the invention, the present invention comprises a method of manufacturing a hollow fusion panel for supporting furniture, which comprises the steps of:
According to one embodiment of the present invention, at least one of the first polymer and the second polymer includes recycled material of thermoplastic polymer.
According to the preferred embodiment, the method further comprises a step of:
According to one embodiment of the present invention, at least one of the first polymer, the second polymer and the third polymer is recycled material of thermoplastic polymer.
According to the preferred embodiment, the method further comprises a step of:
According to the preferred embodiment, the portion of the second panel member is stretched and recessed toward the first panel member until the second polymer layer of the second panel member is fused with the second polymer layer of the first panel member to form the peak point.
According to the preferred embodiment, the method further comprises a step of:
According to the preferred embodiment, the fused body corresponding to the second panel member is stretched and recessed in the molding die toward the cavity to form the supporting structure and is protruded outwardly to form at least one reinforcing rib, wherein the reinforcing rib is located in the recessed cavity and is integrally extended to the supporting structure.
According to the preferred embodiment, the reinforcing rib is defined at a portion of the supporting structure which is protruded toward the first panel member and is formed in a U-shaped wave form, wherein the reinforcing rib is extended along a bottom of the recessed cavity.
The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments in the following description are merely examples, and those skilled in the art can think of other obvious variations. The basic principles of the present invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.
Those skilled in the art should understand that in the disclosure of the present invention, the terms of the orientation or positional relationship indicated by “longitudinal”, “lateral”, “upper”, “lower”, “front”, “rear”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inner”, “outer”, etc. are based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, so the above terms should not be understood as limiting the present invention.
It can be understood that the structure disclosed according to the present invention may have other suitable shapes, sizes, configurations, arrangements and features. It can be understood that the term “a” should be understood as “at least one” or “one or more”, that is, in one embodiment, the number of an element may be one, while in other embodiments, the number can be more than one, and the term “one” cannot be understood as a restriction on the number. The detailed description of the exemplary embodiment is as follows.
The present invention will be further described in detail below with reference to the preferred embodiment of the drawings.
Referring to
Each of the upper (outer) panel member 1 and the lower (inner) panel member 2 according to the preferred embodiment has a three-layer structure that each includes an outer layer 3, an intermediate layer 5, and an inner layer 4. Also, the lower panel member 2 is facing upwards, that is in the direction toward the upper panel member 1, and is recessed until the inner layer 4 of the lower panel member 2 being fused with the inner layer 4 of the upper panel member 1 to form a predetermined number of joint supporting structures 6 distributed in a predetermined manner.
An edge structure of the multi-layer hollow fusion panel 1′ is described as follows. As shown in
According to the preferred embodiment, each of the joint supporting structures 6, having a sinusoidal waveform and a recessed cavity therein, is configured to have an elongated shape or strip shape. As shown in
For the raw material structure of the double-outer single-inner three-layer multi-layer hollow fusion panel 1′: the outer layers 3 of the upper panel member 1 and the lower panel member 2 are both made of high density polyethylene. The intermediate layers 5 of the upper panel member 1 and the lower panel member 2 are made of a mixture selected from high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber. The inner layers 4 of the upper panel member 1 and the lower panel member 2 are made of metallocene polyethylene.
It is appreciated that only the outer layer 3 of the upper panel member 1 is an exterior portion that is being exposed to outside, so that only the outer layer 3 of the upper panel member 1 is required to be made of new material of high density polyethylene. The intermediate layer 5 and the inner layer 4 of the upper panel member 1 are interior portions and thus the intermediate layer 5 and the inner layer 4 of the upper panel member 1 can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the intermediate layer 5 and the inner layer 4 of the upper panel member 1 can be recycled materials.
Similarly, if the outer layer 3 of the lower panel member 2 is also an exterior portion that is being exposed to outside, the outer layer 3 of the lower panel member 1 is made of new material of high density polyethylene, and the raw materials of the intermediate layer 5 and the inner layer 4 of the lower panel member 2 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the intermediate layer 5 and the inner layer 4 of the lower panel member 2 can be recycled materials.
It is worth mentioning that when the hollow fusion panel 1′ of the present invention is used to construct as a tabletop, a shed, a storage container, a construction panel, and etc. that the lower panel member 2 does not require to be exposed to outside, the outer layer 3, the inner layer 4 and the intermediate layer 5 of the lower panel member 2 can all be made of recycled materials or a mixture of new and recycled materials.
As a result, the outer layer 3 has the properties of high surface strength, scratch resistance, and oil resistance. The inner layer 4 has a low thermoplastic shrinkage ratio and provides rigid frame structure support. The intermediate layer 5 has a predetermined elasticity and energy absorption and high strength, and provides an effective buffering effect to any impact and drop which may damage the panel.
According to the preferred embodiment of the present invention, when the intermediate layer 5 is made of a mixture of high density polyethylene and calcium carbonate, the mass percentage of high density polyethylene is 70% to 85%, and the mass percentage of calcium carbonate is 15% to 30%.
According to the preferred embodiment of the present invention, when the intermediate layer 5 is made of high density polyethylene and glass fiber, the mass percentage of high density polyethylene is 60% to 85%, and the mass percentage of glass fiber is 15% to 40%.
It should be noted that the mass percentage of the high density polyethylene, calcium carbonate, glass fiber mentioned above can be applied to both the new material or recycled material thereof. Preferably, since the high density polyethylene is the major content of the intermediate layer 5 and the inner layer 4, it can be made that only the high density polyethylene is recycled material.
New high density polyethylene is made by combining ethylene molecules to form polymer chains through synthetization and polymerization process, ethylene is derived from crude oil or natural gas, wherein ethylene is a key feedstock for the production of high density polyethylene. For high-pressure polymerization, ethylene gas is subjected to high pressure and temperature in the presence of a catalyst, that leads to the formation of high density polyethylene. For low-pressure or Ziegler-Natta polymerization, a catalyst, such as a transition metal compound, is used to facilitate the polymerization of ethylene at low pressure.
To recycle high density polyethylene, plastic products such as bottles, containers, pipes, jugs, and the like are collected and sorted for the high density polyethylene material HDPE, such as polypropylene (PP) or polyethylene terephthalate (PET) are separated. Typical recycling process, but not limited to, includes shredding the collected high density polyethylene materials into small pieces, washing the shredded plastic thoroughly to remove contaminants, melting down the clean high density polyethylene flakes, and extruding the melted high density polyethylene in predetermined shape, such as small pellets or granules, to make recycling high density polyethylene for use.
According to the preferred embodiment, each of the upper panel member 1 and the lower panel member 2 of the multi-panel multi-layer hollow fusion panel 1′ is configured to have the above-mentioned double-outer single-inner three-layer structure, so that when the outer layer 3 is strongly impacted and dropped, the inner layer 4 can actively even break to absorb the energy, and that since the material of the intermediate layer 5 has a resilience tension, the inner layer 4 can still be reset to its original position so as to ensure the integrity and function of the entire panel. Therefore, the hollow composite panel of the present invention has the advantages of high surface strength, high flatness, overall impact resistance, deformation resistance, more stable structure, higher performance, and longer service life.
The multi-panel multi-layer hollow fusion panel 1′ can be applied to many different applications. For example, it can be applied to tables and chairs, such as tabletop panels, seat panels and back panels of chairs, furniture, sheds, storage containers, and etc., It can also be applied to other products where the panel is not easy to break. It can also be applied to construction materials such as wall partitions, wall panels, door panels, fence panels, outdoor floors, insulation panels, screen panels, and partition panels.
According to the preferred embodiment of the present invention, the parameters of the high density polyethylene used in the outer layer 3 are as follows:
According to the preferred embodiment of the present invention, the parameters of the high density polyethylene used in the intermediate layer 5 are as follows:
According to the preferred embodiment of the present invention, the parameters of the metallocene polyethylene used in the inner layer 4 are as follows: melting fat: 2.0 g/10 min; elongation at break: 420% in longitudinal direction and 830% in transverse direction; tensile strength at break: 62 MPa in longitudinal direction, 25 MPa in transverse direction; dart impact strength <48 g; and Eikmandorf tearing strength: 21° C. in longitudinal direction, 430° C. in transverse direction.
Furthermore, a person who skilled in the art should understand that, as an example of a simplified application, the outer layer 3, the intermediate layer 5 and the inner layer 4 can be made of the same material (new and/or recycled material) or the material with different grades or different levels. For example, the outer layer 3, the intermediate layer 5 and the inner layer 4 can be made of high density polyethylene. In addition, the outer layer 3 can be made of material having high hardness level and bright color, the intermediate layer 5 can be a composite layer, and the inner layer 3 can be made of recycled materials and a predetermined proportion of structural filling materials. These configurations can save the material cost and allow quick color changing capability.
As shown in
The raw material structure of the double-layer multi-layer hollow fusion panel 1′ is as follows: the outer layers 3 of the upper panel member 1 and the lower panel member 2 are both made of high density polyethylene, and the inner layers 4 of the upper panel member 1 and the lower panel member 2 are made of a mixture selected from high density polyethylene, metallocene polyethylene and calcium carbonate, or both made of a mixture of high-density polyethylene, metallocene polyethylene and glass fiber.
As a result, the outer layer 3 has the properties of high surface strength, scratch resistance, and oil resistance. The inner layer 4 has a low thermoplastic shrinkage ratio and provides rigid frame structure support which also has a predetermined elasticity and energy absorption and high strength and provides an effective buffering effect to any impact and drop which may damage the panel.
According to this alternative mode of the preferred embodiment of the present invention, for the inner layer 4, the mass percentage of the metallocene polyethylene is 10% to 15%, the mass percentage of calcium carbonate is 15% to 20%, and the rest is high density polyethylene. Alternatively, for the inner layer 4, the mass percentage of the metallocene polyethylene is 10% to 15%, the mass percentage of the glass fiber is 15% to 25%, and the rest is high density polyethylene.
Also, when the outer layer 3 of the upper panel member 1 is an exterior portion that is being exposed to outside, only the outer layer 3 of the upper panel member 1 is required to be made of new material of high density polyethylene. The inner layer 4 of the upper panel member 1 is an interior portion that can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the inner layer 4 of the upper panel member 1 can be recycled materials.
Similarly, if the outer layer 3 of the lower panel member 2 is also an exterior portion that is being exposed to outside, the outer layer 3 of the lower panel member 1 is made of new material of high density polyethylene, and the raw materials of the inner layer 4 of the lower panel member 2 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the inner layer 4 of the lower panel member 2 can be recycled materials.
Further, when the hollow fusion panel 1′ of the present invention is used to construct as a tabletop, a shed, a storage container, a construction panel, and etc. that the lower panel member 2 does not require to be exposed to outside, the outer layer 3 and the inner layer 4 of the lower panel member 2 can all be made of recycled materials or a mixture of new and recycled materials.
Same as the preferred embodiment, the mass percentage of the high density polyethylene, calcium carbonate, glass fiber mentioned above can be applied to both the new material and recycled material thereof. Preferably, since the high density polyethylene is the major content of the intermediate layer 5 and the inner layer 4, it can be made that only the high density polyethylene is recycled material.
In addition, the parameter performance of the high density polyethylene and metallocene polyethylene used in this alternative mode can refer to the above preferred embodiment, which will not be further described here.
The above descriptions are for the preferred embodiment and its alternative mode of the present invention. It should be pointed out that for a person who skilled in the art, without departing from the principle of the present invention, various modifications or improvements can be made to the present invention. For example, the outer layer 3, the intermediate layer 5, and the inner layer 4 of the upper layer member 1 and the outer layer 3, the intermediate layer 5, and the inner layer 4 of the lower layer member 2 can be configured to have more than one layer structure, which should be within the scope of the present invention.
Referring to
The hollow fusion panel 1′ can be constructed as a panel having a relatively thinner thickness with excellent performance. The hollow fusion panel 1′ may include a first panel member 30′ and a second panel member 40′, wherein at least a portion of the first panel member 30′ and at least a portion of the second panel member 40′ is configured to maintain a predetermined distance to define at least one cavity 100′ therebetween and surroundingly to form a hollow panel structure.
A plurality portions of the second panel member 40′ is extended toward the first panel member 30′ to form a predetermined number of supporting structures 41′ arranged in predetermined patterns, wherein the supporting structures 41′ are respectively extended to the first panel member 30′ until being fused with the first panel member 30′ during thermal blow molding.
At least portions of the second panel member 40′ are stretched and recessed towards the first panel member 30′ to form the supporting structures 41′. In other words, without increasing the overall weight of the hollow fusion panel 1′, the supporting structures 41′ are formed with respect to the first panel member 30′ to provide supporting effect so as to enhance the overall strength of the entire hollow fusion panel 1′.
In addition, since the second panel member 40′ is stretched and recessed to form the supporting structures 41′, at least some portions of the second panel member 40′ can be thinner in thickness, so that the thickness of the entire hollow fusion panel 1′ can be reduced. In other words, comparing with the conventional blow-molded panels, the hollow fusion panel 1′ of the present invention can provide better structural strength while having a thinner thickness.
Further, since the second panel member 40′ has the supporting structures 41′ formed and extended to the first panel member 30′ and the inner side of the first panel member 30′ and at least portions of the second panel member 40′ are fused with each other, during the using of the hollow fusion panel 1′, the overall impact resistance of the entire hollow fusion panel 1′ is improved accordingly while subjected to an external collision or impact due to the mutual contact and fusion between the first panel member 30′ and the second panel member 40′.
Due to the fusion of the supporting structures 41′ and the first panel member 30′, the thickness of the fusion positions where the supporting structures 41′ fuse and connect with the first panel member 30′ can be reduced that facilitates heat dissipation at these positions. In detail, if the second panel member 40′ forms the supporting structures 41′ that extend to only attach to the first panel member 30′, then the thickness at each attaching position of the first panel member 30′ and the second panel member 40′ is equal to the sum of the thickness of the first panel member 30′ and the second panel member 40′ at the corresponding attaching position. For the first panel member 30′, since the thickness at each of the attaching positions is greater than that of other adjacent positions, heat may accumulate in these attaching positions during the manufacturing process, that will affect the quality of the final product, such as uneven shrinkage problem caused by uneven heat dissipation.
However, the fusion of the supporting structure 41′ and the first panel member 30′ can improve the above problem. By means of the fusion of the supporting structures 41′ of the second panel member 40′ and the first panel member 30′, the material of the second panel member 40′ forming the supporting structures 41′ merges into the first panel member 30′, and the material of the first panel member 30′ merges into the supporting structures 41′. It is understood that gaps between the materials forming the first panel member 30′ and the supporting structures 41′ of the second panel member 40′ are eliminated due to the mutual fusion of the supporting structures 41′ and the first panel member 30′, so that the thickness of each of the fusion positions of the first panel member 30′ and the supporting structures 41′ would be less than the sum of the thickness of the first panel member 30′ and the thickness of the supporting structure before fusion, such that the heat dissipation problem can thus be improved.
In addition, due to the mutual fusion of materials, the structure between the supporting structure 41′ and the first panel member 30′ is more tight and rigid.
Furthermore, the hollow fusion panel 1′ is configured as a multilayer structure. However, in the conventional art, the entire plastic panel is usually made of the same material while being required to achieve the desired structural strength, scratch resistance, impact resistance, and etc. A high performance plastic panel needs to achieve a variety of excellent performance through the same material, which undoubtedly requires the material itself to have higher requirements, so that it is often necessary to use more expensive modified materials, or that it is often necessary to redesign the structure of the plastic panel, expecting to obtain panels with excellent performance through structural improvements other than the materials.
In the preferred embodiment, the hollow fusion panel 1′ is designed as a multilayer structure, so different materials can be used to composite and meet different performance requirements, thereby lowering the demands and requirements of the materials to be used as a whole.
In detail, in this embodiment, the hollow fusion panel 1′ may include a first layer 10 and a second layer 20, wherein the first layer 10 and at least a portion of the second layer 20 are overlapped and composited. The first panel member 30′ may include one or two selected from a combination of a portion of the first layer 10 and at least a portion of the second layer 20, and the second panel member 40′ may include one or two selected from a combination of other at least a portion of the first layer 10 and the other portion of the second layer 20.
The hollow fusion panel 1′ can be implemented as that the first panel member 30′ includes at least a portion of the first layer 10, and the second panel member 40′ includes at least the other portion of the first layer 10 and the entire second layer 20.
The hollow fusion panel 1′ can also be implemented as that the first panel member 30′ includes at least a portion of the first layer 10 and the entire second layer 20, and the second panel member 40′ includes at least the other portion of the first layer 10.
The hollow fusion panel 1′ can also be implemented as that the first panel member 30′ includes at least a portion of the first layer 10 and at least a portion of the second layer 20, and the second panel member 40′ includes at least the other portion of the first layer 10 and at least the other portion of the second layer 20. In this embodiment, the first layer 10 and the second layer 20 are overlapped and composited to form both the first panel member 30′ and the second panel member 40′.
It is worth mentioning that the term “layer” in the disclosure does not refer that the first layer 10 or the second layer 20 must have an apparent boundary therebetween. The first layer 10 and the second layer 20 can be made of the same material, and the connecting boundary between the first layer 10 and the second layer 20 can be obvious or can also be blurred, such as a fusion, bonding, superimposed, or laminated integral composite structure. The first layer 10 and the second layer 20 may also be made of different materials. In particular, the first panel member 30′ includes at least portion of the first layer 10 and at least portion of the second layer 20, wherein at least portions of the first layer 10 and the second layer 20 can be overlapped and composited with each other to form the first panel member 30′.
In the preferred embodiment, the first layer 10 and the second layer 20 are fused with each other at the overlapping junction thereof as an example for description.
Further, in this embodiment, the first layer 10 and the second layer 20 of the hollow fusion panel 1′ are both arranged to be continuous layers, and the first layer 10 and the second layer 20 are completely overlapped. The first layer 10 is an outer layer located outside and the second layer 20 is an inner layer located inside. The second layer 20 surrounds to define the cavity 100′ and the first layer 10 is arranged around the second layer 20.
While only the first layer 10 of the first panel member 30′ is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30′ is required to be made of a new material of high density polyethylene. The second layer 20 of the first panel member 30′ are interior portions and thus the second layer 20 of the first panel member 30′ can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 of the first panel member 30′ can be recycled materials.
Similarly, if the first layer 10 of the second panel member 40′ is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40′ is made of new material of high density polyethylene, and the raw materials of the second layer 20 of the second panel member 40′ can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 of the lower panel member 2 can be recycled materials. It is appreciated that when the second panel member 40′ does not require to be exposed to outside, the first layer 10 and the second layer 20 of the second panel member 40′ can all be made of recycled materials or a mixture of new and recycled materials.
Further, the hollow fusion panel 1′ may further include a third layer 50, wherein the second layer 20 is located between the first layer 10 and the third layer 50, wherein the third layer 50 and at least portion of the second layer 20 are overlapped and fused with each other.
The first panel member 30′ may include one or more selected from a combination of at least portion of the first layer 10, at least portion of the second layer 20, and at least portion of the third layer 50. The second panel member 40′ may include one or more selected from a combination of at least the other portion of the first layer 10, at least the other portion of the second layer 20, and at least the other portion of the third layer 50.
It is understandable that the first panel member 30′ can be a single-layer, double-layer, triple-layer, or multi-layer structure, and the second panel member 40′ can also be a single-layer, double-layer, triple-layer, or multi-layer structure, for example, referring to
In this embodiment, the first panel member 30′ includes at least portion of the first layer 10, at least portion of the second layer 20, and at least portion of the third layer 50. The second panel member 40′ includes at least the other portion of the first layer 10, at least the other portion of the second layer 20, and at least the other portion of the third layer 50. An inner wall of the third layer 50 defines the cavity 100′.
The supporting structure 41′ may each includes one or more selected from a combination of at least portion of the first layer 10, at least portion of the second layer 20 and at least portion of the third layer 50. It can be understood that the number of layers of the supporting structure 41′ and the other portion of the second panel member 40′ may be the same or may be different. In this embodiment, the supporting structures 41′ each includes at least portion of the first layer 10, at least portion of the second layer 20 and at least portion of the third layer 50. In other words, the first layer 10, the second layer 20, and the third layer 50 of the second panel member 40′ extend inwardly at predetermined positions to form the predetermined number of supporting structures 41′ respectively.
The first layer 10 of the hollow fusion panel 1′ is configured to have an excellent first performance, the second layer 20 is configured to have an excellent second performance, and the third layer 50 is configured to have excellent third performance. While the first layer 10 has the excellent first performance, the requirements of the second performance and the third performance can be lowered. While the second layer 20 has the excellent second performance, the requirements of the first performance and the third performance can be lowered. While the third layer 50 has the excellent third performance, the requirements of the first performance and the second performance can be lowered.
Accordingly, the hollow fusion panel 1′ including the first layer 10, the second layer 20 and the third layer 50 finally has the excellent first performance, second performance and third performance overall, but does not need to rely on any material that meets the requirements of the first performance, the second performance and the third performance at the same time.
The layers of the hollow fusion panel 1′ are designed to have different performances. For example, the first layer 10 is designed to be scratch-resistant and has better scratch-resistant performance than the second layer 20 and the third layer 50. For example, the second layer 20 is designed to be impact resistant and has better impact resistance performance than the first layer 10 and the third layer 50. For example, the third layers 30′ is designed to have better supporting strength and has better supporting strength performance than the first layer 10 and the second layer 20.
Optionally, the first layer 10 may be made of high density polyethylene, the second layer 20 may be made of high density polyethylene plus or high density polyethylene plus glass fiber, and the third layer 50 may be made of metallocene polyethylene.
When the first layer 10 of the hollow fusion panel 1′ is made of high density polyethylene, the relative parameters of the high density polyethylene may be melting fat: 1.5 g/10 min, bending strength: 900 MPa, and Shore D69.
When the second layer 20 of the hollow fusion panel 1′ is made of high density polyethylene plus calcium carbonate, the mass percentage of calcium carbonate can be 15% to 30%, and the mass percentage of high density polyethylene can be 70% to 85%. In addition, the relative parameters of the high density polyethylene can be melting fat: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.
When the second layer 20 of the hollow fusion panel 1′ is made of high-density polyethylene and glass fiber, the mass percentage of glass fiber can be 15% to 40%, and the mass percentage of high density polyethylene can be 60% to 85%. Also, the relative parameters of high density polyethylene can be melting fat: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.
When the third layer 50 of the hollow fusion panel 1′ is made of metallocene polyethylene, the relative parameters of the metallocene polyethylene can be melting fat: 2.0 g/10 min, elongation at break: 420% in longitudinal direction, 830% in transverse direction, tensile strength at break: 62 MPa in longitudinal direction, 25 MPa in transverse direction, dart impact strength <48 g, Eikmandorf tear strength: 21° C. in longitudinal direction and 430° C. in transverse direction.
Further, the first panel member 30′ and a portion of each of the supporting structures recessed from the second panel member 40′ can be fused with each other for producing more beneficial effects. In particular, in this embodiment, portions of the third layer 50 of the first panel member 30′ and portions of the third layer 50 of the supporting structures 41′ are fused with each other. It is worth mentioning that the fusion of the first panel member 30′ and the second panel member 40′ does not necessarily require that the materials of the two fusing positions of the first panel member 30′ and the second panel member 40′ be the same before the fusion, wherein person skilled in the art is capable of selecting suitable materials according to requirements.
In addition, when only the first layer 10 of the first panel member 30′ is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30′ is required to be made of a new material of high density polyethylene. The second layer 20 and third layer 50 of the first panel member 30′ are interior portions and thus the second layer 20 and the third layer 50 of the first panel member 30′ can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 and the third layer 50 of the first panel member 30′ can be recycled materials.
Similarly, if the first layer 10 of the second panel member 40′ is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40′ is made of new material of high density polyethylene, and the raw materials of the second layer 20 and the third layer 50 of the second panel member 40′ can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 and the third layer 50 of the lower panel member 2 can be recycled materials.
It is worth mentioning that when the hollow fusion panel 1′ of the present invention is used to construct as a tabletop, a shed, a storage container, a construction panel, and etc. that the second panel member 40′ does not require to be exposed to outside, the first layer 10, the second layer 20 and the third layer 50 of the second panel member 40′ can all be made of recycled materials or a mixture of new and recycled materials.
Alternatively, the first layer 10 can be made of a material or a combination of materials selected from nylon and high density polyethylene, the third layer 50 can be made of a material or a combination of materials selected from high density polyethylene, glass fiber, calcium carbonate and metallocene polyethylene, and the second layer 20 can be a bonding layer made of bonding adhesive adapted to better connecting the first layer 10 and the third layer 50 to form an integral body. In such configuration, the mass percentage of the first layer 10 can be 5-6%, the mass percentage of the second layer 20 can be 2-3%, and the mass percentage of the third layer can be as much as 90% or more. In this case, when only the first layer 10 of the first panel member 30′ is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30′ is required to be made of new material, i.e. new nylon and/or high density polyethylene. The third layer 50 of the first panel member 30′ is interior portions and thus the third layer 50 of the first panel member 30′ can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the third layer 50 of the first panel member 30′ can be recycled materials.
Similarly, if the first layer 10 of the second panel member 40′ is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40′ is made of a new material of high density polyethylene, and the raw materials of the third layer 50 of the second panel member 40′ can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the third layer 50 of the lower panel member 2 can be recycled materials. It is appreciated that when the second panel member 40′ does not require to be exposed to outside, the first layer 10 and the third layer 50 of the second panel member 40′ can all be made of recycled materials or a mixture of new and recycled materials.
Appreciated to the fusion configuration of the present invention, at least 30% of the raw material for producing the hollow fusion panel 1′ of the present invention can be recycled materials. In favor to the global environment, the hollow fusion panel 1′ of the present invention may contains up to 90% recycled materials. Preferably, 65% recycled material can be used to produce the hollow fusion panel 1′ of the present invention.
Before the first panel member 30′ and the second panel member 40′ where is closed thereto are fused with each other, the largest thickness of the hollow fusion panel 1′ is the contact position where the supporting structure contacting the first panel member 30′, that is such maximum thickness is the sum of a total thickness of the first layer 10, the second layer 20, and the third layer 50 of the first panel member 30′, and at total thickness of the first layer 10, the second layer 20, and the third layer 50 of the second panel member 40′.
After the first panel member 30′ and the second panel member 40′ are fused with each other, for example, two opposing third layers 30′ of the first panel member 30′ and the supporting structure 41′ of the second panel member 40′ are at least partially fused with each other, wherein a maximum thickness of the hollow fusion panel 1′ is less than the sum of the thickness of the first panel member 30′ and the thickness of the second panel member 40′, and is greater than or equal to a total thickness of partial thickness of the first layer 10, partial thickness of the second layer 20, and partial thickness of the third layer 50 of the first panel member 30′ plus partial thickness of the first layer 10 and partial thickness the second layer 20 of the second panel member 40′. The reason is that the third layer 50 part of the second panel member 40′ may be completely fused with the third layer 50 part of the first panel member 30′.
Accordingly, a thickness of the maximum thickness position of the hollow fusion panel 1′ can be decreased, thereby facilitating heat dissipation thereat.
In addition, since the second layer 20 and the third layer 50 can be made of different materials, the fusion of the first panel member 30′ and the supporting structure 41′ may render the heat dissipation of portions of the third layer 50 of the first panel member 30′ at those fusing positions being more difficult than that of before fusion with the supporting structure 41′, which may lead to different shrinkage rates at various positions of the third layer 50 of the first panel member 30′, which may further affect the corresponding portions of the second layer 20 and the first layer 10 of the first panel member 30′, resulting in uneven surface of the first panel member 30′. However, due to the multi-layer configuration of the first panel member 30′, the heat transfer efficiency and shrinkage rates of the first layer 10, the second layer 20 and the third layer 50 may be different. The heat dissipation may have a certain influence on the third layer 50, but this influence can be compensated or reduced as much as possible by selecting the right material to be used for the first layer 10 or the second layer 20.
Further, in the conventional art, relevant technicians would generally try to avoid any contact between the second panel member 40′ and the first panel member 30′ which are made of the same material as to reduce the defective rate of the product. Therefore, under the framework of the conventional art, it is necessary to arrange as many supporting structures 41′ as possible for supporting the first panel member 30′ as much as possible under the premise of smaller contact area. In the preferred embodiment, since the supporting structures 41′ can each maintain a certain contact area with the first panel member 30′, it is beneficial to the structural strength of the hollow fusion panel 1′ of the present invention while without affecting the product yield thereof. Accordingly, the number of the supporting structures 41′ does not need to be arranged as much as the conventional art does. In other words, the total number of the supporting structures 41′ can be reduced and the distance between the adjacent supporting structures 41′ can be reasonably enlarged to facilitate manufacturing, such as to facilitate demolding, and also to reduce the possibility of collateral influence of the adjacent supporting structures 41′ during the manufacturing process.
Further, in the conventional art, relevant technicians would try to avoid any contact between the second panel member 40′ and the first panel member 30′ to reduce product defective rate, especially when the first panel member 30′ is made thinner, wherein the increasing of the thickness at the inner side of the first panel member 30′ would cause adverse effect in heat dissipation for the first panel member 30′. Therefore, the thinner the panel thickness, the smaller the contact area between the first panel member 30′ and the second panel member 40′. However, according to the preferred embodiment of the present invention, larger contact area between the first panel member 30′ and the second panel member 40′ can be arranged, especially when a thinner first panel member 30′ is used, that is beneficial, on the one hand, to the support of the first panel member 30′, and on the other hand, to the firmness and rigidness of the integration of the first panel member 30′ and the second panel member 40′. In the conventional art, the contact area of the first panel member 30′ and the second panel member 40′ should be arranged as little as possible, or even have to avoid any contact of the first panel member 30′ and the second panel member 40′ other than the edge connection position of the first panel member 30′ and the second panel member 40′. In the preferred embodiment of the present invention, the total contact area of the supporting structures 41′ of the first panel member 30′ and the second panel member 40′ is relatively larger. When the first panel member 30′ is impacted, the impact force applied thereon can be quickly transmitted to the second panel member 40′, while the cavity 100′ formed between the first panel member 30′ and the second panel member 40′ can serve as a buffer and provide shock absorption effect.
According to the preferred embodiment of the present invention, the thickness of the first panel member 30′ of the hollow fusion panel 1′ may be referred as t, and this value would be an average thickness of the first panel member 30′. The contact area between the first panel member 30′ of the hollow fusion panel 1′ and the corresponding supporting structure 41′ at this fusing position is referred as s, and this value may be a mean value of the contact area between the plurality of supporting structures 41′ and the first panel member 30′. The ratio of the thickness of the first panel member 30′ of the hollow fusion panel 1′ to the contact area is x=s/t2. According to one embodiment of the present invention, t may be 2 mm and s may be 0.5 mm2, where x is 0.5/4=0.125. According to the preferred embodiment of the present invention, x may be greater than 0.1.
According to one embodiment of the present invention, the thickness of the first panel member 30′ of the hollow fusion panel 1′ may be referred as t, and the area of the first panel member 30′ occupied by the corresponding contact peak 43′ is referred as s. Then, t can be 3 mm and s can be 6 mm2, where x=s/t2=6/9, which is greater than 0.1.
Furthermore, each of the supporting structures 41′ can form a recessed cavity 400′, having a W-shaped cross-section, in a direction toward the first panel member 30′. The recessed cavity 400′, having an elongated oval shape, has a bottom portion with two arc-shape end peaks, and is defined by a surrounding peripheral edge wall inclinedly extending upwards and inwards to form the supporting structure 41′ for strengthening the second panel member 40′. Each of the supporting structures 41′ is provided with at least one reinforcing rib 42′. In this embodiment, each of the supporting structures 41′ is provided with a pair of the reinforcing ribs 42′, transversally extended across the bottom portion of the recessed cavity 400′, that is the relative top portion of the supporting structure 41′. It is worth mentioning that a wave-shaped structure is an ideal reinforcing structure, so the pair of wave-shaped reinforcing ribs 42′ also forms the above-mentioned three-peak wave supporting structure 41′, which greatly strengthens the impact resistance and robustness of the second panel member 40 ‘.
The supporting structure 41’ can extend toward the first panel member 30′ to form at least one contact peak point 43′, wherein the first panel member 30′ fuses with the second panel member 40′ at the contact peak point 43′. In this example, each of the supporting structures 41′ forms three contact peak points 43′, such that when the first panel member 30′ is impacted, the combining of the contact peak points 43′ with the first panel member 30′ provide an enforcement effect to the first panel member 30′. Accordingly, the impact force applied to the first panel member 30′ is more evenly transmitted to the second panel member 40′, while the first panel member 30′ and the cavity 100′ formed on the second panel member 40′ can provide buffering and shock absorbing effects.
Further, the hollow fusion panel 1′ can be manufactured by blow molding technology, such as extrusion blow molding, injection blow molding and injection stretch blow molding. The melted materials used to manufacture the first layer 10, the second layer 20 and the third layer 50 can be co-extruded through a mold head to form a mold blank in a parison mold, wherein the first layer 10, the second layer 20, and the third layer 50 are fused with each other and define a cavity surrounded by the first layer 10, the second layer 20 and the third layer 50. The parison mold provides an exterior extrusion pressure to the mold blank and the air blow in the mold blank within the parison mold provides interior extrusion pressure to press the mold blank against the parison mold until the hollow fusion panel 1′ is blow-molded from the mold blank. Those skilled in the art can understand that this is one blow molding method selected from various blow molding producing methods for the hollow fusion panel 1′.
During the manufacturing process, portions of the first layer 10, portions of the second layer 20 and portions of the third layer 50 used to form the second panel member 40′ are stretched to protrude toward the first panel member 30′ to form the supporting structures 41′ while the second panel member 40′ simultaneously forms the recessed cavities 400′ with respect to the supporting structures 41′ respectively.
At least a portion of the second panel member 40′ is stretched, so the thickness of at least a portion of the second panel member is thinner than the thickness of the first panel member 30′. For example, a thickness of the portion of the first layer 10 forming the supporting structure 41′ is generally thinner than that of the portion of the first layer 10 forming the first panel member 30′.
Referring to
Referring to
Referring to
It should be understood by those skilled in the art that the number of layers of the first panel member 30′ and the second panel member 40′ can be the same or different, and the first panel member 30′ and the second panel member 40′ can be selectively arranged according to requirements.
Referring to
In this alternative mode, at least one of the supporting structures 41′ is formed to have two contact peak points 43′ and is arranged with one reinforcing rib 42′.
The contact area between the corresponding supporting structure 41′ and the first panel member 30′ can be 4*3 mm2, and the thickness of the first panel member 30′ can be 3 mm, so that x can be 12/9, which is greater than 0.1.
Referring to
In this alternative mode, at least one of the supporting structures 41′ is formed to have a single contact peak 43′.
The contact area between the single supporting structure 41′ and the first panel member 30′ may be 4*4 mm2, and the thickness of the first panel member 30′ can be 4 mm, so that x can be 16/16, which is greater than 0.1.
Referring to
First, heat the first polymer, such as high density polyethylene, of the first polymer layer 10, the second polymer, such as high density polyethylene or a combination of high density polyethylene, calcium carbonate and/or glass fiber, of the second polymer layer 20, and the third polymer, such as high density polyethylene or a combination of high density polyethylene, glass fiber, calcium carbonate, and/or metallocene polyethylene, of the third polymer layer 50 respectively at a predetermined temperature to obtain the first polymer, the second polymer and the third polymer in fluid form. When new material is used, the new material, in form of small pellets or granules, is received in the corresponding chamber A1, A2 or A3 and heated to melt by the feeding unit 201′. When recycled material is used, the recycled material, in form of small pellets or granules, is contained in the corresponding chamber A1, A2 or A3 and heated to melt by the feeding unit 201′. When a mixture of new and recycled materials is used, the new and recycled materials, in form of small pellets or granules, are contained in the corresponding chamber A1, A2 or A3 and heated to melt by the heater B.
Then, co-extrude the first polymer, the second polymer and the third polymer to form the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 respectively, wherein an inner surface of the first polymer layer 10 and an outer surface of the second polymer layer 20 are fused with each other, and an inner surface of the second polymer layer 20 and an outer surface of the third polymer layer 50 are fused with each other.
It is worth mentioning that, alternatively, in the co-extrusion step, the first polymer layer 10 and an outer surface of the second polymer layer 20 are fused with each other and are surrounded to form the cavity 100′. The first polymer layer 10 is a continuous material layer to surround the second polymer layer 20, and the second polymer layer 20 is a continuous material layer to surround the third polymer layer 50. In other words, after co-extruding the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50, surrounding the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 to form the cavity 100′.
Then, the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are fused with each other and placed in a mold for molding. A flow of gas can be blown into the mold, such that the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are biased against an inner wall of the mold, Therefore, the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 can be molded along the inner wall of the mold.
The molded first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are then cooled and demolded to form the blow-molded hollow fusion panel 1′.
It should be understood that the method of cooling the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 can be achieved by the introduction of gas. The gas can be any commercially available gas in a pressurized tank, or it can be air. The gas itself should not be harmful to the first polymer, the second polymer, and the third polymer, and should not damage the mold. The gas can be, but should not be limited to, air, helium, neon, argon, or any combination of the foregoing. Of course, it should be understood that the cooling method of the blow-molded hollow fusion panel 1′ after molding should not be limited to the above-mentioned air cooling method.
It should be understood that the first polymer, the second polymer and the third polymer are preferably formed in a melting state before they are extruded, wherein the first polymer, the second polymer, and the third polymer can be heated separately to maintain their fluidities. The extrusion step is performed during the heating process, such that the first polymer, the second polymer and the third polymer are heated uniformly, so as to enhance uniformity of the first polymer, the second polymer, and the third polymer.
It should be understood that when the first polymer, the second polymer and the third polymer are respectively extruded to form the first polymer layer 10, the second polymer layer 20, the second polymer layer 20 and the third polymer layer 50, wherein the first polymer layer 10, the second polymer layer 20, the second polymer layer 20 and the third polymer layer 50 are fused with each other. A person skilled in the art can select the first polymer, the second polymer, and the third polymer, so that the first polymer, the second polymer and the third polymer have good viscosity after being heated.
As shown in
The blow molding equipment 2′ comprises a feeding unit 201′, an extrusion unit 202′, and a blow molding unit 203′, wherein the first polymer, the second polymer, and the third polymer are respectively fed to the feeding unit 201′.
The feeding unit 201′ comprises a first feeding screw rod 2011′, a second feeding screw rod 2012′, and a third feeding screw rod 2013′, wherein the first polymer is fed through the first feeding screw rod 2011′, the second polymer is fed through the second feeding screw rod 2012′, and the third polymer is fed through the third feeding screw rod 2013′.
The first feeding screw rod 2011′, the second feeding screw rod 2012′, and the third feeding screw rod 2013′ can be configured to heat up the first polymer, the second polymer, and the third polymer respectively to ensure the first polymer, the second polymer, and the third polymer in a fluid state. It should be understood that before respectively feeding the first polymer, the second polymer and the third polymer into the first feed screw rod 2011′, the second feed screw rod 2012′ and the third feeding screw rod 2013′, a mixing step may be performed, for example, the raw material and the plastic additive such as catalyst are mixed and then fed to the feeding unit 201′.
The first feed screw rod 2011′, the second feed screw rod 2012′, and the third feed screw rod 2013′ are arranged for heat treating the first polymer, the second polymer and the third polymer respectively. In one embodiment, the operating temperatures of the first feeding screw rod 2011′, the second feeding screw rod 2012′, and the third feeding screw rod 2013′ are set with a range from 160° C. to 180° C. It should be understood that according to the transformation of the first polymer, the second polymer, and the third polymer, the heating temperatures thereof can be adjusted correspondingly, such that the first polymer, the second polymer and the third polymer are respectively heated to a desired fluid state, so as to maintain a desired flow speed and viscosity.
Furthermore, in one embodiment, the first polymer layer 10 of the blow-molded hollow fusion panel 1′ can be implemented to have the properties of high surface strength, scratch resistance, and oil stain resistance. The second polymer layer 20 can be implemented to have an energy absorbing structure or a material with high rigid ability and can effectively provide a buffering effect of the blow-molded panel due to any external impact or drop. The third polymer layer 50 can be implemented to have a low thermoplastic shrinkage ratio and to provide frame support.
For example, the first polymer is implemented as high-density polyethylene, and the parameters related to the high density polyethylene may be melting rate: 1.5 g/10 min, bending strength: 900 MPa, and Shore D69.
The second polymer is implemented as a mixture of high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber. For the first example of the second polymer made of the mixture of high-density polyethylene and calcium carbonate, the mass percentage of calcium carbonate is 15-30%, the mass percentage of high-density polyethylene is 70-85%, and the parameters related to high-density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63. For the second example of the second polymer made of the mixture of high-density polyethylene and glass fiber, the mass percentage of glass fiber is 15-40%, the mass percentage of high density polyethylene is 60-85%, and the related parameters of high-density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.
The third polymer can be implemented as metallocene polyethylene. The related parameters of the metallocene polyethylene are melting rate: 2.0 g/10 min, elongation at break: longitudinal 420%, transverse 830%, tensile strength at break: longitudinal 62 MPa, transverse 25 MPa, dart impact strength <48 g, Elmendorf tear strength: longitudinal 21° C., transverse 430° C.
It should be understood that the materials of the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 are not limited to the aforementioned materials.
The second polymer layer 20 can be embodied as a micro-foam layer to provide a cushioning effect. Since the second polymer layer 20 is located and sandwiched between the first polymer layer 10 and the third polymer layer 50, the second polymer layer 20 can be selected in different colors, such as black color. The second polymer layer 20 can also be made of recycled plastic, such as recycled high density polyethylene, to reduce material cost.
The second polymer layer 20 is embodied as an intermediary layer. Via the second polymer layer 20, the first polymer layer 10 and the third polymer layer 50 are bonded or adhered together. For example, at least a portion of the first polymer layer 10 and at least a portion of the second polymer layer 20 are fused with each other, and at least a portion of the second polymer layer 20 and the third polymer layer 50 are fused with each other. However, the first polymer layer 10 and the third polymer layer 50 are difficult to adhere to or fuse with each other. It should be understood that the intermediate layer does not have to be made of polymer, and it can be an inorganic adhesive or other types of connecting media as mentioned above.
The extrusion unit 202′ is operatively connected to the first feeding screw rod 2011′, the second feeding screw rod 2012′, and the third feeding screw rod 2013′ of the feeding unit 201′. The extrusion unit 202′ has a first extrusion channel 2020A′, a second extrusion channel 2020B′ and a third extrusion channel 2020C′. The first extrusion channel 2020A′ is operatively connected to a first feeding channel 2011A′ of the first feeding screw rod 2011′. The second extrusion channel 2020B′ is operatively connected to a second feeding channel 2012A′ of the second feeding screw rod 2012′. The third extrusion channel 2020C′ is operatively connected to a third feeding channel 2013A′ of the third feeding screw rod 2013′.
The number of the feeding channels of the feeding unit 201′ and the number of the extrusion channels of the extrusion unit 202′ can be set and modified according to requirements.
The sizes and shapes of first extrusion channel 2020A′, the second extrusion channel 2020B′, and the third extrusion channel 2020C′ are selectively configured to form the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 with predetermined thicknesses and shapes.
It is worth mentioning that the size of each of the first extrusion channel 2020A′, the second extrusion channel 2020B′, and the third extrusion channel 2020C′ is adjustable to control the thickness of the first polymer layer 10, the second polymer layer 10′ and the third polymer layer 50.
In this embodiment, the second extrusion channel 2020B′ is coaxially aligned within the first extrusion channel 2020A′, and the third extrusion channel 2020C′ is coaxially aligned within the second extrusion channel 2020B′. After the third polymer is extruded from the third extrusion channel 2020C′ to form the third polymer layer 50, at the same time, the second polymer is extruded from the second extrusion channel 2020B′ to form the second polymer layer 20, the third polymer layer 50 is circumferentially encircled with and fused to the second polymer layer 20. Similarly, the second polymer layer 20 is circumferentially encircled with and fused to the first polymer layer 10.
After the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 are extruded and fused with each other at a predetermined length, an end thereof is sealed, such that the fused body has a closed end and an opened end for air ventilation.
It should be understood that the location of the opening should not be limited to the above example. The first polymer, the second polymer, and the third polymer can be extruded from top to bottom, wherein the opening, i.e. the opened end, can be formed on the upper side of the fused body. Alternatively, the opening can be formed on the lateral side or lower side of the fused body. A person who skilled in the art can select the location of the opening according to requirements.
Preferably, in this embodiment, the end of the fused body is sealed when 20% to 40% of the fused body is formed by extruding the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50. Then, a step of pre-blowing the air into the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 to form the cavity 100′.
The blow molding unit 203′ comprises a molding die 2031′ and an air blower 2032′, wherein the air blower 2032′ is configured to blow an air flow into the molding die 2031′. The air blower 2032′ comprises at least one blowing needle 20321′ and an air tank 20322′, wherein the blowing needle 20321′ is communicably connected to the air tank 20322′.
The air blower 2032′ can be operatively installed in the extrusion unit 202′, or can be independently connected to the extrusion unit 202′.
During the extrusion of the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50, a left mold 20311′ and a right mold 20312′ of the molding die 2031′ are moved toward each other to left and right sides of the fused body respectively. The fused body is gradually extruded into a molding space of the molding die 2031′ between the left and right molds 20311′, 20312′, at the same time, the left and right molds 20311′, 20312′ are moved closer to each other until the fused body is completed formed within a molding space 20310′ of the molding die 2031′.
It should be understood that, according to the amount of material being fed, different numbers of fused body can be manufactured at one time. If small amount of material is fed in the feeding unit 201′ for a single feeding manner, the extrusion unit 202′ is configured to extrude all the first polymer, the second polymer, and the third polymer in a single feeding manner so as to form one single fused body. After the fused body is placed in the molding die 2031′ for processing, the blow-molded hollow fusion panel 1′ is formed.
Furthermore, at least one of an inner wall of the left mold 20311′ and the right mold 20312′ of the molding die 2031′ is configured to have a predetermined shape, such as a wave form. At least a portion of the fused body is biased against the inner wall of the left mold 20311′, and at least a portion of fused body is biased against the inner wall of the right mold 20312′ to form the first panel member 10′ and the second panel member 20′ of the blow molding hollow fusion panel 1′ respectively. In this process, since the first panel member 30′ and the second panel member 40′ are blown to maintain a relatively high pressure, the first polymer layer 10 and the second polymer layer 20 and the third polymer layer 50 can be fused closely.
For example, the left mold 20311′ of the molding die 2031′ is configured to mold the second panel member 20′, and the right mold 20312′ of the molding die 2031′ is configured to mold the first panel member 10′.
The molding die 2031′ further comprises at least one protrusion 203111′ integrally formed at the left mold 20311′, wherein the protrusion 203111′ is correspondingly aligned with the supporting structure 60′ of the second panel member 40′. When the fused body is biased against the left mold 20311′, the fused body is stretched to form the second panel member 40′ with the supporting structure 60′. Through this configuration, the overall weight of the second panel member 40′ will not increased, but the structural strength of the blow-molded hollow fusion panel 1′ can be enhanced. In other words, the weight of the second panel member 40′ will not be changed, but the material thereof is stretched to form the supporting structure 60′ so as to ensure no additional material of the second panel member 40′ being added to form the supporting structure 60′. Thus, since the supporting structure 60′ is stretched, the thickness becomes thinner, so as to enhance the heat dissipation in the subsequent steps.
The blowing operation to the molding die 2031′ can be maintained during the closing and molding process of the molding die 2031′. The blow time can be set with a range from 65 to 70 seconds. Then, the gas is discharged and the molding die 2031′ is cooled for demolding. This process will take 15-20 seconds to complete. Finally, the molded blow-molded hollow fusion panel 1′ can be removed from the molding die 2031′ once the molding die 2031′ is opened.
Edges of the first panel member 30′ and the second panel member 40′ are connected to each other. During the closing process of the molding die 2031′, some material may overflow and leak at the edge position, such that edges of the blow-molded hollow fusion panel 1′ can be trimmed after the blow-molded hollow fusion panel 1′ is formed.
It should be understood that in the above example, the blow-molded hollow fusion panel 1′ is constructed to have the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50, wherein the second polymer layer 20 is encircled by the first polymer layer 10, and the third polymer layer 50 is encircled by the second polymer layer 20.
In another embodiment of the present invention, the first panel member 30′ and/or the second panel member 40′ of the blow-molded hollow fusion panel 1′ can be constructed to have a double-layer structure.
Referring to
The tabletop panel 1001′ can be prepared from a multi-layer hollow fusion panel 1′ of the present invention, which can be made into various shapes such as a circle, a rectangle, and etc., to meet different requirements, wherein, referring to
In other words, the hollow fusion panel 1′ as illustrated in
Referring to
Multiple configurations can be utilized to mount the leg members 1021′ with the hollow fusion panel 1′ made tabletop 1001′. For example, four corner mounts 1030′ can be screwed to the outer bending walls 11′ of the hollow fusion panel 1′ and the four leg members 1021′ are attached to the corner mounts 1030′ respectively, as shown in
Referring to
It is appreciated that multiple mounting methods can be applied to mount the hollow fusion panel 1′ of the present invention to a leg assembly to form a table or a desk. The mounting configuration as illustrated in
To apply the hollow fusion panel 1′ of the present invention to form a shelf or a rack is as simple as replacing the one or more wooden made or metal made panels as shown in
Referring to
The hollow fusion panel 1′ can be made of any shape that blow molding manufacturing method as disclosed in the present invention is processable, such as a circular shape as shown in
When the second panel member 40′ is folded along the surface and through a center of the circle, the second panel member 40′ has at least a part of the support member 41′ while the direction of force is crossed, thereby facilitating the inner support strength of hollow fusion panel 1′.
Referring to
Referring to
It is appreciated that, according to the above-described embodiments and producing methods of the blow-molded hollow fusion panel 1′ of the present invention, the first panel member 1, 10′, 30′ and the second panel member 2, 20′, 40′ can be respectively configured as the outer panel member 1, 10′, 30′ and the inner panel member 2, 20′, 40′ of the supporting furniture. Please referring to
As mentioned above, the parison mold of the blow molding unit 203′ (as shown in
After the formation of the inner panel member 2, 20′, 40′ within and fused with the outer panel member 1, 10′, 30′, a feeding opening 201-21 of the second feeding unit 201-2 is shut such that the continuous feeding of the first material through the first feeding unit 201-1 fills the feeding opening 201-21 and ensures the inner panel member 2, 20′, 40′ being surrounded and covered by the outer panel member 1, 10, 30, completely.
It is worth mentioning that the outer panel member 1, 10′, 30′ can be made of new material and the inner panel member 2, 20′, 40′ can be made of recycled material. The material or a combination of the materials used to construct the outer panel member 1′, 10′, 30′ can be made of strengthened and anti-scratching durable material, such as nylon and high density polyethylene. Also, the material or a combination of the materials used to construct the inner panel member 2, 20′, 40′ can be made of shock absorbing and supporting materials, for example, elected from high density polyethylene, glass fiber, calcium carbonate and metallocene polyethylene.
It is further appreciated that, according to the above-described embodiments, and producing methods of the blow-molded hollow fusion panel 1′ of the present invention, the first panel member 1, 10′, 30′ and the second panel member 2, 20′, 40′ can be respectively configured as the upper or outer panel member 1, 10′, 30′ and the lower or inner panel member 2, 20′, 40′ of the supporting furniture. For example, when the supporting furniture is a blow-molded banquet tabletop, the first panel member is embodied as an upper or outer panel member 1, 10′, 30′ and the second panel member is embodied as a lower or inner panel member 2, 20′, 40′. When the blow-molded hollow fusion panel 1′ is a partition panel, a shelf panel, a cabinet wall panel, the first panel member is embodied as a first side panel member 1, 10′, 30′ and the second panel member is embodied as a second side panel member 2, 20′, 40′, wherein the first side and second side panel members 1, 10, 30′, 2, 20′, 40′ can be embodied as left side and right side panel members or, alternatively, outer and inner side panel members. Please referring to
Referring to
Referring to
Referring to
Those skilled in the art should understand that the above description and the embodiments of the present invention shown in the drawings are only examples and do not limit the present invention.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
This application is a Continuation-In-Part application that claims the benefit of priority under 35U.S.C. § 120 to a non-provisional application, application Ser. No. 17/630,157, filed Jan. 25, 2022, and a non-provisional application, application Ser. No. 18/228,167, filed Jul. 31, 2023, which is a Continuation application that claims the benefit of priority under 35U.S.C. § 120 to a non-provisional application, application Ser. No. 17/630,163, filed Jan. 28, 2022, which are incorporated herewith by references in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17630163 | Jan 2022 | US |
| Child | 18288167 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17630157 | Jan 2022 | US |
| Child | 18801819 | US | |
| Parent | 18288167 | Oct 2023 | US |
| Child | 18801819 | US |
