BLOW-MOLDED PLASTIC STRUCTURES

Abstract

A large, thin, generally planar panel constructed from blow-molded plastic may include a first surface, a second surface, and a hollow interior portion disposed between the first and second surfaces. The panel may include a nominal panel thickness (PT), which may be the distance between the first surface and the second surface, and a nominal wall thickness (WT), which may be the thickness of the outer wall of the blow-molded plastic structure. A plurality of depressions may be integrally formed in the second surface and a nominal distance (D) separating adjacent depressions may be measured from an edge of one depression to an edge of the adjacent depression. The relationship between the nominal panel thickness, the nominal wall thickness, and the nominal distance between adjacent depressions is shown by the equation WT.Math.PT.Math.D≦0.030.

Claims

1. A large, thin, generally planar panel constructed from blow-molded plastic, the blow-molded plastic panel comprising: a first surface; a second surface; a nominal panel thickness (PT) measured between the first surface and the second surface; a hollow interior portion at least partially disposed between the first surface and the second surface, the first surface, the second surface and the hollow interior portion being integrally formed during the blow-molding process as part of a unitary, one-piece structure; a nominal wall thickness (WT) of the first surface and the second surface; a plurality of depressions integrally formed in the second surface and extending towards the first surface, the plurality of depressions covering at least a majority of the second surface; and a nominal distance (D) separating adjacent depressions measured from an edge of one depression to an edge of the adjacent depression; wherein WT.Math.PT.Math.D≦0.030.

2. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.5 inches.

3. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.3 inches.

4. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.25 inches.

5. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.2 inches.

6. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.15 inches.

7. The blow-molded plastic panel as in claim 1, wherein the nominal panel thickness is less than about 0.1 inches.

8. The blow-molded plastic panel as in claim 1, wherein the nominal wall thickness is less than about 0.05 inches.

9. The blow-molded plastic panel as in claim 1, wherein the nominal wall thickness is less than about 0.04 inches.

10. The blow-molded plastic panel as in claim 1, wherein the panel has a size of at least one square foot.

11. The blow-molded plastic panel as in claim 1, wherein the panel has a size of at least two square feet.

12. The blow-molded plastic panel as in claim 1, wherein the panel has a size of at least three square feet.

13. The blow-molded plastic panel as in claim 1, wherein the panel has a size of at least four square feet.

14. The blow-molded plastic panel as in claim 1, wherein the panel has a size of at least five square feet.

15. The blow-molded plastic panel as in claim 1, wherein the plurality of depressions are disposed in a generally uniform arrangement.

16. The blow-molded plastic panel as in claim 1, wherein the plurality of depressions are disposed in a generally uniform arrangement with each depression separated from an adjacent depression by a generally constant distance.

17. The blow-molded plastic panel as in claim 1, wherein the plurality of depressions includes depressions with a generally uniform configuration and generally uniform characteristics disposed in a generally uniform pattern that covers at least substantially the entire second surface to form a structure with generally uniform strength and structural integrity.

18. The blow-molded plastic panel as in claim 1, wherein each depression in the plurality of depressions has a generally uniform configuration and is separated from an adjacent depression by a generally constant distance; and wherein the plurality of depressions covers at least substantially the entire second surface to form a structure with generally uniform strength and structural integrity.

19. The blow-molded plastic panel as in claim 1, wherein the first surface has a generally planar outer surface and forms an upper surface of a table top.

20. The blow-molded plastic panel as in claim 1, wherein the depressions in the plurality of depressions are sized and configured to help support the first surface in a generally consistent manner so that the first surface has generally uniform characteristics.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The appended drawings contain figures of preferred embodiments to further illustrate and clarify the above and other aspects, advantages and features of the present invention. It will be appreciated that these drawings depict only preferred embodiments of the invention and are not intended to limit its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0033] FIG. 1 is an upper perspective view of an exemplary embodiment of a table, the table including a table top comprising large, thin, generally planar blow-molded plastic structure with a nominal thickness generally equal to or less than one-half inch;

[0034] FIG. 2 is a lower perspective view of the table shown in FIG. 1, illustrating the table legs or leg assemblies in an extended position;

[0035] FIG. 3 is another lower perspective view of the table shown in FIG. 1, illustrating the table legs in a collapsed position;

[0036] FIG. 4 is a lower perspective view of a portion of the table shown in FIG. 1, showing the table top;

[0037] FIG. 5 is an enlarged lower perspective view of a portion of the table top shown in FIG. 4;

[0038] FIG. 6 is a bottom view of the portion of the table top shown in FIG. 5;

[0039] FIG. 7 is an enlarged bottom view of a portion of the table top shown in FIG. 6, identified by a broken line and number 7 in FIG. 6;

[0040] FIG. 8 is an enlarged bottom view of a portion of the table top shown in FIG. 6, identified by a broken line and the number 8 in FIG. 6;

[0041] FIG. 9 is an enlarged bottom view of a portion of the table top shown in FIG. 6, identified by a broken line and the number 9 in FIG. 6;

[0042] FIG. 10 is an enlarged cross-sectional side view of a portion of the table top shown by lines 10-10 in FIG. 7;

[0043] FIG. 11 is an enlarged cross-sectional side view of a portion of the table top shown by lines 11-11 in FIG. 8;

[0044] FIG. 12 is an enlarged cross-sectional side view of a portion of the table top shown by lines 12-12 in FIG. 9;

[0045] FIG. 13 is an upper perspective view of another exemplary embodiment of a table, illustrating the table as a fold-in-half table in the collapsed position and including a table top comprising large, thin, generally planar blow-molded plastic structure with a nominal thickness generally equal to or less than one-half inch;

[0046] FIG. 14 is an upper perspective view of another exemplary embodiment of a table, illustrating the table in a use position with the table legs in an extended position and including a table top comprising large, thin, generally planar blow-molded plastic structure with a nominal thickness generally equal to or less than one-half inch;

[0047] FIG. 15 is a lower perspective view of the table shown in FIG. 14;

[0048] FIG. 16 is a lower perspective view of the table shown in FIG. 14, illustrating the table legs in a collapsed position;

[0049] FIG. 17 is a lower perspective view of a portion of the table shown in FIG. 14, showing the table top;

[0050] FIG. 18 is an enlarged lower perspective view of a portion of the table top shown in FIG. 17;

[0051] FIG. 19 is a bottom view of the portion of the table top shown in FIG. 18;

[0052] FIG. 20 is an enlarged bottom view of a portion of the table top shown in FIG. 19, identified by a broken line and the number 20 in FIG. 19;

[0053] FIG. 21 is an enlarged cross-sectional side view of a portion of the table top shown by lines 21-21 in FIG. 20;

[0054] FIG. 22 is an upper perspective view of another exemplary embodiment of a table, the table illustrated as a fold-in-half table that is shown in the collapsed position and including a table top comprising large, thin, generally planar blow-molded plastic structure with a nominal thickness generally equal to or less than one-half inch;

[0055] FIG. 23 is an enlarged bottom view of a portion of the table top shown in FIG. 6, identified by a broken line and the number 23 in FIG. 6;

[0056] FIG. 24 is an enlarged bottom view of a portion of the table top shown in FIG. 6, identified by a broken line and the number 24 in FIG. 6;

[0057] FIG. 25 is an enlarged cross-sectional side view of a portion of the table top shown by lines 25-25 in FIG. 23;

[0058] FIG. 26 is an enlarged cross-sectional side view of a portion of the table top shown by lines 26-26 in FIG. 24;

[0059] FIG. 27 is an enlarged bottom view of a portion of the table top shown in FIG. 19, identified by a broken line and the number 27 in FIG. 19;

[0060] FIG. 28 is an enlarged bottom view of a portion of the table top shown in FIG. 19, identified by a broken line and the number 28 in FIG. 19;

[0061] FIG. 29 is an enlarged cross-sectional side view of a portion of the table top shown by lines 29-29 in FIG. 27; and

[0062] FIG. 30 is an enlarged cross-sectional side view of a portion of the table top shown by lines 30-30 in FIG. 28.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0063] The present invention is generally directed towards large, thin blow-molded plastic structures. The large, thin blow-molded plastic structures may have areas with a size of at least one square foot, a nominal thickness generally equal to or less than one-half inch, at least one surface with a generally planar configuration, and/or one or more depressions formed in or one more surfaces. For convenience and readability, such structures may be referred to as panels but the principles of the present invention are not limited to panels. It will be understood that, in light of the present disclosure, such large, thin blow-molded plastic structures may have a variety of shapes, sizes, configurations, and arrangements. Exemplary embodiments of structures that may be made in accordance with the present disclosure may include table tops, chair seats, chair backs, basketball backboards, wall panels, roof panels, floor panels, storage bins, sports equipment, and the like

[0064] Additionally, to assist in the description of exemplary embodiments, words such as top, bottom, front, rear, right and left may be used. It will be appreciated that the exemplary embodiments can be disposed in other positions, used in a variety of situations, and may perform one or more functions. In addition, the drawings, which may be to scale, illustrate various shapes, sizes, configurations, arrangements, aspects and features of the exemplary embodiments. It will be appreciated that structures made in accordance with the present disclosure may have other suitable shapes, sizes, configurations, arrangements, aspects, and features. A detailed description of exemplary embodiments of now follows.

[0065] As shown in the accompany figures, a table 10 is an exemplary embodiment of a structure that may include a large, thin-blow molded plastic structure. In particular, the table 10 may include a table top 12 and the table top may be a large, thin blow-molded plastic structure with a nominal thickness generally equal to or less than one-half inch. While the tables 10 and the table tops 12 shown in the accompanying figures are exemplary embodiments of large, thin blow-molded plastic structures that may have a nominal thickness generally equal to or less than one-half inch, one of ordinary skill in the art will appreciate after reviewing this disclosure that other blow-molded plastic structures may have one or more such features.

[0066] As shown in the accompanying figures, the exemplary table 10 may include a table top 12 with a first side 14, a second side 16, a first end 18, a second end 20, an upper or working surface 22, and a lower or mounting surface 24. A hollow interior portion 26 may be disposed between the upper and lower surfaces 22, 24. The upper surface 22, the lower surface 24, and the hollow interior portion 26 may be integrally formed during the blow-molding process as part of a unitary, one-piece structure. One or more other features, which may be described below, may also be integrally formed with the upper surface 22, the lower surface 24, and/or the hollow interior portion 26 during the blow-molding process as part of a unitary, one-piece structure.

[0067] As shown in FIGS. 4 and 5, a lip 28 may be disposed about at least a portion of a periphery of the table top 12. The lip 28, which may be disposed about an outer perimeter of the table top 12, may form at least part of an outer edge or boundary of table top. The lip 28 may extend downwardly relative to the lower surface 24 of the table top 12 and the lip may extend around all or one or more portions of table top. The lip 28 may also have different heights. For example, the lip 28 could have a larger height in the corners than the sides or ends of the table top 12. In addition, the lip 28 may only be disposed in the corners, sides, and/or ends of the table top 12. Further, while the lip 28 may extend downwardly relative to the lower surface 24 of the table top 12, the lip may be disposed at any suitable angle and it could be aligned with the upper surface 22 of the table top. All or a portion of the lip 28 may be compression molded and the lip may be integrally formed with the table top 12 during a blow-molded process as part of a unitary, one-piece structure. It will be understood that the table top 12 and the lip 28 may also be formed from two or more pieces that are subsequently attached by any suitable mechanism or method such as fasteners, adhesives, and like. It will also be understood that the lip 28 is not required.

[0068] The table 10 may include a frame 30 and the frame may include a first side rail 32 and a second side rail 34. The first side rail 32 may be disposed at least proximate and substantially parallel to the first side 14 of the table top 12 and the second side rail 34 may be disposed at least proximate and substantially parallel to the second side 16 of the table top. The side rails 32, 34 may extend generally along the length of the table top 12. The length and configuration of the side rails 32, 34 may depend, for example, upon the length and configuration of the table top 12. The side rails 32, 34 may include one or more components depending, for example, if the table 10 is a fold-in-half table. The frame 30 may also include a first end rail 36 that is disposed along the first end 18 of the table top 12 and a second end rail 38 that is disposed along the second end 20 of the table top. The frame 30 may also include one or more corners and the corners may separate components or part of the side rails 32, 34 and/or end rails 36, 38. The corners of the frame 30 may be generally aligned with corresponding corners of the table top 12. In addition, the frame 30 may be generally aligned with the lip 28. For example, an outer surface of the frame 30 may be generally aligned with and directly adjacent or contacting an inner surface of the lip 28. The frame 30 may be sized and configured to support the outer edges or perimeter of the table top 12. One or more portions of the frame 30, however, could be spaced inwardly from the outer perimeter of the table top 12. The frame 30 may also be sized and configured to help prevent bowing, twisting, or deformation of table top 12. It will be appreciated that the frame 30 could have a variety of shapes, sizes, configurations, and/or arrangements depending, for example, upon the size and configuration of the table 10 or table top 12. It will also be appreciated that the frame 30, side rails 32, 34, and/or end rails 36, 38 may not be required.

[0069] The frame 30 may be attached to the table top 12 by one or more fasteners, such as screws, bolts, rivets and the like. For example, the table top 12 may include one or more attachment portions that are sized and configured to facilitate attachment of the frame 30 and the table top. The table top 12 may also include one or more frame receiving portions that are sized and configured to receive a portion of the frame 30. Additionally, the table top 12 may be sized and configured to allow an upper portion of the frame 30 to be disposed proximate the upper surface 22 of the table top 12. Further, the table top 12 and/or the frame 30 may be sized and configured to minimize the overall height of the table top and the frame, which may allow a table 10 with a thinner configuration to be constructed.

[0070] In greater detail, the table top 12 may include one or more fastener receiving portions 40 that are sized and configured to receive at least a portion of a fastener. The fastener receiving portions 40 may include one or ribs, engaging portions, and the like that are sized and configured to help provide secure engagement of the fastener and the fastener receiving portion. Advantageously, the fastener receiving portions 40, which may be integrally formed with the table top 12 as part of a unitary, one-piece structure, may allow secure attachment of the frame 30 to the table top 12 because the table top 12 may have such a small thickness, height, or thin configuration that fasteners would not be able to be securely attached directly to the table top.

[0071] The fastener receiving portions 40 may allow the frame 30 and the table top 12 to be directly connected. For example, in one exemplary embodiment, a fastener could connect the frame 30 and the fastener receiving portion 40 to securely connect the frame and the table top 12. In another exemplary embodiment, a fastener could connect the lip 28, the frame 30, and the fastener receiving portion 40. In yet another exemplary embodiment, a fastener could connect a compression molded portion of the table top 12, the frame 30, and the fastener receiving portion 40. One skill in the art will understand, after reviewing this disclosure, that other suitable means or methods for connecting the frame 30 and/or the table top 12 may be employed, including, but not limited to, mechanical connectors, glues, epoxies, bonding materials, and the like.

[0072] As shown in FIGS. 1-3, for example, the table 10 may include a first leg assembly or support pedestal 42 and a second leg assembly or support pedestal 44. The first and second leg assemblies 42, 44 may be movable relative to the table top 12. For example, the first and second leg assemblies 42, 44 may be movable between an extended or use position in which the leg assemblies extend outwardly relative to the table top 12, such as illustrated in FIGS. 1 and 2, and a collapsed or storage position in which the leg assemblies are positioned at least proximate and generally parallel to the lower surface 24 of the table top, such as illustrated in FIG. 3. The leg assemblies 42, 44 may be pivotally attached to the frame 30, the table top 12, or other suitable portions of the table 10. It will be appreciated that the leg assemblies 42, 44 do not have to be movable relative to the table top 12, the table 10 may include any suitable number of legs and/or leg assemblies, and the leg assemblies may have other suitable shapes, sizes, configurations, and arrangements depending, for example, upon the intended use of the table.

[0073] One or more support braces 46, 48, such as shown in FIGS. 2 and 3, may be connected to the leg assemblies 42, 44 and the table top 12. For example, as shown in the accompanying figures, one end of the support brace 46 may include a pair of arms 50, 52 that are attached to the first leg assembly 42 and the other end of the support brace may be attached to another portion of the table 10, such as a cross bar 54 that extends across at least a portion of the table top 12. Similarly, the support brace 48 may include a pair of arms 56, 58 that are attached to the second leg assembly 44 and the other end of the support brace may be attached to the cross bar 54. The support braces 46, 48 may include other portions such as brace body, overlapping portions, and a locking mechanism such as a locking ring. The locking ring may slide along at least a portion of the support brace and the locking ring may be sized and configured to fit over the overlapping portions of the support brace when the leg assembly is in the extended position. Advantageously, the locking ring may be used to secure the leg assembly in the extended position. It will be appreciated that other mechanisms may be used to lock the leg assemblies 42, 44 in a desired position. It will also be appreciated that the support braces 46, 48, arms 50, 52, 56, 58, and cross bar 54 may have other suitable shapes, sizes, configurations, and arrangements depending, for example, upon the size and intended use of the table 10.

[0074] The table top 12 may include at least one thin profile section 60 that has a large size and a nominal thickness generally equal to or less than one-half inch. The thin profile section 60 may have a generally planar upper surface 22 (which may be a substantially smooth, flat, and/or even surface) and a generally planar lower surface 24 (which may be a surface disposed in generally the same plane and, in an exemplary embodiment, include a plurality of depressions). Any suitable portion of the table top 12 could include the thin profile section 60, such as a center portion of the table top, and the thin profile section 60 may form a minority, majority, substantially all, or the entire table top 12. One skill in the art will appreciate, after reviewing this disclosure, that the thin profile section 60 may form any desired portion or portions of the table top 12.

[0075] In the exemplary embodiment shown in FIGS. 2-5, substantially all or the entire table top 12 may comprise a thin profile section 60 (which may or may not include the lip 28). For example, if the table top 12 has a length of about eight (8) feet and a width of about two and one-half (2.5) feet, the table top may have a size of about twenty (20) square feet. If the table top 12 has a length of about six (6) feet and a width of about two and one-half (2.5) feet, the table top may have a size of about fifteen (15) square feet. Thus, the table top 12 may have a thin profile section 60 because it has an area larger than about one square foot, about two square feet, about three square feet, about four square feet, about five square feet, about six square feet, or more. The table top 12 may also have a thin profile section 60 because the upper and lower surfaces 22, 24 may be separated by generally equal to or less than one-half inch. One skilled in the art will appreciate, after reviewing this disclosure, that the thin profile sections 60 may have various suitable shapes, sizes, configurations, and arrangements depending, for example, upon the intended use of the table 10.

[0076] A blow-molded plastic structure with a thin profile section 60, whether part of the table top 12 or other structure, may be referred to as a panel for convenience. The panel 60 may have a nominal panel thickness PT, which may be the mean or average thickness of the panel. For example, the nominal panel thickness PT may be the mean or average distance between the upper and lower surfaces 22, 24 of the table top 12. While the panel 60 may have localized areas that are larger or smaller, the nominal panel thickness PT is preferably generally equal to or less than one-half inch. More preferably, the nominal panel thickness PT is significantly less than one-half inch, such as between about 0.40 inches and about 0.10 inches. For example, the nominal panel thickness PT may be about 0.35 inches, about 0.30 inches, about 0.25 inches, about 0.20 inches, about 0.15 inches, or about 0.10 inches. Therefore, after reviewing this disclosure, one skilled in the art will appreciate that the nominal panel thickness PT for large, thin blow-molded plastic structures may be generally equal to or significantly or considerably less than one-half inch.

[0077] One skilled in the art will appreciate that the panel 60 may include other features, structures, and portions. For example, the panel 60 may include one or more portions 62 where an injector or needle is inserted into the plastic materials during the blow-molding process. The panel 60 may also include one or more portions 64 which facilitate removal of the panel from the mold during the blow-molding process. The portions 64, for instance, may facilitate ejection of the blow-molded plastic structure from the mold when the blow-molding process is completed. The panel 60 may also include other structures such as the fastener receiving portions 40 and structures that facilitate attachment of the frame 30 and/or the leg assemblies 42, 44 to the table top 12. These types of structures are typically not included or considered when determining the nominal panel thickness PT.

[0078] The panel 60 may also have a nominal wall thickness WT, which may be the mean or average measurement of the thickness of the outer wall of the blow-molded plastic structure. For example, the nominal wall thickness WT may be the mean or average thickness of the upper surface 22 and/or the lower surface 24 of the table top 12. It will be appreciated that the nominal wall thickness WT may include localized areas that are larger or smaller. For example, the lower surface 22 may include localized areas of decreased wall thickness WT where the plastic is stretched or deformed to form depressions (which are described in more detail below). The nominal wall thickness WT, however, may not include portions of the table top 12 such as the fastener receiving portions 40, portions 62 and/or portions 64. The nominal wall thickness WT for the blow-molded plastic table top 12 may be less than or generally equal to about 0.05 inches. In particular, the nominal wall thickness WT for the table top 12 may be between about 0.05 inches and about 0.03 inches. For example, the nominal wall thickness WT may be about 0.045 inches, about 0.04 inches, or about 0.035 inches.

[0079] As shown in the accompanying figures, the lower surface 24 of the table top 12 may include a plurality of depressions 70. The depressions 70 may be closely spaced and a distance between adjacent depressions may be measured from an edge of one depression to an edge of the adjacent depression. The nominal distance D between adjacent depressions may be mean or average edge-to-edge distance between adjacent depressions. As shown in the accompanying figures, the nominal distance D between adjacent depressions may be generally uniform or consistent. The nominal distance D between adjacent depressions, however, can vary or change. The nominal distance D between adjacent depressions may be measured along an axis aligned with a center of a plurality of generally aligned depressions. For example, the nominal distance D may be measured between adjacent depressions aligned along a length or width of the table top 12. The nominal distance D may also be measured between adjacent depressions aligned at an angle, such as a diagonal, relative to a side and/or end of the table top 12. Alternatively, the nominal distance D could be the distance to the closest adjacent depression.

[0080] In greater detail, the lower surface 24 of table top 12 may include a plurality of depressions 70 and the depressions may be sized and configured to increase the strength and/or structural integrity of the table top. The ends of the depressions 70 may contact or engage the upper surface 22 of the table top 12 and/or the ends of the depressions may be spaced from the upper surface of the table top by a distance. As shown in the accompanying figures, the depressions 70 may cover a majority, substantially all, or the entire lower surface 24 of the table top 12. After reviewing this disclosure, it will be appreciated that the depressions 70 may be disposed in and/or cover any desired portion of the table top 12.

[0081] The depressions 70 may be arranged into a predetermined pattern or array, and the pattern may repeat any suitable number of times. The pattern may include one or more depressions 70 disposed in a uniform or consistent arrangement. The depressions 70 disposed in the pattern may be sized and configured to increase the strength and/or structural integrity of the table top 12. The depressions 70 may also be arranged to help create a table top 12 with generally uniform properties and characteristics. For example, closely spacing the depressions 70 over substantially the entire lower surface 24 may allow the table top 12 to have increased strength and generally uniform properties and characteristics.

[0082] The depressions 70 may be disposed in a pattern or array that minimizes the nominal distance D between adjacent depressions. Advantageously, minimizing the nominal distance D between adjacent depressions may minimize the unsupported areas of the opposing surface. Minimizing the nominal distance D between adjacent depressions may also increase the structural integrity and strength of the blow-molded plastic structure. In addition, minimizing the nominal distance D between adjacent depressions may increase the smoothness, evenness, and/or flatness of the opposing surface. For instance, the accompanying figures illustrate several exemplary configurations and arrangements of closely spaced depressions 70 and are separated by the nominal distance D. For instance, the lower surface 24 of the table top 12 may include a plurality of closely spaced depressions 70 that are separated by the nominal distance D and that may help create an upper surface 22 with increased smoothness, evenness, and/or flatness.

[0083] Advantageously, the smaller nominal distance D between adjacent depressions 70 may increase the structural integrity and strength of the blow-molded plastic structure, which may allow the nominal wall thickness WT of the blow-molded plastic structure to be decreased. Accordingly, less plastic materials may be used to construct blow-molded plastic structures because of the reduced nominal wall thickness WT and that may reduce costs. In addition, the decreased nominal wall thickness WT may allow the blow-molded plastic structures to cool more quickly during the manufacturing process because it may dissipate heat more rapidly. The blow-molded plastic structures may also be removed from the mold more quickly and/or at a higher temperature because, for example, of the increased strength and/or structural integrity. These and other factors may significantly decrease the time required to construct blow-molded plastic structures and it may increase manufacturing efficiency by, for example, decreasing manufacturing cycle time.

[0084] As discussed above, one skilled in the art previously thought large (i.e., an area of at least one, two, three, four, five or more square feet) blow-molded plastic structures required opposing surfaces to be spaced apart by significantly more than one-half inch. Large, thin blow-molded plastic structures, however, can be constructed with opposing surfaces spaced apart by one-half inch or less. In addition to the opposing surfaces being separated by one-half inch or less, a plurality of closely spaced depressions 70 can be formed. Significantly, this may allow the nominal wall thickness WT of the large, thin blow-molded plastic to be decreased.

[0085] In greater detail, decreasing the distance between the opposing surfaces to one-half inch or less, increasing the number of depressions 70, and decreasing the nominal distance D between adjacent depressions provides the surprising and unexpected result that large, thin blow-molded plastic structures can be constructed. Specifically, it was previously thought that the distance between opposing surfaces had to be significantly more than one-half inch when constructing large blow-molded plastic structures. Decreasing the distance between opposing surfaces to one-half inch or significantly less than one-half inch, however, allows the nominal wall thickness WT to be decreased and allows the nominal distance D between adjacent depressions to be decreased. Additionally, large, thin blow-molded plastic structures with a thickness of less than one-half inch may have considerable stiffness, rigidity and structural integrity, despite the fact that these surfaces are separated by a distance that is considerably less than one-half inch.

[0086] The relationship between the nominal wall thickness WT, nominal panel thickness PT, and nominal edge-to-edge distance between adjacent depressions D for large, thin blow-molded plastic structures is shown in the following equation:

WT.Math.PT.Math.D≦0.030

For example, if the nominal wall thickness WT is about 0.04 inches, the nominal panel thickness PT is about 0.5 inches, and the nominal distance D between adjacent depressions is about 0.7 inches, the result is 0.014, which is less than 0.030. In an exemplary embodiment, as the nominal wall thickness WT decreases, the nominal distance D between adjacent depressions may decrease.

[0087] Advantageously, a significant reduction in weight may occur for structures that satisfy the above equation. For example, a known table top with a 0.05 inch WT, a 0.7 inch PT, and a 1.0 inch D may have a weight of about 5 pounds. This known table top does not satisfy the above equation because (0.05)(0.7)(1.0)=0.035. An embodiment of a table top with a similar size that satisfies the above equation, however, may have a significant reduction in weight. For instance, an exemplary embodiment of a table top may have a nominal wall thickness WT of about 0.04 inch, a nominal panel thickness PT of about 0.5 inch, and a nominal distance D between adjacent depressions of about 0.7 inch. This exemplary table top satisfies the above equation because (0.04)(0.5)(0.7)=0.014 and has a weight of about 3 pounds, which is significant reduction from the known table top that has a weight of about 5 pounds. Thus, a forty percent (40%) weight reduction may be achieved if the above equation is satisfied in comparison to conventional table tops of the same size. In addition, table tops that satisfy the above equation may reduce manufacturing cycle time by about ten percent (10%) or more because, among other reasons, less plastic materials may be used and heat may be dissipated more rapidly. Further, table tops that satisfy this equation may have a thinner profile because the height of the table top may be decreased.

[0088] Advantageously, structures that satisfy this equation and have closely spaced depressions 70 arranged into a predetermined pattern may create high-strength, lightweight structures with generally uniform properties and/or characteristics. In addition, if the depressions 70 are arranged into a pattern with generally constant and uniform spacing, even if other features, objects or items are formed in the structure, the structure may have generally uniform properties and/or characteristics. If desired, one or more depressions 70 may be formed in the other features, objects or items to maintain a generally uniform and consistent pattern. Thus, the depressions 70 may be spaced so that the distance between adjacent depressions is minimized, at least substantially the entire surface is covered with depressions, and the depressions may be disposed in a generally uniform and consistent pattern even if other features, objects or items are formed in the blow-molded plastic structure.

[0089] In order to obtain a generally uniform and consistent pattern of depressions 70, it may be desired to eliminate or minimize other features, objects or items formed in the blow-molded structure. If desired, the generally uniform and consistent pattern of depressions 70 may be disposed in, about, and/or around these features, objects and items.

[0090] The depressions 70 may be sized and configured to allow the depressions to be closely spaced. For example, one or more sidewalls 72 of the depressions 70 may be disposed at a relatively steep angle to allow the depressions to be closely spaced. In an exemplary embodiment, the sidewalls 72 of the depressions 70 may be disposed at an angle between about sixty degrees (60°) and about eight-five degrees (85°) relative to the lower surface 24 of the table top 12. The sidewalls 72 may also be positioned at an angle of about seventy-five degrees (75°) or more with respect to the lower surface 24 of the table top 12. It will be appreciated that the sidewalls 72 may be positioned at any desired angle relative to the lower surface 24 of the table top 12 depending, for example, upon the size and configuration of the depressions 70.

[0091] The table top 12 illustrates the depressions 70 may be disposed in one or more exemplary patterns. For example, as shown in the accompanying figures, the depressions 70 may be disposed in a first pattern 74, a second pattern 76, a third pattern 78, and a fourth pattern 80. The patterns 74, 76, 78, and 80 may be symmetrically disposed on each side of the table top 12. For readability and convenience, only one side of the table top 12 will be discussed below in detail because the other side may be the same or a mirror image. It will be appreciated, however, that the table top 12 does not have to be symmetrical and the table top could include any suitable number, size, shape, configuration and arrangement of depressions and/or patterns.

[0092] The patterns 74, 76, 78, and 80 may include depressions 70 with different sizes, shapes, configurations and/or arrangements. For example, the depressions 70 may have different sized openings and/or ends. The depressions 70 may also have different configurations such as sidewalls 72 disposed at different angles and ends with multiple engagement surfaces. Exemplary embodiments of the patterns are shown in FIGS. 4-6 (patterns 74, 76, and 78) and FIGS. 15-19 (pattern 80). For readability, all of the depressions are generally identified as depressions 70 even though the depressions may have different sizes, shapes, configurations and arrangements. It will be appreciated, after reviewing this disclosure, that any number and configuration of patterns and depressions may be utilized depending, for example, upon the intended use of the blow-molded plastic structure.

[0093] As seen in FIGS. 6, 7, and 10, the first pattern 74 of depressions 70 may be disposed towards the first end 18 of the table top 12 and the depressions may have a generally circular configuration with a first portion 82, a second portion 84, and a sidewall 86. The first portion 82 of the depression 70 may have a diameter between about 0.30 inches and about 0.80 inches, such as between about 0.40 inches and about 0.67 inches (e.g., measured at wider and narrower parts). The second portion 84 of the depression 70 may have a diameter between about 0.03 inches and about 0.20 inches, such as between about 0.06 inches and about 0.17 inches (e.g., measured at wider and narrower parts). The sidewall 86 of the depression 70 may be disposed between an angle of about seventy degrees (70°) and about sixty degrees (60°), such as about sixty-five degrees (65°) relative to the lower surface 24 of the table top 12. The first pattern 74 may have a nominal panel thickness PT between about 0.40 inches and about 0.50 inches, such as about 0.435 inches (the distance between an upper portion of the upper surface and a lower portion of the lower surface); or a nominal panel thickness between about 0.30 and about 0.40 inches, such as about 0.375 inches (the distance between an inner portion of the upper surface and an inner portion of the lower surface). The first pattern 74 may have a nominal wall thickness WT between about 0.03 inches and about 0.05 inches, such as about 0.04 inches. The first panel may have a nominal distance D between adjacent depressions between about 0.50 inches and about 0.60 inches, such as about 0.54 inches. Thus, the above equation for the first pattern 74 of depressions 70 is (0.04)(0.435)(0.54)=0.01, which is less than 0.030. Thus, the first pattern 74 satisfies the above equation.

[0094] In greater detail, as best seen in FIGS. 7 and 10, the depressions 70 of the first pattern 74 of depressions may include an engagement surface 88 and the engagement surface may engage the upper surface 22 of the table top 12. The engagement surface 88 may support the upper surface 22 of the table top 12 and may help create a table top with generally uniform properties and characteristics.

[0095] As seen in FIGS. 6, 8, and 11, the second pattern 76 of depressions 70 may be disposed adjacent to the first pattern 74 of depressions and the depressions may have a generally circular configuration with a first portion 90, a second portion 92, and a sidewall 94. The first portion 90 of the depressions 70 may have a diameter between about 1.0 inches and about 0.90 inches, such as about 0.95 inches at a wider part. The first portion 90 of the depression 70 may have a diameter between about 0.50 and about 0.70 inches, such as about 0.58 inches at a narrower part. The upper portion 92 of the depression 70 may have a diameter between about 0.60 inches and about 0.50 inches, such as between about 0.54 inches at a wider part. The upper portion 92 of the depression 70 may have a diameter between about 0.40 inches and about 0.50 inches, such as about 0.42 inches at a narrower part. The sidewall 94 of the depression 70 may be disposed between an angle of about eighty-five degrees (85°) and about seventy degrees (70°), such as about eighty degrees (80°) relative to the lower surface 24 and/or upper surface 22 of the table top 12. The second pattern 76 may have a nominal panel thickness PT between about 0.40 inches and about 0.50 inches, such as about 0.435 inches (the distance between an upper portion of the upper surface and a lower portion of the lower surface); or a nominal panel thickness between about 0.30 and about 0.40 inches, such as about 0.375 inches (the distance between an inner portion of the upper surface and an inner portion of the lower surface). The second pattern 76 may have a nominal wall thickness WT between about 0.03 inches and about 0.05 inches, such as about 0.04 inches. The second pattern 76 may have a nominal distance D between adjacent depressions between about 0.7 inches and about 0.9 inches, such as about 0.78 inches. Thus, the above equation for the second pattern 76 of depressions 70 is (0.04)(0.435)(0.78)=0.013, which is less than 0.030 and this pattern satisfies the above equation.

[0096] As best seen in FIGS. 8 and 11, the depressions 70 of the second pattern 76 of depressions 70 may include an engagement surface 96 and the engagement surface may engage the upper surface 22 of the table top 12. The engagement surface 96 may support the upper surface 22 of the table top 12 and may help create a table top with generally uniform properties and characteristics. As seen in FIG. 8, the engagement surface 96 may include one or more engaging portions 98 and one or more conduits or pathways 100. For example, the engagement surface 96 may include four engaging portions 98 and four pathways 100. The engaging portions 98 may be sized and configured engage and/or support the upper surface 22 of the table top 12 and the pathways 100 may be sized and configured to facilitate gas flow during the blow-molding process. In particular, the engaging portions 98 and the pathways 100 may allow increased gas flow during the blow-molding process, which may facilitate construction of the blow-molded plastic structure.

[0097] The third pattern 78 of depressions 70 may be disposed in multiple sections of the table top 12, such as proximate a center portion of the table top and proximate the first end 18 of the table top. As seen in FIGS. 6, 9, and 12, the third pattern 78 if depressions 70 may have a generally circular configuration with a first portion 102, a second portion 104, and a sidewall 106. The lower portion 102 of the depressions may have a diameter between about 0.60 inches and about 0.80 inches, such as about 0.71 inches at wider part. The lower portion 102 if the depressions 70 may have a diameter between about 0.20 inches and about 0.3 inches, such as about 0.22 inches at narrower part. The upper portion 104 of the depression 70 may have a diameter between about 0.10 inches and about 0.20 inches, such as about 0.18 inches at a wider part. The upper portion 104 of the depression 70 may have a diameter between about 0.05 inches and about 0.10 inches, such as about 0.06 inches at a narrower part. The sidewall 106 of the depression 70 may be disposed between an angle of about seventy-five degrees (75°) and about eighty-five degrees (85°), such as about eighty degrees (80°) relative to the lower surface 24 of the table top 12. The third pattern 78 may have a nominal panel thickness PT between about 0.40 inches and about 0.50 inches, such as about 0.435 inches (the distance between an upper portion of the upper surface and a lower portion of the lower surface); or a nominal panel thickness between about 0.30 and about 0.40 inches, such as about 0.375 inches (the distance between an inner portion of the upper surface and an inner portion of the lower surface). The third pattern 78 may have a nominal wall thickness WT between about 0.03 inches and about 0.05 inches, such as about 0.04 inches. The third pattern 78 may have a nominal distance D between adjacent depressions between about 0.5 inches and about 0.7 inches, such as about 0.59 inches. Thus, the above equation for the third pattern 78 of depressions 70 is (0.04)(0.435)(0.59)=0.010, which is less than 0.030 and the third pattern satisfies the above equation.

[0098] As best seen in FIGS. 9 and 12, the depressions 70 of the third pattern 78 of depressions 70 may include an engagement surface 108 and the engagement surface may engage the upper surface 22 of the table top 12. The engagement surface 108 may support the upper surface 22 of the table top 12 and may help create a table top with generally uniform properties and characteristics.

[0099] Different sections of the table top 12 may include different patterns of depressions depending, for example, upon the intended use of the table 10. For instance, the first end 18 and center portion of the table top 12 may have the same pattern of depressions so that these portions of the table top have similar properties and characteristics. Other portions of the table top 12 may include different patterns because it may be desirable for different portions of the table top to have different properties and characteristics. For example, one pattern may provide increased strength, rigidity, torsion resistance, and/or the like, which may be beneficial for certain portions of the table top. It may be desirable for other portions of the table top to have different properties or characteristics such as a smoother, more even, or flatter surface. Accordingly, after reviewing this disclosure, one skilled in the art will understand that different portions of the blow-molded plastic structure may have different patterns of depressions.

[0100] The table top 12 can also include the fourth pattern 80 and, as shown in FIGS. 15-21, the depressions 70 may cover substantially all of the lower surface 24 of the table top 12. The depressions 70 in the fourth pattern 80 may have a generally circular configuration with a first portion 110, a second portion 112, and a sidewall 114. The first portion 110 of the depression 70 may have a diameter between about 0.60 inches and about 0.80 inches, such as about 0.71 inches at a wider part. The first portion 110 of the depression 70 may have a diameter between about 0.20 and about 0.30 inches, such as about 0.25 inches at a narrower part. The second portion 112 of the depression 70 may have a diameter between about 0.10 inches and about 0.20 inches, such as about 0.17 inches at a wider part; and a diameter between about 0.05 inches and about 0.10 inches, such as about 0.06 inches at a narrower part. The sidewall 114 of the depressions 70 may be disposed between an angle of about seventy-five degrees (75°) and about eight-five degrees (85°), such as about eighty degrees (80°) relative to the lower surface 24 of the table top 12. The fourth pattern 80 may have a nominal panel thickness PT between about 0.40 inches and about 0.60 inches, such as about 0.50 inches (the distance between an upper portion of the upper surface and a lower portion of the lower surface); or a nominal panel thickness between about 0.40 and about 0.50 inches, such as about 0.44 inches (the distance between an inner portion of the upper surface and an inner portion of the lower surface). The fourth pattern 80 may have a nominal wall thickness WT between about 0.03 inches and about 0.05 inches, such as about 0.04 inches. The fourth pattern 80 may have a nominal distance D between adjacent depressions between about 0.5 inches and about 0.7 inches, such as about 0.59 inches. Thus, the above equation for the fourth pattern 80 of depressions 70 is (0.04)(0.50)(0.59)=0.012, which is less than 0.030 and the fourth pattern satisfies the above equation.

[0101] As best seen in FIGS. 19-21, the depressions 70 of the fourth pattern 80 of depressions may include an engagement surface 116 and the engagement surface may engage the upper surface 22 of the table top 12. The engagement surface 116 may support the upper surface 22 of the table top 12 and may help create a table top with generally uniform properties and characteristics.

[0102] In view of the above-disclosure, one skilled in the art will appreciate that a large, thin blow-molded plastic structure, such as a table top 12, may be constructed with one or more patterns of depressions. The patterns may be repeating and the depressions in the patterns may have generally uniform size, shape, configuration, and arrangement, which may allow the structure to have generally uniform properties and characteristics.

[0103] The table top 12 may also include other portions such as one or more frame receiving portions 120 that are sized and configured to receive portions of the frame 30. The frame receiving portions 120, which may be best seen in FIGS. 6, 19, and 23-30, may be disposed about an outer perimeter of the table top 12. The frame receiving portions 120 may have a reduced thickness in comparison to the thickness of the table top 12 and the frame receiving portions may be disposed adjacent and/or be at least partially formed or defined by the lip 28. In addition, one or more depressions 70 may be disposed in the frame receiving portions 120 and the depressions may help support the upper surface 22 of the table top 12 disposed above the frame 30.

[0104] In greater detail, as shown in FIGS. 6 and 23, the frame receiving portion 120 may be disposed along a side or edge of the table top 12, such as the first and second sides 14, 16 of the table top. The frame receiving portion 120 may be sized and configured to receive a portion of the frame 30, such as an upper portion of the frame. The frame receiving portion 120 may be at least partially formed or defined by the portion of the lip 28 that extends downwardly from the lower surface 24 of the table top 12. Thus, the lip 28 may form an edge or sidewall of the frame receiving portion 120. The lip 28 may also help protect the frame 30 from damage and the lip may facilitate attachment of the frame to the table top 12.

[0105] As shown in FIGS. 23 and 25, one or more depressions 70 may be disposed in the frame receiving portion 120 and the frame receiving portion may have a generally U-shaped configuration with a first sidewall 122, a second sidewall 124, a first portion 126, and a second portion 128. The frame receiving portion 120 may have a height between about 0.40 inches and about 0.60 inches, such as about 0.50 inches, and a width between about 0.40 inches and about 0.60 inches, such as about 0.50 inches. The thickness of the plastic in the second portion 128 of the frame receiving portion 120 may be between about 0.20 and 0.04 inches. After reviewing this disclosure, one skilled in the art will appreciate that the frame receiving portion 120 may have other suitable shapes, sizes, configurations and arrangements depending, for example, upon the type of frame 30 or intended use of the table 10.

[0106] The table top 12 may also include a cross bar receiving portion 130 that is sized and configured to receive the cross bar 54. For example, as seen in FIGS. 6, 24, and 26, the cross bar receiving portion 130 may have a curved engagement surface 132 with a first portion 134 and a second portion 136. If desired, the engagement surface 132 of the cross bar receiving portion 130 may correspond to the size and shape of the cross bar 54. The cross bar receiving portion 130 may include one or more depressions 70 and, for a fold-in-half table, one portion of the cross bar receiving portion may be disposed in a first section of the table top 12 and another portion of the cross bar receiving portion may be disposed in a second section of the table top. The cross bar receiving portion 130 may have a height between about 0.30 inches and about 0.50 inches, such as about 0.40 inches, and a thickness of the plastic in the second portion 136 of the cross bar receiving portion 130 may be between about 0.20 and 0.04 inches.

[0107] Another exemplary embodiment of a frame receiving portion 140 is shown in FIGS. 19, 27, and 29. The frame receiving portion 140 may include one or more depressions 70 and the frame receiving portion may be disposed adjacent and/or be formed or defined by a portion of the lip 28. As seen in FIG. 29, the frame receiving portion 140 may have a generally U-shaped configuration with a first sidewall 142, a second sidewall 144, a first portion 146, and a second portion 148. The frame receiving portion 140 may have a height between about 0.40 inches and about 0.60 inches, such as about 0.50 inches, and a width between about 0.60 inches and about 0.80 inches, such as about 0.70 inches. The thickness of the plastic in the second portion 148 of the frame receiving portion 140 may be between about 0.20 and 0.04 inches. The second sidewall 144 may be at least partially defined by the lip 28 and the lip may have a between about 0.30 inches and about 50 inches, such as about 0.40 inches.

[0108] Another exemplary embodiment of a cross bar receiving portion 150 is seen in FIGS. 19, 28, and 30. The cross bar receiving portion 150 may have a curved engagement surface 152 with a first sidewall 154 and a second sidewall 156. If desired, the engagement surface 152 of the cross bar receiving portion 150 may correspond to the size and shape of the cross bar 54. The cross bar receiving portion 150 may include one or more depressions 70 and, for a fold-in-half table, one portion of the cross bar receiving portion may be disposed in a first section of the table top 12 and another portion of the cross bar receiving portion may be disposed in a second section of the table top. The cross bar receiving portion 150 may include a first portion 158 and a second portion 160. The cross bar receiving portion 150 may have a height between about 0.30 inches and about 0.50 inches, such as about 0.40 inches, and a thickness of the plastic in the second portion 160 of the cross bar receiving portion may be between about 0.20 and 0.04 inches. One skilled in the art will appreciated, after reviewing this disclosure, that the cross bar receiving portions 130, 150 may have other suitable shapes, sizes, configurations, and arrangements depending, for example, upon the type of table 10, cross bar 54, and the like.

[0109] As discussed above, previous large, generally planar blow-molded plastic structures required the opposing surfaces to be spaced apart by significantly more than one-half inch. The foregoing description, however, provides for the surprising and unexpected result that large, thin, generally planar blow-molded plastic structures may have a thickness generally equal to or less than one-half inch.

[0110] Although this invention has been described in terms of certain preferred embodiments, other embodiments apparent to those of ordinary skill in the art are also within the scope of this invention. Accordingly, the scope of the invention is intended to be defined only by the claims which follow.