CONNECTION OF A SUPPORT TO A MOLDED PLASTIC STRUCTURE

Abstract

A blow-molded plastic structure, such as a table top, may include an undercut. For example, the table top may include a frame receiving portion and a frame connecting structure with an undercut may be disposed in the frame receiving portion. A first portion of the frame may contact or engage the frame connecting structure when the frame is connected to the table top. In an exemplary embodiment, a first side of the frame receiving portion may include a first frame connecting portion with an undercut and a second side of the frame receiving portion may include a second frame connecting portion with an undercut. The first frame connecting portion with an undercut may be disposed on an opposing surface from the second frame connecting portion with an undercut.

Claims

1. A table comprising: a blow-molded plastic table top constructed using a blow-molding process, the table top comprising: an upper surface; a lower surface; a frame receiving portion disposed in the lower surface of the table top; a first frame connecting structure with an undercut disposed in a first portion of the frame receiving portion; and a second frame connecting structure with an undercut disposed in a second portion of the frame receiving portion; a frame connected to the table top, a first portion of the frame contacting the first frame connecting structure, a second portion of the frame contacting the second frame connecting structure; and one or more support members that are sized and configured to support the table top above a surface.

2. The table of claim 1, wherein the first portion of the frame engages a lower surface of the undercut of the first frame connecting structure; and wherein the second portion of the frame engages a lower surface of the undercut of the second frame connecting structure.

3. The table of claim 1, wherein the first frame connecting structure is disposed on a first side of the frame receiving portion and the second frame connecting structure is disposed on a second side of the frame receiving portion.

4. The table of claim 1, wherein the first fame connecting structure comprises an outwardly extending structure with an undercut.

5. The table of claim 1, wherein the second fame connecting structure comprises an inwardly extending structure with an undercut.

6. The table of claim 1, wherein the frame is connected to the table top without the use of any fasteners.

7. The table of claim 1, wherein the upper surface, the lower surface, the frame receiving portion, the first frame connecting structure with an undercut, and the second frame connecting structure with an undercut are integrally formed as part of a unitary, one-piece structure during the blow-molding process.

8. The table to claim 1, wherein a portion of the frame is inserted into the frame receiving portion and then the frame is moved within the frame receiving portion to engage the first portion of the frame with the undercut of the first frame connecting structure and to engage the second portion of the frame with the undercut of the second frame connecting structure.

9. The table of claim 1, further comprising a cutout in the frame, the cutout allowing the frame to be inserted into the frame receiving portion.

10. The table of claim 1, further comprising one or more outwardly extending tabs of the frame and one or more receiving portions in the table top, the tabs being disposed in the receiving portions when the frame is connected to the table top.

11. A method of connecting a frame to a blow-molded plastic table top, the method comprising: providing a table top with a frame receiving portion, the frame receiving portion including a first frame connecting structure with an undercut disposed in a first portion of the frame receiving portion and a second frame connecting structure with an undercut disposed in a second portion of the frame receiving portion; inserting a portion of the frame into the frame receiving portion; and moving the frame relative to the table top so that a first portion of the frame contacts the first frame connecting structure and a second portion of the frame contacts the second frame connecting structure.

12. The method of claim 11, wherein the first portion of the frame engages a lower surface of the undercut of the first frame connecting structure; and wherein the second portion of the frame engages a lower surface of the undercut of the second frame connecting structure.

13. The method of claim 11, wherein the first frame connecting structure is disposed on a first side of the frame receiving portion and the second frame connecting structure is disposed on a second side of the frame receiving portion.

14. The method of claim 11, wherein the first portion of the frame engages the undercut of the first frame connecting structure; and wherein the second portion of the frame engages the undercut of the second frame connecting structure.

15. The method of claim 11, further comprising one or more outwardly extending tabs of the frame and one or more receiving portions in the table top, the tabs being disposed in the receiving portions when the frame is connected to the table top.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The appended drawings contain figures of exemplary 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 exemplary embodiments of the invention and are not intended to limit its scope. Additionally, it will be appreciated that while the drawings may illustrate preferred sizes, scales, relationships and configurations of the invention, the drawings are not intended to limit the scope of the claimed invention. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0037] FIG. 1A is a upper perspective view of an exemplary molded plastic structure and a support, such as a frame;

[0038] FIG. 1B is an upper perspective view of the molded plastic structure and frame shown in FIG. 1A, illustrating the frame and molded plastic structure disposed in a first position;

[0039] FIG. 1C is an upper perspective view of the molded plastic structure and frame shown in FIG. 1A, illustrating the frame and molded plastic structure disposed in a second position;

[0040] FIG. 2A is a upper perspective view of an exemplary molded plastic structure and a support, such as a frame;

[0041] FIG. 2B is an upper perspective view of the molded plastic structure and frame shown in FIG. 2A, illustrating the frame and molded plastic structure disposed in a first position;

[0042] FIG. 2C is an upper perspective view of the molded plastic structure and frame shown in FIG. 2A, illustrating the frame and molded plastic structure disposed in a second position;

[0043] FIG. 3A is cross-sectional side view along lines 3A-3A shown in FIG. 1B;

[0044] FIG. 3B is cross-sectional side view along lines 3B-3B shown in FIG. 1C;

[0045] FIG. 3C is a cross-sectional side along lines 3C-3C;

[0046] FIG. 4A is cross-sectional side view along lines 4A-4A shown in FIG. 1B;

[0047] FIG. 4B is cross-sectional side view along lines 4B-4B shown in FIG. 1C;

[0048] FIG. 5A is an enlarged upper perspective view of an exemplary molded plastic structure;

[0049] FIG. 5B is another enlarged upper perspective view of an exemplary molded plastic structure;

[0050] FIG. 6A is an enlarged perspective view of an exemplary support, such as a frame; and

[0051] FIG. 6B is another enlarged perspective view of an exemplary support, such as a frame.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0052] The following exemplary embodiments are generally described in connection with blow-molded plastic structures such as a table top. The principles of the present invention, however, are not limited to a table top. In particular, the principles of the present invention may be implemented in other articles of furniture and in other structures that include blow-molded plastic components. In addition, it will be understood that, with the benefit of the present disclosure, the structures can have a variety of shapes, sizes, configurations, and arrangements. Moreover, the invention disclosed herein and components thereof may be successfully used in connection with other types of structures such as furniture (e.g., tables, picnic tables, chairs, etc.), objects (e.g., sheds, deck boxes, coolers, garden boxes, playground equipment, sporting goods, water sports equipment, etc.), and the like.

[0053] To assist in the description of exemplary embodiments shown in the accompanying figures, words such as top, bottom, front, rear, right and left may be used. The accompanying figures may be, but are not necessarily, drawn to scale. It will further be appreciated the structures can be disposed in a variety of desired positions or orientations, and used in numerous locations, environments and arrangements. A detailed description of some exemplary embodiments of the structures now follows.

[0054] An exemplary structure may be constructed from molded plastic. The exemplary molded plastic structure may be constructed from blow-molded plastic. In the accompanying figures, the exemplary molded plastic structure may be referred to as a table top or a portion of a table top. The table top may include an upper portion, a lower portion, and an outer boundary. The upper portion and the lower portion of the table top may be spaced apart by a distance. The table top may include a hollow interior portion disposed between the upper portion and the lower portion. The hollow interior portion may be filled with foam or other suitable materials, if desired.

[0055] The table top may further include one or more sides, corners, and ends. The table top may be integrally formed as part of unitary, one-piece structure during the blow-molding process. It will be appreciated that the table top may have a variety of suitable shapes, sizes, configurations, and/or arrangements depending, for example, upon the intended use of the table. It will also be appreciated that the table top may be constructed using various materials and may include one or more features, aspects, and the like. While the molded plastic structure may be described as being a table top or a portion of a table top, it will be appreciated that the molded plastic structure may another suitable structure such as a chair seat, shed, deck box, and the like.

[0056] Although not shown in the accompanying figures, the table may include one or more support structures or legs, which may be sized and configured to support the table top above a surface such as the floor or ground. The support structures may include one or more supports and the support structures may be movable between a use position and a collapsed or storage position. It will be appreciated that the table may include any suitable number of support structures and/or legs depending, for example, upon the intended use of the table. It will also be appreciated that the support structures and/or legs may have different shapes, sizes, configurations, and/or arrangements depending, for example, upon the type or intended use of the table.

[0057] The table may include a frame that is connected to the table top. The frame may support the table top and may facilitate attachment of the support structures to the table. The exemplary frame shown in the accompanying figures may be a side rail of a frame and a table top may include a side rail disposed proximate each side of the table top. It will be appreciated that the frame may have different shapes, sizes, configurations, and/or arrangements depending, for example upon the type or intended use of the table. It will be appreciated that the frame and table top may have other components, features, aspects, characteristics and the like, if desired.

[0058] It will be appreciated with the benefit of the present disclosure that the table top and frame may include any suitable number of components and the components may have various sizes, shapes, configurations, and arrangements depending, for example, upon the intended use of the table. It will further be appreciated that the table top and frame may include other components, features, aspects, characteristics and the like, if desired; but none of the features, aspects or components may be required.

[0059] The table top may include one or more undercuts. For example, the table top may include an outwardly extending portion with an undercut. As shown in the accompanying figures, the outwardly extending portion may extend outwardly from a portion of the table top and it may include a projection with an undercut. For instance, the outwardly extending portion may include a ramp or sloped surface and an overhang. A relief or recess may be disposed under the overhang and the lower surface of the overhang may include a generally planar surface. The lower surface of the overhang may be disposed at an angle and the lower surface of the overhang may be sized and configured to engage or contact a portion of the frame.

[0060] The table top may include an inwardly extending portion with an undercut. As shown in the accompanying figures, the inwardly extending portion may extend inwardly into a portion of the table top and it may include a projection with an undercut. The inwardly extending portion may include an opening and a receiving portion. The inwardly extending portion may include an undercut with a relief or recess and the lower surface of the overhang may include a generally planar surface. The lower surface of the undercut may be disposed at an angle and the lower surface of the undercut may be sized and configured to engage or contact a portion of the frame.

[0061] The table top may include a frame receiving portion that is sized and configured to receive at least a portion of a frame. For example, the frame receiving portion may include a channel or recess disposed in a lower portion of the table top. The frame receiving portion may include a first portion and a structure with an undercut may be disposed in the first portion of the frame receiving portion. The frame receiving portion may include a second portion and a structure with an undercut may be disposed in the second portion of the frame receiving portion. In an exemplary embodiment, the frame receiving portion may include a first side with an undercut, such as an outwardly extending structure with an undercut, and a second side with an undercut, such as an inwardly extending portion with an undercut. As shown in the accompanying figures, the undercut on the first side of the frame receiving portion may be at least partially aligned with the undercut on the second side of the frame receiving portion. After reviewing this disclosure, it will be appreciated that any suitable number, shape, size, configuration, and/or arrangement of undercuts may be disposed on the first and/or second portions of the frame receiving portion. After reviewing this disclosure, it will also be appreciated that one or more undercuts may be aligned, generally disposed in the same plane, disposed in a symmetrical configuration, and the like. The undercuts, however, do not have to be aligned, generally disposed in the same plane, or disposed in a symmetrical configuration. Instead, the undercuts may be offset, spaced apart, and/or disposed in other suitable configurations and arrangements. Further, the undercuts may be any suitable combination of outwardly extending and/or inwardly extending structures depending, for example, upon the intended use of the table.

[0062] The frame may be sized and configured to be at least partially disposed in the frame receiving portion. The frame may include one or more openings or cutouts to allow the frame to be at least partially disposed in the frame receiving portion. For example, the frame may include cutout that allows the frame to be disposed about the outwardly extending structure with an undercut. The frame may also include a surface that is sized and configured to engage or contact a corresponding surface of the undercut when the frame is connected to the table top.

[0063] The frame may include one or more tabs or outwardly extending portions that are sized and configured to be at least partially disposed in the inwardly extending structures with an undercut. For example, the tab may be disposed in the opening of the inwardly extending structure when the frame is inserted into the frame receiving portion. The tab may include a surface that is sized and configured to engage or contact a corresponding surface of the undercut when the frame is connected to the table top.

[0064] Advantageously, the frame and frame receiving portion may be sized and configured to allow the frame to be inserted into the frame receiving portion and then moved so that the frame engages the undercut on the first side of the frame receiving portion and the undercut on the second side of the frame receiving portion. This may facilitate secure attachment of the frame to the table top because opposing portions of the frame may be secured to the table top.

[0065] For example, FIG. 1A illustrates an exemplary frame and exemplary portion of a table top disposed in a generally vertically aligned configuration. As shown in FIG. 1B, the frame may be at least partially disposed in a frame receiving portion of the table top. As shown in FIG. 1C, the frame may be moved relative to the table top to connect the frame and table top.

[0066] FIGS. 2A-2C illustrate the connection of the frame and table top from a different viewpoint. For example, FIG. 2A illustrates the frame and portion of a table top in a generally vertically aligned configuration. FIG. 2B illustrate the frame at least partially disposed in the frame receiving portion of the table top. FIG. 2C illustrate the frame may be moved relative to the table top to connect the frame and table top.

[0067] The frame and/or table top may include other features and aspects. For example, the table top may include one or more angled surfaces, such as ramps, which may help position the frame relative to the table top. The angled surfaces may also help prevent unintentional detachment of the frame from the table top. The table top may also include one or more receiving portions that are sized and configured to receiving a portion of the frame. The receiving portions may receive a portion of the frame and may help prevent inadvertent disconnection of the frame and table top. For instance, the frame may include an outwardly extending portion and the outwardly extending portion may move along an angled surface when the frame is being moved within the frame receiving portion to a locked position. When the frame is disposed in the locked position, the outwardly extending portion may be disposed in the receiving portion and engagement of the outwardly extending portion with the receiving portion may help secure the frame in a locked position.

[0068] The inwardly or outwardly extending portions with an undercut cannot be formed with traditional blow-molding techniques. Instead, a tool allows the inwardly extending portion with an undercut to be formed during the blow-molding process. The exemplary tool may include a base, a first finger, and a second finger. The first and second fingers may be movable between a molding position in which the blow-molded structure may be formed and a release position in which the blow-molded structure may be released from the tool. The first finger may include a stop and the second finger may include a stop, and the stops may help control movement of the fingers. For example, the stops may help position the fingers in the molding position and/or the release position. The fingers may also include more than one stop, which may help position the fingers in the molding position and/or the release position. The first and second fingers may include an end, such as a distal end, that extends outwardly relative to an upper surface of the base. A portion of the first and second fingers, which may include the distal ends, may be sized and configured to contact or touch the plastic during the blow-molding process. Thus, the distal ends of the fingers may help form the plastic into the desired shape during the molding process. The first and second fingers may also include another end, such as a proximal end, and the proximal end of the fingers may be disposed at least proximate a lower surface of the base. The fingers may be connected to a device, such as a motor, cam, piston, driver, and the like, and the device may help control movement of one or more of the fingers. For example, the device may move the fingers between the molding position and the release position.

[0069] The fingers may include outwardly extending portions and the outwardly extending portions may be sized and configured to form the undercuts in the inwardly extending portions. In greater detail, an outwardly extending portion may be disposed at the distal end of each finger and the outwardly extending portions may extend in opposing directions. For example, in the molding position, the outwardly extending portions may extend in opposite directions and the outwardly extending portions may be disposed in generally the same plane. The outwardly extending portions may include a generally planar first surface and a generally planar second surface that are separated by a distance. The first and second generally planar surfaces may be generally aligned in parallel planes. The first and second generally planar surfaces, however, do not have to be aligned or disposed in generally parallel planes. For example, the first and second generally planar surfaces could be disposed at an angle depending, for example, upon the type of undercut to be formed. The outwardly extending portions may also include an outer edge or wall that extends between the first and second surfaces.

[0070] When the tool is disposed in the molding position, an upper surface of the first and second fingers and/or an upper surface of the outwardly extending portions may be generally aligned and/or disposed in the same plane. The upper surfaces of the first and second fingers and/or the upper surfaces of the outwardly extending portions may also be aligned with a portion of the base, such as an upper surface of the guide. The guide may have a generally wedge or triangular-shaped configuration and the upper surface of the first and second fingers and/or an upper surface of the outwardly extending portions may be generally aligned with the upper surface of the guide. In the molding position, the outer surfaces of the fingers proximate the base may be separated by a first distance, the outer surfaces of the fingers proximate the outwardly extending portions may be separated by a second distance, and the outermost ends or edges of the outwardly extending portions of the fingers may be separated by a third distance. The first distance may be greater than the second distance or the third distance, and this portion of the tool may form the base of the inwardly extending portion during the molding process. The second distance may be smaller than the first distance and the third distance, and the second distance may help identify the narrowest portion of the inwardly extending portion. The third distance may be smaller than the first distance and larger than the second distance, and the third distance may help identify the undercut.

[0071] When the blow-molded structure is being formed, the plastic may contact and be disposed about an upper, exterior portion of the first and second fingers, the outwardly extending portions, and a portion of the base, such as a portion of the guide and/or the upper surface of the base. Advantageously, the tool may allow the inwardly extending portion with the undercut to be created during the blow-molding process. In addition, the structure may be removed from the tool after the structure is formed without any, or substantially without any, deformation of the molded plastic structure. Significantly, the undercut can include planar surfaces and/or sharp angles, which may facilitate secure connection for components, such as fasteners, connectors, or other objects, to the chair seat.

[0072] Structures constructed from blow-molded plastic may have unique and distinctive properties, and some aspects of blow-molding may not be compatible with other types of molding such as injection molding, rotational molding, vacuum fuming, and the like. For example, because a blow-molded plastic structure is formed by using air or gas to inflate a parison of molten plastic, some features or structures that can be made from some types of molding processes cannot be manufactured using known blow-molding techniques. In addition, a blow-molded plastic structure is generally formed with an outer surface of the structure engaging the face of the mold and a hollow interior that is filled with pressurized gas during the molding process. Thus, blow-molded plastic structures may not be manufactured with the devices, molds, structures, and the like of other types of molding processes because of the different properties and configurations of blow-molded plastic structures. Further, because most blow-molded plastic structures include opposing walls separated by a distance and enclosing a hollow interior portion, processes or structures that may work with a single layer of material may not work with a blow-molded structure. Accordingly, after reviewing this disclosure, one skill in the art will appreciate the significant differences between the blow-molded plastic structures and methods disclosed herein, and other types of molded plastic structures and methods.

[0073] One of ordinary skill in the art may appreciate after reviewing this disclosure that the chair seat and structures disclosed herein may have a number of different aspects, features, characteristics and configurations. Further, chair seat and structures may have any suitable number of aspects, features, characteristics and configurations depending, for example, upon the intended use of the chair or other structure.

[0074] One of ordinary skill will appreciate that the structures disclosed herein may have various suitable sizes, shapes, configurations, and/or arrangements. Other exemplary configurations are shown below:

[0075] 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.