Fusion panel and application

Abstract

A fusion panel includes a first panel member, a second panel member, a first layer and a second layer, wherein the first layer is overlapped and fused with the second layer. Edges of the first panel member and the second panel member are connected to each other to form a cavity therebetween with a hollow structure. The first panel member is constructed to have at least one of a portion of the first layer and a portion of the second layer. The second panel member is constructed to have at least one of a portion of the first layer and a portion of the second layer.

Claims

1. A blow molded fusion panel, comprising: first and second layers overlapped and fused with each other, wherein said first layer is made of a first material and said second layer is made of a second material; a third layer fused with said second layer to sandwich said second layer between said first layer and said third layer; and first and second panel members spaced apart from each other to define a cavity therebetween, wherein each of said first and second panel members is constructed by said first, second and third layers, wherein a plurality of different portions of each of said first layer, said second layer and said third layer of said second panel member is concurrently stretched and recessed into said cavity to form a plurality of supporting structures respectively, such that each of said supporting structures is constructed by said first, second and third layers, wherein said supporting structures are extended to bias against said first panel member so as to support said first panel member, wherein said cavity is formed between said third layer of said first panel member and said third layer of said second panel member, wherein said first layer of each of said first panel member and said second panel member is embodied as an outer layer, said third layer of each of said first panel member and said second panel member is embodied as an inner layer being made to provide frame support, said second layer of each of said first panel member and said second panel member is embodied as an intermediate layer being made to provide a buffering effect for said first layer and said third layer.

2. The blow molded fusion panel, as recited in claim 1, wherein said third layer of each of said supporting structures is fused with said third layer of said first panel member.

3. The blow molded fusion panel, as recited in claim 1, wherein a top of each of said supporting structures has a U-shaped waving structure to form two or more peak points biasing against said first panel member.

4. The blow molded fusion panel, as recited in claim 2, wherein a top of each of said supporting structures has a U-shaped waving structure to form two or more peak points biasing against said first panel member.

5. The blow molded fusion panel, as recited in claim 3, further comprising a plurality of reinforcing ribs, wherein each of said reinforcing ribs is integrally formed with each of said supporting structures at a position that said reinforcing rib is located between said peak points.

6. The blow molded fusion panel, as recited in claim 3, wherein each of said supporting structures comprises a supporting top wall defining said peak points thereat, and a supporting sidewall inclinedly extended from said supporting top wall to said second panel member so as to form a recessed cavity encircled within said supporting sidewall, wherein a size of said recessed cavity is reduced from said second panel member to said first panel member.

7. The blow molded fusion panel, as recited in claim 1, wherein said supporting structures are arranged in an interval manner and in a staggered manner.

8. The blow molded fusion panel, as recited in claim 1, wherein said second panel member is blow-molded to stretch and recess said portions thereof into said cavity to form said supporting structures for ensuring no additional material of said second panel member being added to form said supporting structures.

9. The blow molded fusion panel, as recited in claim 2, wherein said second panel member is blow-molded to stretch and recess said portions thereof into said cavity to form said supporting structures for ensuring no additional material of said second panel member being added to form said supporting structures.

10. A blow molded fusion panel, comprising: first and second layers overlapped and fused with each other, wherein said first layer is made of a first material and said second layer is made of a second material; a third layer fused with said second layer to sandwich said second layer between said first layer and said third layer; and first and second panel members spaced apart from each other to define a cavity therebetween, wherein each of said first and second panel members is constructed by said first layer, said second layer and said third layer, wherein a plurality of different portions of each of said first layer, said second layer and said third layer is concurrently stretched and recessed into said cavity to form a plurality of supporting structures respectively, wherein said supporting structures are extended to bias against said first panel member so as to support said first panel member, wherein said cavity is formed between said third layer of said first panel member and said third layer of said second panel member, wherein said first layer is made of high density polyethylene, wherein said third layer is made of metallocene polyethylene, wherein said second layer is made of a mixture of metallocene polyethylene and calcium carbonate or a mixture of high density polyethylene and calcium carbonate or a mixture high density polyethylene and glass fiber.

11. The blow molded fusion panel, as recited in claim 10, wherein said third layer of each of said supporting structures is fused with said third layer of said first panel member.

12. The blow molded fusion panel, as recited in claim 10, wherein a top of each of said supporting structures has a U-shaped waving structure to form two or more peak points biasing against said first panel member.

13. The blow molded fusion panel, as recited in claim 12, further comprising a plurality of reinforcing ribs, wherein each of said reinforcing ribs is integrally formed with each of said supporting structures at a position that said reinforcing rib is located between said peak points.

14. The blow molded fusion panel, as recited in claim 12, wherein each of said supporting structures comprises a supporting top wall defining said peak points thereat, and a supporting sidewall inclinedly extended from said supporting top wall to said second panel member so as to form a recessed cavity encircled within said supporting sidewall, wherein a size of said recessed cavity is reduced from said second panel member to said first panel member.

15. The blow molded fusion panel, as recited in claim 10, wherein said supporting structures are arranged in an interval manner and in a staggered manner.

16. The blow molded fusion panel, as recited in claim 10, wherein said plurality of different portions of said third layer of said second panel member are concurrently stretched and recessed along with said plurality of different portions of said first layer and said plurality of different portions of said second layer of said second panel member into said cavity to form said supporting structures respectively, such that each of said supporting structures is constructed by said first, second and third layers.

17. The blow molded fusion panel, as recited in claim 14, further comprising a plurality of reinforcing ribs, wherein each of said reinforcing ribs is integrally formed with each of said supporting structures at a position that said reinforcing rib is located between said peak points.

18. The blow molded fusion panel, as recited in claim 17, wherein each of said supporting structures comprises a supporting top wall defining said peak points thereat, and a supporting sidewall inclinedly extended from said supporting top wall to said second panel member so as to form a recessed cavity encircled within said supporting sidewall, wherein a size of said recessed cavity is reduced from said second panel member to said first panel member.

19. The blow molded fusion panel, as recited in claim 10, wherein said second panel member is blow-molded to stretch and recess said portions thereof into said cavity to form said supporting structures for ensuring no additional material of said second panel member being added to form said supporting structures.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a sectional perspective view of a blow molded panel according to a first preferred embodiment of the present invention.

(2) FIG. 2 is an enlarged perspective view of the blow molded panel at section A of FIG. 1 according to the above first preferred embodiment of the present invention.

(3) FIG. 3 is an enlarged perspective view of the blow molded panel at section B of FIG. 1 according to the above first preferred embodiment of the present invention.

(4) FIG. 4 is a sectional perspective view of a blow molded panel according to a second preferred embodiment of the present invention.

(5) FIG. 5A is a sectional view of the blow molded panel according to the above first preferred embodiment of the present invention.

(6) FIG. 5B is a bottom view of the blow molded panel according to the above first preferred embodiment of the present invention.

(7) FIG. 6 is an enlarged sectional view of the blow molded panel at section I of FIG. 5B according to the above first preferred embodiment of the present invention.

(8) FIG. 7A is an enlarged sectional view of the blow molded panel at section J of FIG. 5B according to the above first preferred embodiment of the present invention.

(9) FIG. 7B is an enlarged perspective view of the blow molded panel at section J of FIG. 5B according to the above first preferred embodiment of the present invention.

(10) FIG. 7C is another enlarged sectional view of the blow molded panel at section J of FIG. 5B according to the above first preferred embodiment of the present invention.

(11) FIG. 8 is a flow diagram illustrating a manufacturing method of the blow molded panel according to the above first preferred embodiment of the present invention.

(12) FIG. 9 is a perspective view of a blow molded panel according to a third preferred embodiment of the present invention.

(13) FIG. 10 is a perspective view of a blow molded panel according to a fourth preferred embodiment of the present invention.

(14) FIG. 11 is a perspective view of a blow molded panel according to a fifth preferred embodiment of the present invention.

(15) FIG. 12 is a perspective view of a blow molded panel according to a sixth preferred embodiment of the present invention.

(16) FIG. 13 is a perspective view of a blow molded panel according to a seventh preferred embodiment of the present invention.

(17) FIG. 14 is a perspective view of a table incorporating with the blow molded panel according to the above preferred embodiments of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(18) The following description is disclosed to enable any person skilled in the art to make and use the present invention. Preferred embodiments are provided in the following description only as examples and modifications will be apparent to those skilled in the art. The general principles defined in the following description would be applied to other embodiments, alternatives, modifications, equivalents, and applications without departing from the spirit and scope of the present invention.

(19) It is appreciated that the terms longitudinal, transverse, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, interior and exterior and in the following description refer to the orientation or positioning relationship in the accompanying drawings for easy understanding of the present invention without limiting the actual location or orientation of the present invention. Therefore, the above terms should not be an actual location limitation of the elements of the present invention.

(20) It is appreciated that the terms one, a, and an in the following description refer to at least one or one or more in the embodiment. In particular, the term a in one embodiment may refer to one while in another embodiment may refer to more than one. Therefore, the above terms should not be an actual numerical limitation of the elements of the present invention.

(21) The present invention will be further described in detail below with reference to the embodiments of the drawings.

Embodiment 1

(22) Referring to FIGS. 1 to 3 of the drawings, a blow molded panel according to a first preferred embodiment of the present invention is illustrated, wherein the blow molded panel comprises an upper panel member 1 and a lower panel member 2. The upper and lower panel members 1, 2 are space apart with each other to form a hollow structure through a blow molding process.

(23) According to the preferred embodiment, each of the upper and lower panel members 1, 2 is constructed to have a triple layer structure. In other words, each of the upper and lower panel members 1, 2 comprises an outer layer 3, an intermediate layer 5, and an inner layer 4 sandwiched together. In addition, the lower panel member 2 has a square wave configuration that portions of the lower panel member 2 are extended upwardly to the upper panel member 1, wherein the lower panel member 2 is stretched and recessed to the upper panel member 1 at a position that the inner layer 4 of the lower panel member 2 is fused with the inner layer 4 of the upper panel member 1 to form a plurality of predetermined contact supporting structures 6 distributed underneath the upper panel member 1.

(24) FIG. 3 illustrates the edge structure of the blow molded panel, wherein the upper panel member 1 further comprises an outer bending wall 11 being bent downwardly at an outer edge of the upper panel member 1. The lower panel member 2 further comprises an inner bending wall 21 being bent downwardly at an outer edge of the lower panel member 2. A bottom of the inner layer 4 of the outer bending wall 11 and a bottom of the inner layer 4 of the inner bending wall 21 are integrated with each other.

(25) According to the preferred embodiment, each of the contact supporting structures 6, having a sinusoidal waveform, is configured to have an elongated shape or strip shape, wherein each of the contact supporting structures 6 comprises two reinforcing ribs 61. As shown in FIGS. 1 and 2, the contact supporting structure 6 is configured to have two reinforcing ribs 61 and three contacting points 62 alternating with the reinforcing ribs 61.

(26) For the raw material structure of the double panel members with triple layer configuration of the blow molded panel, the outer layers 3 of the upper and lower panel members 1, 2 are made of high density polyethylene. The intermediate layers 5 of the upper and lower panel members 1, 2 are made of a mixture of high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber. The inner layers 4 of the upper and lower panel members 1, 2 are made of metallocene polyethylene.

(27) 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.

(28) In one embodiment, 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 70-85%, and the mass percentage of calcium carbonate is 15-30%.

(29) In one embodiment, when the intermediate layer 5 is made of a mixture of high density polyethylene and glass fiber, the mass percentage of high density polyethylene is 60-85%, and the mass percentage of glass fiber is 15-40%.

(30) For the raw material structure of the double panel members with triple layer configuration of the blow molded panel, the inner layer 4 can be broken to absorb the energy when an external force is applied on the outer layer 3 due to the high impact or drop. Due to the material properties of the intermediate layer 5, the intermediate layer 5 provides a relatively high resilient tensile force to restore the inner layer 4 so as to ensure the integrity of the panel and the function of the panel. Therefore, the hollow composite panel has the advantages of high surface strength, high flatness, excellent impact resistance, excellent deformation resistance, excellent rigid structure, higher performance and long service life.

(31) The multi-panel multi-layer configuration of the blow molded panel of the present invention is able to apply to many different applications. For example, the blow molded panel can be applied to tables and chairs, such as tabletop panels, seat panels, and back panels etc. The blow molded panel can also be applied to other products where the panel is easy to break. The blow molded panel can be applied to building materials such as wall partitions, wall panels, door panels, fence panels, outdoor floors, insulation panels, and partition panels.

(32) According to the first preferred embodiment of the present invention, the parameters of the high density polyethylene used in the outer layer 3 are shown as follows: melting rate: 1.5 g/10 min, bending strength: 900 MPa, Shore D69.

(33) According to the first preferred embodiment of the present invention, the parameters of the high density polyethylene used in the intermediate layer 5 are as follows: melting rate: 0.35 g/10 min, bending strength: 1050 MPa, Shore D63.

(34) According to the first preferred embodiment of the present invention, the parameters of the metallocene polyethylene used in the inner layer 4 are as follows: Melting rate: 2.0 g/10 min; Elongation at break: 420% in longitudinal direction and 830% in transverse direction; Tensile strength at break: longitudinal 62 MPa, transverse 25 MPa; Dart impact strength <48 g; Eikmandorf tearing strength: 21 C. in longitudinal direction, 430 C. in transverse direction.

(35) Furthermore, a person who skilled in the art should understand that, as an example of a simplified application, the outer layer, the intermediate layer and the inner layer can be made of the same material, or the material with different grades or different levels. For example, the outer layer, the intermediate layer and the inner layer can be made of high density polyethylene. In addition, the outer layer can be made of material having high hardness level and bright color, the intermediate layer can be a composite layer, and the inner layer 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.

Embodiment 2

(36) As shown in FIG. 4, the blow molded panel according to a second embodiment illustrates an alternative mode, wherein the blow molded panel comprises an upper panel member 1 and a lower panel member 2 each having a double-layer configuration. In other words, each of the upper and lower panel members 1, 2 is constructed to have an outer layer 3 and an inner layer 4. Accordingly, the lower panel member 2 has a square wave configuration that portions of the lower panel member 2 are extended upwardly to the upper panel member 1, wherein the lower panel member 2 is stretched and recessed to the upper panel member 1 at a position that the inner layer 4 of the lower panel member 2 is fused with the inner layer 4 of the upper panel member 1 to form a plurality of predetermined contact supporting structures 6 distributed underneath the upper panel member 1.

(37) For the raw material structure of the double panel members with triple layer configuration of the blow molded panel, the outer layers 3 of the upper and lower panel members 1, 2 are made of high density polyethylene. The inner layers 4 of the upper and lower panel members 1, 2 are made of a mixture of high density polyethylene, metallocene polyethylene and calcium carbonate, or a mixture of high density polyethylene, metallocene polyethylene and glass fiber.

(38) According to the second preferred embodiment of the present invention, for the inner layer 4, the mass percentage of metallocene polyethylene is 10-15%, the mass percentage of calcium carbonate is 15-20%, and the rest is high density polyethylene. Alternatively, for the inner layer 4, 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.

(39) In addition, the parameters of the high density polyethylene and metallocene polyethylene applied in this embodiment can refer to the above Embodiment 1, and the description will not be expanded here.

(40) The above descriptions are for the preferred embodiments 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, the intermediate layer, and the inner layer of the upper layer member and the outer layer, the intermediate layer, and the inner layer of the lower layer member can be configured to have more than one layer structure, which should be within the scope of the present invention.

(41) According to one aspect of the present invention as a modification, as shown in FIGS. 5A to 8, the present invention provides a fusion panel 1 and its manufacturing method thereof.

(42) The fusion panel 1 is made of plastic to form a plastic panel, wherein the fusion panel 1 has an advantage same as the existing plastic products such as lightweight, and has an advantage different from the existing plastic products such as excellent structural strength.

(43) The fusion panel 1 comprises a first layer 10 and a second layer 20, wherein the first layer 10 is overlapped on and fused with at least a portion the second layer 20, such that the layers of the fusion panel 1 are closely combined together.

(44) The first layer 10 and the second layer 20 are overlapped each other to form at least one cavity 100 therebetween. For example, the first layer 10 is embodied as an outer layer and the second layer 20 is embodied as an inner layer. The cavity 100 is formed and surrounded by an inner wall of the second layer 20.

(45) The fusion panel 1 comprises a first panel member 30 and a second panel member 40, wherein edges of the first panel member 30 and the second panel member 40 are connected to each other to form at least one cavity 100.

(46) The first panel member 30 can be configured to have a substantial planar, flat, or smooth structure. Generally, the second partial panel 40 can be configured to have a substantial planar, flat or smooth structure. Of course, the first panel member 30 or the second panel member 40 can also be made with any texture according to actual requirements. The first panel member 30 and the second panel member 40 can be used as desk panels, wall panels, floor panels, or roof panels, and should not be limited for the other usages.

(47) The first panel member 30 is constructed to have at least one of a portion of the first layer 10 and a portion of the second layer 20. The second panel member 30 is constructed to have at least one of a portion of the first layer 10 and a portion of the second layer 20.

(48) In other words, when the size of the first layer 10 is smaller than the size of the second layer 20, the first panel member 30 is preferably constructed to have the first layer 10 and a portion of the second layer 20, wherein the second panel member 40 is constructed to have another portion of the second layer 20. When the size of the second layer 20 is smaller than the size of the second layer 20, is preferably constructed to have a portion of the first layer 10 and the second layer 20, wherein the second panel member 40 is constructed to have another portion of the first layer 10.

(49) In one embodiment, an inner surface of the first layer 10 is completely overlapped with an outer surface of the second layer 20. The first panel member 30 is constructed to have a portion of the first layer 10 and the second layer 20 superimposed on each other, wherein the second panel member 40 is constructed to have other portion of the first layer 10 and the second layer 20 superimposed on each other.

(50) The first panel member 30 and the second panel member 40 are positioned at opposite direction. When the first panel member 30 and the second panel member 40 are formed to have a two layer structure, the portion of the second layer 20 at of the first panel member 30 and the portion of the second layer 20 at the second panel member 40 are aligned in a face to face manner. Preferably, at least a portion of the first panel member 30 and at least a portion of the second panel member 40 are parallel to each other. For example, when the fusion panel 1 is embodied as a tabletop or a chair panel. It should be understood that the application of the fusion panel 1 should not be limited to furniture and home decoration, wherein the use of fusion panel 1 can also be applied to the field of decoration, such as automobiles, and can also be applied to the field of toys. The user is able to apply the fusion panel 1 to different fields according to actual requirements.

(51) Furthermore, as shown in FIG. 6, the fused layer 1 further comprises a third layer 50, wherein the third layer 50 is located at an inner side of the second layer 20. In other words, the second layer 20 is located between the first layer 10 and the third layer 50. The first panel member 30 is constructed to have at least one of a portion of the first layer 10, a portion of the second layer 20, and a portion of the third layer 50. The second panel member 30 is constructed to have at least one of another portion of the first layer 10, another portion of the second layer 20, and another portion of the third layer 50.

(52) In one example, the first panel member 30 can be configured to have a single layer structure, a double layer structure or a three layer structure, wherein the third panel can be configured to have a single layer structure, wherein the second panel can be configured to have a double layer structure. The second panel member 40 is constructed to have at least a portion of the first layer 10 and at least a portion of the second layer 20 being superimposed on each other. Alternatively, at least a portion of the first layer 10 and at least a portion of the third layer 50 are superimposed on each other, Alternatively, at least a portion of the second layer 20 and the third layer 50 are superimposed on each other. The first panel member 30 can be configured to have a single layer structure, a double layer structure or a three layer structure, wherein the third panel member 50 can be configured to have a three layer structure or a multi-layer structure.

(53) The second layer 20 and the first layer 10 are fused with each other at a connection thereof, and the second layer 20 and the third layer 50 are fused with each other at a connection thereof. In other words, the first layer 10 and the third layer 50 will not required for being fused with each other, wherein the second layer 20 functions as a connecting means to tightly connect the first layer 10 and the third layer 50 with each other.

(54) Furthermore, the fusion panel 1 provides a first function, a second function and a third function, wherein the first layer 10 is configured to have the first function, the second layer 20 is configured to have the second function, and the third layer 10 is configured to have the third function. In other words, the fusion panel 1 provides all the first function, the second function and the third function by fusing the first layer 10, the second layer 20 and the third layer 50 to compensate the weakness of each other, so as to reduce the requirement for each layer of the fusion panel 1.

(55) For example, the first layer 10 of the fusion panel 1 is configured to have the first function of high surface strength, scratch resistance and oil resistance. The second layer 20 of the fusion panel 1 is configured to have the second function of energy absorbing structure or a material with high rigidness, which can effectively absorb any external force applied to the fusion panel 1 due to the impact or drop thereof. The third layer 50 of the fusion panel 1 is configured to have the third function of low thermoplastic shrinkage ratio and frame support.

(56) The colors of the first layer 10, the second layer 20 and the third layer 50 can be the same or different. Preferably, the second layer 20 and the third layer 50 can be configured to have mixed colors because the second layer 20 and the third layer 50 of the fusion panel 1 are difficult to be seen.

(57) The first layer 10, the second layer 20 and the third layer 50 can be made of same material or different materials. When the first layer 10 is embodied as an outer layer, the second layer 20 is embodied as an intermediate layer, and the third layer 50 is embodied as an inner layer, the first layer 10 is made of high density polyethylene, the second layer 20 is made of a mixture of high density polyethylene and calcium carbonate or a mixture high density polyethylene and glass fiber, and the third layer 50 is made of metallocene polyethylene. The second layer 20 as the intermediate layer and the third layer 50 as the inner layer are difficult to be seen from outside, such that the color and luster requirements for the second layer 20 and the third layer 50 can be reduced. Therefore, the second layer 20 and the third layer 50 can also be made of recycled plastic to reduce the manufacturing costs.

(58) When the first layer 10 of the fusion panel 1 is made of high density polyethylene, the related parameters of the high density polyethylene are melting rate: 1.5 g/10 min, bending strength: 900 MPa, and Shore D69.

(59) When the second layer 20 of the fusion panel 1 is made of the mixture of high density polyethylene and calcium carbonate, the mass percentage of calcium carbonate is 15-30%, and the mass percentage of high density polyethylene is 70-85%, wherein the related parameters of high density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.

(60) When the second layer 20 of the fusion panel 1 is made of the mixture of high density polyethylene and glass fiber, the mass percentage of glass fiber is 15-40%, and the mass percentage of high density polyethylene is 60-85%, wherein the related parameters of high density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.

(61) When the third layer 50 of the fusion panel 1 is made of 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.

(62) It should be understood that the composition of each layer of the fusion panel 1 should not be limited to the above example, wherein the second layer 20 can be embodied as a micro-foam layer to provide a buffering effect.

(63) According to the preferred embodiment, the first panel member 30 of the fusion panel 1 is configured to have a three-layer structure, and the second partial panel 40 is configured to have a three-layer structure. When the first panel member 30 is positioned above the second panel member 40, the layer structure from top to bottom is configured as a portion of the first layer 10, a portion of the second layer 20, a portion of the third layer 50, another portion of the third layer 50, another portion of the second layer 20, and another portion of the first layer 10. The cavity 100 is formed within the inner walls of the third layers 50.

(64) When the first panel member 30 of the fusion panel 1 is configured to have a double-layer structure, and the second panel member 40 is configured to have a double-layer structure, the second layer 20 is configured to have better impact resistance or to have better support strength.

(65) Furthermore, the fusion panel 1 further comprises at least one supporting structure 60, wherein the supporting structure 60 is located in the cavity 100 to support the first panel member 30. At least a portion of the second panel member 40 is extended toward the cavity to form the supporting structure 60, wherein the supporting structure 60 can be, but should not be limited to, protrusions, bumps, and ridges.

(66) The supporting structure 60 can be configured to have a portion of the third layer 50 of the partial panel member 40, wherein the third layer 50 of the partial panel member 40 is inwardly extended to form the supporting structure 60. The supporting structure 60 can be configured to have a portion of the second layer 20 and a portion of the third layer 50 of the partial panel member 40, wherein at least a portion of the second layer 20 and at least a portion of the third layer 50 of the partial panel member 40 are inwardly and concurrently extended to form the supporting structure 60.

(67) According to the preferred embodiment, a portion of the first layer 10, a portion of the second layer 20 and a portion of the third layer 50 of the partial panel member 40 are inwardly and concurrently extended to form the supporting structure 60. In other words, a portion of the second panel member 40 is stretched and recessed to form a recessed cavity 400 corresponding to the supporting structure 60.

(68) The second panel member 40 further comprises a second panel main body 41 and the supporting structure 60, wherein the supporting structure 60 is integrally extended to the second panel main body 41. Preferably, two or more of the supporting structures 60 are provided, wherein the supporting structures 60 are spaced apart from each other in a predetermined interval.

(69) The recessed cavity 400 is formed at the surface of the second panel member 40, wherein the supporting structures 60 are configured correspondingly to the recessed cavities 400 respectively. In fact, at least a portion of the second panel member 40 is recessed to form the supporting structure 60.

(70) The recessed cavity 400 is configured to have a W-shaped cross section, and the overall shape thereof is configured to have an oblong shape with two arc-shaped ends, wherein peripheral walls of the recessed cavity 200 are upwardly and inwardly extended as inclined walls to form the supporting structure 60 of the second panel member 20.

(71) The supporting structure 60 has an upper end and a lower end, wherein the upper end of the supporting structure 60 is configured to support the first panel member 30, and the lower end of the supporting structure 60 is connected to the second panel main body 41. A cross sectional area of the supporting structure 60 is gradually increased from the upper end of the supporting structure 60 to the lower end thereof around the second panel member 40.

(72) Particularly, the supporting structure 60 further comprises a supporting sidewall 61, as a surrounding wall, extended from the second panel main body 41 to encircle the recessed cavity 400, wherein the supporting sidewall 61 is extended inclinedly, such that a space formed within the supporting sidewall 61 at the upper end of the supporting structure 60 is smaller than a space formed within the supporting sidewall 61 at the lower end of the supporting structure 60.

(73) When the first panel member 30 is located above the second panel member 40, the supporting structure 60 formed by the second panel member 40 is configured to have a tapered shape with a larger base and a smaller top structure so as to provide a stable configuration of the supporting structure 60.

(74) The supporting structure 60 further comprises a supporting top wall 62 extended from the supporting sidewall 61, wherein the supporting top wall 62 is extended to support at least a portion of an inner wall of the first panel member 30.

(75) Furthermore, the fusion panel 1 further comprises at least one reinforcing rib 70, wherein the reinforcing rib 70 is integrally provided on the supporting structure 60 to support the supporting structure 60. The recessed cavity 400 is encircled and formed within the supporting sidewall 61 of the supporting structure 60, wherein the recessed cavity 400 can be seen from an outer side of the second panel member 40. The reinforcing rib 70 is disposed in the recessed cavity 400 and is extended two sides of the supporting sidewall 61.

(76) In one embodiment, the supporting structure 60 has a narrow elongated shape, wherein the reinforcing ribs 70 is extended at a width direction of the supporting structure 60. More than one reinforcing ribs 70 is provided, for example, two, three or more of the reinforcing ribs 70.

(77) According to this embodiment, each of the supporting structures 60 is provided with a pair of reinforcing ribs 70, wherein the reinforcing ribs 70 are horizontally extended to across a bottom of the recessed cavity 200 which is the corresponding top of the supporting structure 60.

(78) The reinforcing rib 70 is formed in a U-shaped wave manner, wherein the reinforcing rib 70 can be integrally extended to the supporting structure 60, or can be formed by outwardly extending at least a portion of the supporting structure 60.

(79) It is worth mentioning that the wave-shaped structure of the reinforcing rib 70 is the best reinforcing structure, such that the two wave-shaped reinforcing rib 70 in pair will form the supporting structure 60 with three-peak wave configuration, which greatly strengthens the second panel member 40 to provide the impact resistance and to enhance the rigidity.

(80) The second panel member 20 is formed with at least one contact peak point 63 at the supporting top wall 62, wherein the contact peak point 63 is located higher than the surrounding portion and is close to the first panel member 30. Particularly, at least a portion of the second panel member 40 is extended toward the cavity, which is extended toward the first panel member 30 to define the peak point 63 at the second panel member 20. Accordingly, the portion of the second panel member 40 is stretched and recessed toward the first panel member 30 until the third layer 50 of the second panel member 40 and the third layer 50 of the first panel member 30 are fused with each other to form the peak point 63. The first panel member 30 is supported at a position of the peak point 63. At least a portion of the second panel member 20 is formed in a wave form to define the peak point 63. The number of peak point 63 can be varied and configured with a predetermined interval when two or more peak points 63 are formed. The reinforcing ribs 70 and the peak points 63 are located within the recessed cavity 400 and are configured in a concave-convex arrangement, as shown in FIG. 7A, such that the reinforcing ribs 70 and the peak points 63 are alternating with each other to form the contact supporting structure 60.

(81) In other words, the peak points 63 are formed with the supporting structure 60. At least a portion of the supporting structure 60 is outwardly extended to form the reinforcing rib 70 with two spaced apart peak points 63.

(82) As shown in FIGS. 5A to 7C, the supporting structure 60 is configured to have three peaks to form three peak points 63. At the position of each of the supporting structure 60, the third layer 50 of the second panel member 40 is stretched and recessed to the third layer 50 of the first panel member 30 and is fused to the third layer 50 of the first panel member 30 to form an integrated body during the blow molding process. Therefore, the second panel member 40 is combined with the first panel member 30 by the peak points 63 of the supporting structure 60 in order to form a hollow panel. Accordingly, the second panel member 40 is configured in a wave form with three peak structure of the supporting structure 60 to form the reinforcing ribs 70. Since the peak points 63 are coupled at the first panel member 30, the reinforcing support and structure of the first panel member 30 will be formed. The external impact and force applied to the first panel member 30 will be directly and evenly distributed to the second panel member 40 so as to provide a supporting force to the first panel member 30. Furthermore, the cavity 100 between the first panel member 30 and the second panel member 40 is configured to provide cushioning and shock absorbing effects.

(83) As shown in FIG. 5B, a plurality of supporting structures 60 are evenly distributed in the vertical and horizontal directions and are spaced apart at an even interval, such that the vertical extending supporting structures 60 and the horizontal extending supporting structures 60 are alternating with each other. Therefore, the material cost and the overall weight of the fusion panel 1 will be substantially reduced to have the hollow structure. On the other words, the fusion panel 1 provides an impact resistant and rigid structure that crosses the vertical and horizontal directions. Furthermore, through the peak points 63 of each of the supporting structures 60, the multiple joints between the first panel member 30 and the second panel member 40 are evenly distributed and formed to fuse the first panel member 30 and the second panel member 40. Therefore, the first panel member 30 and the second panel member 40 are integrated with each other, such that the external impact and force on the first panel member 30 can be directly and evenly distributed to the second panel member 40 so as to evenly distribute the external impact and force. Then, once the external impact and force is evenly distributed at the fusion panel 1, the external impact and force will be transferred to the ground via a panel supporting structure, such as supporting legs supported on the ground.

(84) Two or more of the peak points 63 are preferably formed by one supporting structure 60. When two or more supporting structure 60 are provided, the supporting structure 60 may have the same or different numbers of the peak points 63. For example, one of the supporting structure 60 may have the same or different numbers of the peak points 63. As an example of this embodiment, one of the supporting structure 60 is formed with three contact peak points 63, while another supporting structure 60 is also formed with three contact peak points 63.

(85) Preferably, the contact peak points 63 formed by the supporting structure 60 of the second partial panel member 40 are located at the same elevated position to have the same height to enhance the flatness and support for the first panel member 30.

(86) The contact peak 63 is formed to create a gap between the supporting structure 60 and the first panel member 30 to enhance heat dissipation during the manufacturing process.

(87) It should be understood that the supporting top wall 62 of the supporting structure 60 can also form as a flat surface to completely integrate with the inner wall of the first panel member 30.

(88) It is worth mentioning that the reinforcing rib 70 can be formed by outwardly protruding the supporting top wall 62 of the supporting structure 60, such that, the reinforcing rib 70 is formed without increasing the weight of the fusion panel 1.

(89) Furthermore, when the supporting top wall 62 is protruded outwardly to form the reinforcing rib 70, the contact peak 63 is formed at the supporting structure 60. The protruded reinforcing rib 70 is defined between a concave portion between two adjacent contact peak points 63 of the supporting structure 60.

(90) Two or more supporting structures 60 are provided, wherein the supporting structures 60 are provided at a small area, a large area, or an entire second panel main body 41 of the second panel member 40. Some of the supporting structures 60 can be configured to have substantially the same size, shape, configuration or arrangement. The supporting structures 60 are arranged in a predetermined pattern. In this embodiment, the supporting structures 60 are extended to support the first panel member 30, such that the first panel member 30 has substantially similar properties and characteristics, such as flatness, uniformity, and consistency, strength, hardness, etc.

(91) It should be understood that the number of the supporting structures 60 is configured corresponding to the size of the first panel member 30. When incorporating with a smaller size of the first panel member 30, the number of the supporting structures 60 can be reduced, for example, only one supporting structure 60. When incorporating with a larger size of the first panel member 30, the number of the supporting structures 60 can be increased to distribute at the first panel member 30.

(92) The supporting structures 60 are arranged in an interval manner. It is worth mentioning that in this embodiment, since each of the supporting structures 60 has a narrow elongated shape, the adjacent supporting structures 60 are spaced apart from each other and are configured in a staggered manner. For example, one of the supporting structure 60 is extended in the longitudinal direction, and the adjacent supporting structure 60 is extended in the transverse direction. When the external force is applied at the fusion panel 1 along a length direction of one of the supporting structures 60 and along a width direction of the adjacent supporting structure 60 at the same time, the impact of the fusion panel 1 will be substantially reduced. It should be understood that only a predetermined number of supporting structures 60 are configured in a staggered manner that the supporting structures 60 are extended perpendicular to each other along the length directions.

(93) It is worth mentioning that if the contact area between the supporting structure 60 and the inner wall of the first panel member 30 is too large, the supporting structure 60 and the inner wall of the first panel member 30 will affect heat dissipation during the manufacturing process. if the contact area between the supporting structure 60 and the inner wall of the first panel member 30 is too small during the manufacturing process, the supporting structure 60 may not sufficiently support the first panel member 30. Therefore, the contact area between the supporting structure 60 and the inner wall of the first panel member 30 must be configured in a predetermined range.

(94) Generally speaking, for the conventional panel, as the number of supporting structures 60 increases and as the thickness of the supporting structure 60 becomes thicker, the support for the inner wall of the first partial panel 30 will increases, and the weight of the fusion panel 1 will be heavier. In this embodiment, as the number of supporting structures 60 increases, the weight of the fusion panel 1 will not be heavier and the thickness of the supporting structure 60 will not need to be increased to increase the supporting strength.

(95) The supporting structure 60 is constructed to have at least one of a portion of the first layer 10, a portion of the second layer 20, and a portion of the third layer 50. The structure of the supporting structure 60 of the second panel member 40 can be the same or different from the structure of the second panel main body 41 thereof. In this embodiment, the supporting structure 60 and the second panel main body 41 are both configured to have three layer structure and are constructed to have a portion of the first layer 10, a portion of the second layer 20, and a portion of the third layer 50.

(96) For the conventional panel constructed to have a single layer structure, one material is generally used for the entire panel. In other words, the single material of the convention panel must achieve the first, second and third functions, such that the requirement of the material will be extremely high and the material cost of the conventional panel is very expensive. In this embodiment, the supporting structure 60 is constructed to have a portion of the first layer 10, a portion of the second layer 20 and a portion of the third layer 50 being fused with each other, such that the first layer 10, the second layer 20 and the third layer 50 are configured to achieve the first, second and third functions respectively.

(97) The supporting strength of the conventional panel is enhanced by increasing the weight thereof, such that it is difficult to improve the supporting strength and at the same time to achieve other properties. According to the preferred embodiment, the strength enhancement of the supporting structure 60 is not restricted by the first layer 10 and the second layer 20. The strength of the supporting structure 60 is achieved by the third layer 50, wherein the supporting structure 60 does not need to increase its weight to enhance the supporting strength. In other words, the supporting structure 60 can be made thinner. Therefore, not only the entire fusion panel 1 can be made lighter, but also the supporting structure 60 of the fusion panel 1 can also be made lighter.

(98) In addition, the first layer 10, the second layer 20, and the third layer 50 are used with each other to further reduce the thickness of the fusion panel 1.

(99) Further, the weight of the second panel member 40 of the fusion panel 1 will not be increased in the process of forming the supporting structure 60. The second panel member 40 can be stretched or pressed to be recessed into the cavity 400 to form the supporting structure 60. 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. The greater the number of the supporting structure 60, the greater the support of the first panel member 30.

(100) Furthermore, since the supporting structure 60 is formed by stretching at least a portion of the second panel member 40, the second panel main body 41 is correspondingly formed to further reduce the thickness of the supporting structure 60 so as to ensure the heat dissipation of the contacting area between the supporting structure 60 and the inner wall of the first panel member 30.

(101) Since the peak point 63 is formed at the supporting structure 60, the contacting area between the supporting structure 60 and the inner wall of the first panel member 30 will be smaller than the contacting area between two panels in a surface-to-surface engagement, so as to enhance the heat dissipation between the supporting structure 60 and the first panel member 30.

(102) It is worth mentioning that when the fusion panel 1 is configured to have a plurality of supporting structures 60, wherein the entire cavity 100 between the first panel member 30 and the second panel member 40 is partitioned by the supporting structures 60 to form a plurality of smaller cavities 100. The cavities 100 between the first panel member 30 and the second panel member 40 can communicate with each other to enhance uniform heat dissipation between the first panel member 30 and the second panel member 40.

(103) Generally speaking, for the conventional panel, when the contacting area between the support structure 60 and the first panel member 30 is enlarged, it is difficult to dissipate heat at the contacting area between the supporting structure 60 and the first panel member 30 during the manufacturing process, such that the surface of the first panel member 30 will become uneven due to the heat dissipation. In this embodiment, when the contacting area between the supporting structure 60 and the first panel member 30 is enlarged, the heat dissipation of the contacting between the supporting structure 60 and the first panel member 30 will not changed or reduced.

(104) Particularly, the supporting structure 60 is constructed to have at least a portion of the first layer 10, at least a portion of the second layer 20 and at least a portion of the third layer 50. The first panel member 30 is constructed to have at least a portion of the first layer 10, at least a portion of the second layer 20, and at least a portion of the third layer 50. At least a portion of the supporting structure 60 is contacted and fused with the first panel member 30.

(105) In other words, it is supposed that the thickness of the supporting structure 60 at the peak point 63 is set as h, and the thickness of the first panel member 30 is set as H. Since at least a portion of the supporting structure 60 is fused with the first panel member 30, the thickness at the connection of the first panel member 30 and the supporting structure 60 is less than H+h, i.e. the sum of the thickness of the supporting structure 60 and the thickness of the first panel member 30. In other words, the supporting structure 60 is not only biased against the first panel member 30 but also fused with the first panel member 30, such that the thickness at the connection of the first panel member 30 and the supporting structure 60 will be reduced so as to enhance the heat dissipation at the supporting structure 60.

(106) Furthermore, in this embodiment, at least a portion of the third layer 50 of the supporting structure 60 is fused to at least a portion of the third layer 50 of the first panel member 30. It should be understood that, in another embodiment of the present invention, a portion of the third layer 50 and a portion of the second layer 20 of the supporting structure 60 can be fused with a portion of the third layer 50 of the first panel member 30 or can be fused with a portion of the second layer 20 and the third layer 50. It should be understood that the fusing depth of the supporting structure 60 and the first panel member 30 can be selectively adjusted by changing the relative position of the first panel member 30 and the second panel member 40, or by controlling the stretching length of the supporting structure 60.

(107) Generally speaking, for the conventional panel, if at least a portion of the supporting structure 60 is fused with at least a portion of the first panel member 30, the thickness at the connection area of the first panel member 30 and the first panel member 30 is larger than the thickness or other areas of the first panel member 30, such that the thicker panel will affect the heat dissipation to make the surface of the first panel member 30 uneven.

(108) On the other hand, in this embodiment, the first layer 10 of the first panel member 30 can be maintained in a flat manner. Since the first panel member 30 is constructed to have at least a portion of the first layer 10, at least a portion of the second layer 20 and at least a portion of the third layer 50, the third layer 50 can be made of a material with a low heat shrinkage ratio, such that the third layer 50 of the first panel member 30 will not be shrunk significantly. Furthermore, the first layer 10 and the third layer 50 is separated by the second layer 20 is to keep the flatness of the first layer 10.

(109) In other words, the flatness of the first panel member 30 of the fusion panel 1 is guaranteed while the connection strength of the supporting structure 60 and the first panel member 30 is maintained.

(110) According to the present invention, the present invention further provides a method of manufacturing the fusion panel 1, which comprises the following steps.

(111) Form the first layer 10 and the second layer 10 of the fusion panel 1.

(112) Form the first panel member 30 and the second panel member 40 with a hollow structure, wherein edges of the first panel member 30 and the second panel member 40 are fused with each other, such that the first panel member 30 is spacedly overlapped on the second panel member 40 to form the hollow structure, wherein the first panel member 30 is constructed to have at least one of a portion of the first layer 10 and a portion of the second layer 20, wherein the second panel member 30 is constructed to have at least one of another portion of the first layer 10 and another portion of the second layer 20, wherein at least a portion of the second panel 40 is extended toward the first panel member 30 to form at least one supporting structure 60 to support the first panel member 30.

(113) According to the preferred embodiment, the step of forming the first panel member 30 and the second panel member 40 further comprises the following steps.

(114) Overlap the first layer 10 with the second layer 20, wherein the first layer 10 and the second layer 20 are fused with each other.

(115) From a space between the first layer 10 with the second layer 20 to form the first panel member 30 ad the second panel member 40 with a hollow structure therebetween.

(116) It should be understood that the first layer 10 and the second layer 20 can be formed separately, for example, via extrusion molding, wherein each of the first layer 10 and the second layer 20 is formed in a fluid state, such that the first layer 10 and the second layer 20 can fuse with each other.

(117) The first layer 10 and the second layer 20 are formed separately and then are fused with each other. In one example, the first layer 10 and the second layer 20 are molded and formed separately, then the first layer 10 is overlapped on the second layer 20, then the overlapped first and second layers 10, 20 are heated at the same time to fuse the first and second layers 10, 20 with each other.

(118) Alternatively, the first layer 10 and the second layer 20 can be fused with each other while being formed. For example, the first layer 10 and the second layer 20 are co-extruded and fused at the same time.

(119) Accordingly, the first layer 10 and the second layer 20 can be formed by forming the first layer 10 first, and then forming the second layer 20, wherein the second layer 20 is fused to the first layer 10 while the second layer 20 is formed. For example, the first layer 10 is formed in a fluid state, wherein the material of the second layer 20 is placed on the first layer 10 to form the second layer 20 being overlapped thereon. When the second layer 20 is being formed, the first layer 10 and the second layer 20 are fused with each other.

(120) Furthermore, it should be understood that the second panel member 40 is formed at the same time when the second layer 20 is formed, then the first layer 10 is placed on the second layer 20 to form first panel member 30, such that the first panel member 30 and the second panel member 40 are formed correspondingly. In other words, the cavity 100 is formed and encircled within the second layer 20 while at least a portion of the second layer 20 is extended into the cavity 100 to form the supporting structure 60 at the same time. Then, the first layer 10 is formed on the outer surface of the second layer 20 and at least a portion of the first layer 10 is extended into the cavity 100 along with the portion of the second layer 20 to form the supporting structure 60, such that the first panel member 30 and the second panel member 40 are formed with the hollow structure.

(121) According to the preferred embodiment, the step of forming the first panel member 30 and the second panel member 40 further comprises the following steps.

(122) Close the first panel member 30 and the second panel member 40 with each other, wherein the cavity 100 is formed between the first panel member 30 and the second panel member 40.

(123) Fuse at least a portion of the supporting structure 60 with the first panel member 30.

(124) It should be understood that the second panel member 40 is formed at the same time when the second layer 20 is formed, wherein at least a portion of the supporting structure 60 is formed and fused with at least a portion the second layer 20 when the second layer 20 is formed. In other words, the fusing process of the supporting structure 60 and the first panel member 30 can be performed after the overlapping process of the first and second layers 10, 20 is completed. Alternatively, the fusing process of the supporting structure 60 and the first panel member 30 can be performed when the inner layer of the fusion panel 1 is formed or after the inner layer of the fusion panel 1 is formed. In this example, the inner layer of the fusion panel 1 is embodied as the second layer 20.

(125) Alternatively, the method of manufacturing the fusion panel 1 comprises the following steps.

(126) Form the first layer 10, the second layer 20 and the third layer 50.

(127) Form the first panel member 30 and the second panel member 40 with a hollow structure, wherein edges of the first panel member 30 and the second panel member 40 are fused with each other, such that the first panel member 30 is spacedly overlapped on the second panel member 40 to form the hollow structure, wherein the first layer 10 is overlapped and fused with the second layer 20, wherein the second layer 20 is overlapped and fused with the third layer 50, wherein the first panel member 30 is constructed to have at least one of a portion of the first layer 10, a portion of the second layer 20 and a portion of the third layer 30, wherein the second panel member 30 is constructed to have at least one of another portion of the first layer 10, another portion of the second layer 20 and another portion of the third layer 50, wherein at least a portion of the second panel 40 is extended toward the first panel member 30 to form at least one supporting structure 60 to support the first panel member 30.

(128) Referring to FIG. 8 of the drawings, the manufacturing process of the fusion panel 1 according to the above preferred embodiment of the present invention is illustrated.

(129) First, provide a first raw material for the first layer 10 of the fusion panel 1, a second raw material for the second layer 20 of the fusion panel 1, and a third raw material for the third layer 50 of the fusion panel 1. The first raw material, the second material, and the third material are different. Alternatively, it should be understood that at least two of the first raw material, the second material, and the third material are the same.

(130) Heat the first raw material, the second raw material, and the third raw material until the first raw material, the second raw material, and the third raw material are formed in a fluid state to flow along a first feeding channel 210A, a second feeding channel 210B, and a third feeding channel 210C of a fusion panel manufacturing equipment 2 respectively. Alternatively, the first raw material, the second raw material, and the third raw material in a fluid state are pushed to flow along the first feeding channel 210A, the second feeding channel 210B, and the third feeding channel 210C respectively.

(131) The first feeding channel 210A is located at an outer side of the second feeding channel 210B. The second feeding channel 210B is located at an outer side of the third feeding channel 210C. Preferably, the first feeding channel 210A, second feeding channel 210B and the third feeding channel 210C are embodied as annular channels each having a ring shape and are coaxially aligned with each other. It should be understood that the cross section of each of the first feeding channel 210A, the second feeding channel 210B, and the third feeding channel 210C should not be limited to have a circular ring shape, it can be formed in an ellipse cross section or even a triangular ring cross section. It should be understood that the first feeding channel 210A, the second feeding channel 210B, and the third feeding channel 210C can be configured at an eccentric manner. For example, a width of the second feeding channel 210B formed at an interval between a first feeding pipe 201 and a second feeding pipe 201B can be uneven, such that the thicknesses of the same layers of the fused layer 1 can be different.

(132) The first feeding channel 210A is formed at an interval between the first feeding pipe 201A and the second feeding pipe 201B, wherein the first raw material is guided to flow along the first feeding channel 210A and is extruded out of the first feeding channel 210A at a first outlet thereof.

(133) The second feeding channel 210B is formed at an interval between the second feeding pipe 201B and a third feeding pipe 201C, wherein the second raw material is guided to flow along the second feeding channel 210B and is extruded out of the second feeding channel 210B at a second outlet thereof.

(134) The third feeding channel 210C is formed at an interval between the third feeding pipe 201C and an inner feeding pipe 201D, wherein the third raw material is guided to flow along the third feeding channel 210C and is extruded out of the third feeding channel 210C at a third outlet thereof.

(135) The second feeding pipe 201B is spacedly sleeved within the first feeding pipe 201A, wherein a distance between the first feeding pipe 201A and the second feeding pipe 201B is approximately equal to the thickness of the first layer 10. The third feeding pipe 201C is spacedly sleeved within the second feeding pipe 201B, wherein a distance between the second feeding pipe 201B and the third feeding pipe 201C is approximately equal to the thickness of the second layer 20. The inner feeding pipe 201D is spacedly sleeved within the third feeding pipe 201C, wherein a distance between the third feeding pipe 201C and the inner feeding pipe 201D is approximately equal to the thickness of the third layer 50. The interior of the inner feeding pipe 201D is configured for ventilation.

(136) When the first raw material, the second raw material, and the third raw material are extruded at the first outlet, the second outlet, and the third outlet, the first layer 10, the second layer 20 and the third layer 50 are formed at the same time, wherein the first layer 10 is superimposed on the second layer 20 while the second layer 20 is superimposed on the third layer 50.

(137) An inner surface of the first layer 10 is contacted with an outer surface of the second layer 20, while an inner surface of the second layer 20 is contacted with an outer surface of the third layer 50. Since the first raw material for the first layer 10, the second raw material for the second layer 20, and the third raw material for the third layer 50 are in fluid state, the first layer 10 and the second layer 20 are fused with each other while the second layer 20 and the third layer 50 are fused with each other.

(138) The first layer 10, the second layer 20 and the third layer 50 are fused with each other to form a fused body 1A, wherein the fused body 1A has a hollow structure that inner walls of the third layer 50 are not contacted with each other.

(139) It should be understood that the first layer 10, the second layer 20 and the third layer 30 can be formed by co-extrusion, or can be extruded separately and then superimposed on each other.

(140) When the fused body 1A is downwardly drops from a predetermined elevated position and is then shaped in a molding die 202, wherein the molding die 202 is closed at two sides of the fused body 1A. Accordingly, the molding die 202 comprises a left mold 2021 and a right mold 2022, wherein the left mold 2021 is moved to the right mold 2022 to a molding space 2020 of the molding die 202.

(141) After the fused body 1A is guided into the molding space 2020, an airflow is introduced into the molding die 202, such that via an air pressure applied to the middle of the fused body 1A by airflow, a portion of the fused body 1A is biased against the left mold 2021 to form the first panel member 30 while another portion of the fused body 1A is biased against the right mold 2022 to form the second panel member 40. Under the air pressure, the first layer 10, the second layer 20 and the third layer 30 can be pressed to be closely fused with each other.

(142) The molding die 202 further comprises at least a protrusion formed at an inner wall of the right mold 2022 to form the supporting structure 60 at the fused body 1A. It is worth mentioning that after the left mold 2021 and the right mold 2022 of the molding die 202 are moved closely to each other, at the connection between the supporting structure 60 and the first panel member 30, a distance between the left mold 2021 and the right mold 2022 is set to be smaller than the sum of the thickness o of the supporting structure 60 sand the thickness of the first panel member 30, such that the supporting structure 60 in a fluid state and at least a portion of the first panel member 30 can be fused with each other.

(143) After the molding die 202 is closed, the fused body is cooled and then demolded to form the blow molded fusion panel 1 with the hollow structure.

(144) It should be understood that the manufacturing method of the fusion panel 1 should not be limited to the above examples. As an example of the second layer 20 embodied as a foam layer, after the first layer 10, the second layer 20 and the third layer 50 are fused with each other under the environmental conditions, such as temperature, pressure, or others, the second layer 20 is foamed to form the foam layer. Alternatively, the foaming of the second layer 20 can be controlled during the first layer 10, the second layer 20 and the third layer 50 being fused with each other.

(145) Referring to FIG. 9, the fusion panel 1 according to a third preferred embodiment of the present invention is shown.

(146) The fusion panel 1 is constructed to have the first layer 10, the second layer 20 and the third layer 50, wherein the second layer 20 is sandwiched between the first layer 10 and the third layer 50.

(147) The difference between the third embodiment and the above mentioned embodiment is that the second layer 20 according to the third embodiment mainly serves as a connecting medium. Since the first layer 10 cannot be directly integrated with the third layer 50, the second layer 50 is provided to fuse between the first layer 10 and the third layer 50, such that the first layer 10 and the third layer 50 can fused together.

(148) Referring to FIG. 10, the fusion panel 1 according to a fourth preferred embodiment of the present invention is shown.

(149) The fusion panel 1 is constructed to have the first layer 10, the second layer 20 and the third layer 50, wherein the second layer 20 is sandwiched between the first layer 10 and the third layer 50.

(150) The difference between the fourth embodiment and the above mentioned embodiment is that, according to the fourth embodiment, the first panel member 30 is constructed to have at least a portion of the first layer 10, at least a portion of the second layer 20, and at least a portion of the third layer 50, and the second panel member 40 is constructed to have at least a portion of the second layer 20 and at least a portion of the third layer 50.

(151) When the first panel member 30 is located above the second panel member 40, the layer configuration of the fused layer 1 from top to bottom is that a portion of the first layer 10, a portion of and the second layer 20, a portion of the third layer 50, another portion of the other third layer 50, and another portion of the second layer 20.

(152) A portion of the third layer 50 of the first panel member 30 can be fused with a portion of the third layer 50 of the second panel member 40.

(153) It should be understood that the number of layers in each location of the fusion panel 1 can be arranged according to requirements or actual need. The first panel member 30 and the second panel member 40 of the fusion panel 1 can be constructed to have four or more layers.

(154) Referring to FIG. 11, the fusion panel 1 according to a fifth preferred embodiment of the present invention is shown.

(155) The difference between the fifth embodiment and the above mentioned embodiment is the supporting structure 60 of the fifth embodiment, wherein some of the supporting structures 60 are formed in a round shape, and some of the supporting structures 60 are formed in an elongated shape. One peak point 63 is provided when the supporting structure 60 is formed in a round shape. Multiple peak points 63 are provided when the supporting structure 60 is formed in an elongated shape. At least two of the supporting structures 60 are arranged in a staggered manner.

(156) Referring to FIG. 12, the fusion panel 1 according to a sixth preferred embodiment of the present invention is shown.

(157) The difference between the sixth embodiment and the above mentioned embodiment is the supporting structure 60 according to the sixth embodiment. Accordingly, the supporting structure 60 is only biased against the inner wall of the first panel member 30. In other words, the supporting structure 60 is only contacted with the first panel member 30 but not fused with the first panel member 30. For example, during the molding process of the fusion panel 1, the depth of the supporting structure 60 is controlled to ensure the supporting structure 60 being only contacted with the first panel member 30. Alternatively, by lower the temperature to reduce the fluidity of the first panel member 30 and the second panel member 40 when pressing the first panel member 30 and the second panel member 40, the supporting structure 60 is pressed close to the first panel member 30 but not fused with the first panel member 30.

(158) It should be understood that the supporting structure 60 is formed by the second panel member 40 and is extended to have a predetermined distance from the first panel member 30. When a load is applied on the first panel member 30, the first panel member 30 is pressed downwardly to move closer to the second panel member 40 until the first panel member 30 is supported by the supporting structure 60.

(159) Referring to FIG. 13, the fusion panel 1 according to a seventh preferred embodiment of the present invention is shown. The difference between the seventh embodiment and the above mentioned embodiment are the supporting structure 60 and the first panel member 30 according to the seventh embodiment.

(160) The fusion panel 1 further comprises a filling layer 80, wherein the filling layer 80 is located between the supporting structure 60 and the first panel member 30. The first panel member 30 is supported by the supporting structure 60 via the filling layer 80. The filling layer 80 can serve as a connecting medium for fusing the support structure 60 and the first panel member 30, or can serve as a buffering medium for buffering between the support structure 60 and the first panel member 30. The filling layer 80 can be injected between the supporting structure 60 and the first panel member 30 after the fusion panel 1 is formed. Alternatively, filling layer 80 can be extruded along with the first layer 10, the second layer 20 and the third layer 50.

(161) Referring to FIG. 14, as also referring to FIGS. 5A to 7C, a table 1000 according to the above preferred embodiments of the present invention is illustrated. The table 1000 comprises a tabletop 1001 and at least one leg device 1002, wherein the tabletop 1001 is supported by the leg device 1002, such that the tabletop 1001 is elevated at a predetermined height from a working surface. The leg device 1002 is arranged to rest on the working surface.

(162) The tabletop 1001 is made by the fusion panel 1, wherein the fusion panel 1 is cut to form an entire tabletop 1001 or two or more fusion panels 1 are cut and combined to form the tabletop 1001. The tabletop 1001 can be formed in, but should not be limited to, a circular shape, a square shape, and a triangular shape.

(163) An upper side and a lower side of the tabletop 1001 can be configured to parallel with each other. That is, the first panel member 30 and the second panel member 40 of the fusion panel 1 are constructed to form the tabletop 1001, wherein at least a portion of the first panel member 30 and a least a portion of the second panel member 40 can be configured to parallel with each other.

(164) It should be understood that the fusion panel 1 can be used in different fields, wherein the first panel member 30 and the second panel member 40 can be configured in a non-parallel manner. For example, the upper surface of the fused layer 1 can form in an arc shape while the lower surface of the fused layer 1 can be flat.

(165) One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting. 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.