Storage Container with Hollow Fusion Panel

Abstract

The present invention provides a storage container which includes at least one hollow fusion panel defining a storage cavity therein. The hollow fusion panel includes a first layer, a second layer, a first panel member and a second panel member, wherein the first panel member and the second panel member are constructed to form a hollow integral structure. The first layer and the second layer are at least partially overlapped and composited such that a plurality of portions of the second panel member are recessed in a direction toward the first panel member to form a predetermined number of supporting structures distributed in a predetermined manner, wherein each of the supporting structures forms a recessed cavity therein and is at least partially fused with the first panel member.

Claims

1. A storage container, comprising one or more hollow fusion panels configured to define a storage cavity therein, wherein each of said one or more hollow fusion panels comprises: a first layer; and a second layer, wherein said first layer and at least a portion of said second layer are overlapped and composited to define a first panel member and a second panel member, wherein at least a portion of said first panel member and at least a portion of said second panel member are constructed to have a predetermined distance therebetween to form at least one cavity so as to form a hollow integral structure, wherein at least one portion of said first layer and at least one portion of said second layer are overlapped and composited in such a manner that said first panel member includes at least one portion selected from a combination of said at least one portion of said first layer and said at least one portion of said second layer, and said second panel member includes at least one portion selected from a combination of at least another portion of said first layer and at least another portion of said second layer, wherein a plurality of portions of said second panel member is recessed in a direction toward said first panel member to form a predetermined number of supporting structures distributed in a predetermined manner, wherein each of said predetermined number of supporting structures forms a recessed cavity, wherein each of said predetermined number of supporting structures and said first panel member are at least partially fused with each other.

2. The storage container, as recited in claim 1, wherein each of said one or more hollow fusion panels further includes a third layer, wherein said second layer is formed between said first layer and said third layer, wherein said first layer, said second layer and said third layer are combined to form said first panel member and said second panel member, wherein said first panel member includes at least one portion of said first layer, at least one portion of said second layer and at least one portion of said third layer, and the said second panel member includes at least another portion of said first layer, at least another portion of said second layer, and at least another portion of said third layer.

3. The storage container, as recited in claim 1, wherein at least one area of said first panel member being fused and occupied by at least one of said predetermined number of supporting structures is s, and a thickness of a position, where said first panel member and said second panel member are fused with each other is t, where s/t.sup.2 is greater than 0.1.

4. The storage container, as recited in claim 2, wherein at least one area of said first panel member being fused and occupied by at least one of said predetermined number of supporting structures is s, and a thickness of a position, where said first panel member and said second panel member are fused with each other is t, where s/t.sup.2 is greater than 0.1.

5. The storage container, as recited in claim 3, wherein each of said predetermined number of supporting structures is provided with at least one reinforcing rib formed in said recessed cavity and extended integrally with at least one of said predetermined number of supporting structures.

6. The storage container, as recited in claim 4, wherein each of said predetermined number of supporting structures is provided with at least one reinforcing rib formed in said recessed cavity and extended integrally with at least one of said predetermined number of supporting structures.

7. The storage container, as recited in claim 3, wherein each of said one or more hollow fusion panel further includes an engagement joint unit, provided at first and second side edges of said construction panel, including a protruding engaging joint at said first side edge and a recessed engageable joint configured along said second side edge, such that said protruding engaging joint is able to be fittingly engaged with said recessed engageable joint to securely engaging said first side edge of the hollow fusion panel with a second side edge of another construction panel.

8. The storage container, as recited in claim 4, wherein each of said one or more hollow fusion panel further includes an engagement joint unit, provided at first and second side edges of said construction panel, including a protruding engaging joint at said first side edge and a recessed engageable joint configured along said second side edge, such that said protruding engaging joint is able to be fittingly engaged with said recessed engageable joint to securely engaging said first side edge of the hollow fusion panel with a second side edge of another construction panel.

9. The storage container, as recited in claim 1, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

10. The storage container, as recited in claim 2, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

11. The storage container, as recited in claim 3, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

12. The storage container, as recited in claim 4, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

13. The storage container, as recited in claim 7, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

14. The storage container, as recited in claim 8, wherein each of said predetermined number of supporting structures of said second panel member has at least one contact peak point extended in said recessed cavity, wherein said at least one contact peak point is recessed in a direction toward the said first panel member to connect with the said first panel member.

15. The storage container, as recited in claim 9, wherein each of said reinforcing rib has a U-shaped wave-like structure which is formed from at least a portion of said at least one of said predetermined number of supporting structures protruded toward said first panel member, wherein said reinforcing rib is extended across a bottom of said recessed cavity to form at least one contact peak point, wherein said at least one contact peak point is recessed toward said first panel member to connect with the said first panel member.

16. The storage container, as recited in claim 10, wherein each of said reinforcing rib has a U-shaped wave-like structure which is formed from at least a portion of said at least one of said predetermined number of supporting structures protruded toward said first panel member, wherein said reinforcing rib is extended across a bottom of said recessed cavity to form at least one contact peak point, wherein said at least one contact peak point is recessed toward said first panel member to connect with the said first panel member.

17. The storage container, as recited in claim 15, wherein said first layer of said first layer panel is an outer layer located outside, wherein a scratch resistance of said first layer is stronger than that of said second layer and a supporting strength of said second layer of said first panel member is stronger than said first layer of said first panel member, wherein said second layer is completely covered by said first layer and an inner wall of said second layer surrounds and defines said cavity.

18. The storage container, as recited in claim 16, wherein said first layer of said first layer panel is an outer layer located outside, wherein a scratch resistance of said first layer is stronger than that of said second layer and a supporting strength of said second layer of said first panel member is stronger than said first layer of said first panel member, wherein said second layer is completely covered by said first layer and an inner wall of said second layer surrounds and defines said cavity.

19. The storage container, as recited in claim 1, wherein said first layer is made of a material of a high density polyethylene and said second layer is made of a material selected from a mixture of metallocene polyethylene and calcium carbonate and a mixture of metallocene polyethylene and glass fiber, wherein at least a portion of said material of said second layer is made of one or more recycled materials.

20. The storage container, as recited in claim 2, wherein said first layer is made of a material of a high density polyethylene, said third layer is made of a material selected from a mixture of high density polyethylene and calcium carbonate and a mixture of high density polyethylene and glass fiber, and said second layer is made of a material selected from a mixture of metallocene polyethylene and calcium carbonate and a mixture of metallocene polyethylene and glass fiber, wherein at least a portion of said materials of said second layer and said third layer is made of one or more recycled materials.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0078] FIG. 1A to FIG. 1L are schematic views illustrating various conventional storage containers.

[0079] FIG. 2A to FIG. 2T are schematic views illustrating various conventional plastic storage containers.

[0080] FIG. 3A is a partial sectional perspective view of a hollow fusion panel adapted for constructing a shed according to a preferred embodiment of the present invention.

[0081] FIG. 3B is a partial sectional perspective view of a hollow fusion panel with filler layer adapted for constructing a shed according to a preferred embodiment of the present invention.

[0082] FIG. 4 is an enlarged view of encircled part A in FIG. 1.

[0083] FIG. 5 is an enlarged view encircled part B in FIG. 1.

[0084] FIG. 6 is a partial sectional perspective view of an alternative mode of the above preferred embodiment of the present invention.

[0085] FIG. 7A is an elevation view of a hollow fusion panel adapted for constructing a storage container according to the above preferred embodiment of the present invention.

[0086] FIG. 7B is an enlarged top perspective view, illustrating the encircled part J of FIG. 7A, of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0087] FIG. 7C is an enlarged bottom perspective view, illustrating the encircled part J of FIG. 7A, of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0088] FIG. 7D is an enlarged sectional perspective view, illustrating the encircled part J of FIG. 7A, of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0089] FIG. 8A is a sectional perspective view of the hollow fusion panel, viewing from another direction, according to the above preferred embodiment of the present invention from another perspective.

[0090] FIG. 8B illustrates a schematic view and an enlarged partial sectional view thereof, along the line A-A in FIG. 6A, of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0091] FIG. 8C is a partial enlarged plan view, along the line C-C in FIG. 6B, of the hollow fusion panel according to the above preferred embodiment of the present invention taken.

[0092] FIG. 9A illustrates a schematic view and an enlarged partial sectional view thereof of a construction panel according to another alternative mode of the above preferred embodiment of the present invention.

[0093] FIG. 9B illustrates a schematic view and an enlarged partial sectional view thereof of a construction panel according to another alternative mode of the above preferred embodiment of the present invention.

[0094] FIG. 9C illustrates a schematic view and an enlarged partial sectional view thereof of a construction panel according to another alternative mode of the above preferred embodiment of the present invention.

[0095] FIG. 10A is a partial perspective view illustrating another alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0096] FIG. 10B is a partial perspective view illustrating another alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0097] FIG. 11 is a top view of box type hollow fusion panel according to the above preferred embodiment of the present invention.

[0098] FIG. 12 is a flow diagram illustrating a producing method of the blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0099] FIG. 13 illustrates a blow molding equipment for producing the blow-molded construction panel according to the above preferred embodiment of the present invention.

[0100] FIG. 14 is a schematic diagram of the blow molding equipment for producing a blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0101] FIG. 15 is a bottom view of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0102] FIG. 16 is a bottom view of a board type hollow fusion panel according to the above preferred embodiment of the present invention.

[0103] FIG. 17A is a bottom view of another alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0104] FIG. 17B is an enlarged sectional view of a portion along E-E sectional line in FIG. 17A according to the preferred embodiment of the present invention.

[0105] FIG. 18A is a bottom view of another alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0106] FIG. 18B is an enlarged sectional view of a portion along F-F sectional line in FIG. 18A according to the preferred embodiment of the present invention.

[0107] FIG. 19 is a partial sectional perspective view illustrating a combined hollow fusion panel according to the above preferred embodiment of the present invention.

[0108] FIG. 20 is a sectional view with enlarged sectional views of the combined hollow fusion panel according to the above preferred embodiment of the present invention.

[0109] FIG. 21 is a sectional view of an alternative mode of the combined hollow fusion panel according to the above preferred embodiment of the present invention.

[0110] FIG. 22 is a schematic view of a first embodiment of an engagement joint unit to be embodied at side edges of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0111] FIG. 23 is a schematic view of a second embodiment of an engagement joint unit to be embodied at side edges of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0112] FIG. 24 is a schematic view of a third embodiment of an engagement joint unit to be embodied at side edges of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0113] FIG. 25 is a schematic view of a fourth embodiment of an engagement joint unit to be embodied at side edges of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0114] FIG. 26 is a schematic view illustrating a mounting device to be utilized for mounting the hollow fusion panels on an inner wall surface according to the above preferred embodiment of the present invention.

[0115] FIG. 27 is a schematic view illustrating a corner connection device to be utilized between two hollow fusion panels according to the above preferred embodiment of the present invention.

[0116] FIG. 28A and FIG. 28B are examples of storage containers configured with the hollow fusion panels according to the above preferred embodiment of the present invention.

[0117] FIG. 29 is a front perspective view of an exemplary storage container with hollow fusion panel when the storage container is in a closed state, according to the above preferred embodiment of the present invention.

[0118] FIG. 30 is a rear perspective view of the storage container with hollow fusion panel when the storage container is in a closed state, according to the above preferred embodiment of the present invention.

[0119] FIG. 31 is a schematic structural view of the storage container, in an open state, according to the above preferred embodiment of the present invention.

[0120] FIG. 32 is an exploded view of the storage container in an open state, according to the above preferred embodiment of the present invention.

[0121] FIG. 33 is a perspective view of a vertical partition panel, made of the hollow fusion panel, of the storage container according to the above preferred embodiment of the present invention.

[0122] FIG. 34 is a partial front perspective view of a cover panel and a rear panel, made of the hollow fusion panel, of the storage container, when the cover board is open, according to the above preferred embodiment of the present invention.

[0123] FIG. 35 is an enlarged view of portion A in FIG. 29.

[0124] FIG. 36 is a partial rear perspective view of the cover panel and the rear panel of the storage container, when the cover board is open, according to the above preferred embodiment of the present invention.

[0125] FIG. 37 is a partial front perspective view of the storage container when the cover panel is closed according to the above preferred embodiment of the present invention;

[0126] FIG. 38 is an enlarged schematic view of portion B in FIG. 37.

[0127] FIG. 39 is a partial rear perspective view of FIG. 37.

[0128] FIG. 40 is an exploded front perspective view of the cover panel and the rear panel of the storage container according to according to the above preferred embodiment of the present invention.

[0129] FIG. 41 is an exploded rear perspective view of the cover panel and the rear panel of the storage container according to the above preferred embodiment of the present invention.

[0130] FIG. 42 is a perspective view of the storage container in a pre-assembly package state according to the above preferred embodiment of the present invention.

[0131] FIG. 43 is another perspective view of the storage container in a pre-assembly package state according to the above preferred embodiment of the present invention.

[0132] FIG. 44 is an enlarged view of the portion C in FIG. 43.

[0133] FIG. 45 is a bottom perspective view of the storage container in a pre-assembly package state according to the above preferred embodiment of the present invention;

[0134] FIG. 46 is a side perspective view of the storage container in the pre-assembly package state according to the above preferred embodiment of the present invention.

[0135] FIG. 47 is an exploded view of the storage container in the pre-assembly package state according to the above preferred embodiment of the present invention.

[0136] FIG. 48 is another exploded view of the storage container in the pre-assembly package state according to the above preferred embodiment of the present invention.

[0137] FIG. 49 is an exploded view of a lower folding portion of the cover panel and the bottom panel in the pre-assembly package state according to the above preferred embodiment of the present invention.

[0138] FIG. 50 is an exploded view of the lower folding portion of the cover panel and the side panels in the pre-assembly package state according to the above preferred embodiment of the present invention.

[0139] FIG. 51 is a perspective view of the storage container with hollow fusion panel, in open state, according to the above embodiment of the present invention.

[0140] FIG. 52 is a sectional schematic view illustrating the blow molding equipment for manufacturing the blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0141] FIG. 53 is a sectional schematic view illustrating an alternative mode of the blow molding equipment for manufacturing the blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0142] FIG. 54 is a sectional schematic view illustrating another alternative mode of the blow molding equipment for manufacturing the blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0143] FIG. 55 is a partial sectional view of the blow-molded hollow fusion panel, according to the above preferred embodiment, made from the alternative modes of the blow molding equipment as shown in FIG. 53 and FIG. 54.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0144] The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments in the following description are merely examples, and those skilled in the art can think of other obvious variations. The basic principles of the present invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0145] Those skilled in the art should understand that in the disclosure of the present invention, the terms of the orientation or positional relationship indicated by longitudinal, lateral, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, inner, outer, etc. are based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, so the above terms should not be understood as limiting the present invention.

[0146] It can be understood that the structure disclosed according to the present invention may have other suitable shapes, sizes, configurations, arrangements and features. It can be understood that the term a should be understood as at least one or one or more, that is, in one embodiment, the number of an element may be one, while in other embodiments, the number can be more than one, and the term one cannot be understood as a restriction on the number. The detailed description of the exemplary embodiment is as follows.

[0147] The present invention will be further described in detail below with reference to the preferred embodiment of the drawings.

[0148] Referring to FIG. 3A, FIG. 4 and FIG. 5, a hollow fusion panel 1 configured for constructing a storage container C10 (as shown in FIG. 11) to define a storage cavity C13 therein is illustrated, wherein the hollow fusion panel 1 includes an upper panel member 1 and a lower panel member 2, wherein the upper panel member 1 and the lower panel member 2 form a hollow structure by blow molding.

[0149] Each of the upper panel member 1 and the lower panel member 2 according to the preferred embodiment has a three-layer structure that each includes an outer layer 3, an intermediate layer 5, and an inner layer 4. Also, the lower panel member 2 is facing upwards, that is in the direction toward the upper panel member 1, and is recessed until the inner layer 4 of the lower panel member 2 being fused with the inner layer 4 of the upper panel member 1 to form a predetermined number of joint supporting structures 6 distributed in a predetermined manner.

[0150] An edge structure of the multi-layer hollow fusion panel 1 is as follows. As shown in FIG. 5, the upper panel member 1 further comprises an outer bending wall 11 being surroundingly bent downwardly at an outer edge of the upper panel member 1. The lower panel member 2 has an inner bending wall 21 being surroundingly 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 fused and integrated with each other to form an integral body of the multi-layer hollow fusion panel 1.

[0151] According to the preferred embodiment, each of the joint supporting structures 6, having a sinusoidal waveform and a recessed cavity therein, is configured to have an elongated shape or strip shape. As shown in FIG. 3A to FIG. 4, correspondingly, each of the joint supporting structures 6 further has three contact peak points 62 which are arranged spacedly and alternatingly with the reinforcing ribs 61 in intervals.

[0152] For the raw material structure of the double-outer single-inner three-layer multi-layer hollow fusion panel 1: the outer layers 3 of the upper panel member 1 and the lower panel member 2 are both made of high density polyethylene. The intermediate layers 5 of the upper panel member 1 and the lower panel member 2 are made of a mixture selected from high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber. The inner layers 4 of the upper panel member 1 and the lower panel member 2 are made of metallocene polyethylene.

[0153] It is appreciated that only the outer layer 3 of the upper panel member 1 is an exterior portion that is being exposed to outside, so that only the outer layer 3 of the upper panel member 1 is required to be made of new material of high density polyethylene. The intermediate layer 5 and the inner layer 4 of the upper panel member 1 are interior portions and thus the intermediate layer 5 and the inner layer 4 of the upper panel member 1 can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the intermediate layer 5 and the inner layer 4 of the upper panel member 1 can be recycled materials.

[0154] Similarly, if the outer layer 3 of the lower panel member 2 is also an exterior portion that is being exposed to outside, the outer layer 3 of the lower panel member 1 is made of new material of high density polyethylene, and the raw materials of the intermediate layer 5 and the inner layer 4 of the lower panel member 2 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the intermediate layer 5 and the inner layer 4 of the lower panel member 2 can be recycled materials.

[0155] It is worth mentioning that when the hollow fusion panel 1 of the present invention is used to construct a construction wall of the storage container to define the storage cavity therein, the lower panel member 2 does not require to be exposed to outside, the outer layer 3, the inner layer 4 and the intermediate layer 5 of the lower panel member 2 can all be made of recycled materials or a mixture of new and recycled materials.

[0156] 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.

[0157] According to the preferred embodiment of the present invention, when the intermediate layer 5 is made of a mixture of high density polyethylene and calcium carbonate, the mass percentage of high density polyethylene is 70% to 85%, and the mass percentage of calcium carbonate is 15% to 30%.

[0158] According to the preferred embodiment of the present invention, when the intermediate layer 5 is made of high density polyethylene and glass fiber, the mass percentage of high density polyethylene is 60% to 85%, and the mass percentage of glass fiber is 15% to 40%.

[0159] It should be noted that the mass percentage of the high density polyethylene, calcium carbonate, glass fiber mentioned above can be applied to both the new material or recycled material thereof. Preferably, since the high density polyethylene is the major content of the intermediate layer 5 and the inner layer 4, it can be made that only the high density polyethylene is recycled material.

[0160] New high density polyethylene is made by combining ethylene molecules to form polymer chains through synthetization and polymerization process, ethylene is derived from crude oil or natural gas, wherein ethylene is a key feedstock for the production of high density polyethylene. For high-pressure polymerization, ethylene gas is subjected to high pressure and temperature in the presence of a catalyst, that leads to the formation of high density polyethylene. For low-pressure or Ziegler-Natta polymerization, a catalyst, such as a transition metal compound, is used to facilitate the polymerization of ethylene at low pressure.

[0161] To recycle high density polyethylene, plastic products such as bottles, containers, pipes, jugs, and the like are collected and sorted for the high density polyethylene material HDPE, such as polypropylene (PP) or polyethylene terephthalate (PET) are separated. Typical recycling process, but not limited to, includes shredding the collected high density polyethylene materials into small pieces, washing the shredded plastic thoroughly to remove contaminants, melting down the clean high density polyethylene flakes, and extruding the melted high density polyethylene in predetermined shape, such as small pellets or granules, to make recycling high density polyethylene for use.

[0162] According to the preferred embodiment, each of the upper panel member 1 and the lower panel member 2 of the multi-panel multi-layer hollow fusion panel 1 is configured to have the above-mentioned double-outer single-inner three-layer structure, so that when the outer layer 3 is strongly impacted and dropped, the inner layer 4 can actively even break to absorb the energy, and that since the material of the intermediate layer 5 has a resilience tension, the inner layer 4 can still be reset to its original position so as to ensure the integrity and function of the entire panel. Therefore, the hollow composite panel of the present invention has the advantages of high surface strength, high flatness, overall impact resistance, deformation resistance, more stable structure, higher performance, and longer service life.

[0163] The multi-panel multi-layer hollow fusion panel 1 can be applied to construct various types of storage container, including but not limited to outdoor storage box (as shown in FIG. 28A), bedside drawer container (as shown in FIG. 28B), deck box, shoe cabinet or closet, closet, patio deck, trailer storage box, trash container, dumpster, tool container, trailer container, storge room, and the like.

[0164] According to the preferred embodiment of the present invention, the parameters of the high density polyethylene used in the outer layer 3 are as follows: [0165] melting fat: 1.5 g/10 min, bending strength: 900 MPa, Shore D69.

[0166] According to the preferred embodiment of the present invention, the parameters of the high density polyethylene used in the intermediate layer 5 are as follows: [0167] melting fat: 0.35 g/10 min, bending strength: 1050 MPa, Shore D63.

[0168] According to the preferred embodiment of the present invention, the parameters of the metallocene polyethylene used in the inner layer 4 are as follows: melting fat: 2.0 g/10 min; elongation at break: 420% in longitudinal direction and 830% in transverse direction; tensile strength at break: 62 MPa in longitudinal direction, 25 MPa in transverse direction; dart impact strength <48 g; and Eikmandorf tearing strength: 21 C. in longitudinal direction, 430 C. in transverse direction.

[0169] Furthermore, a person who skilled in the art should understand that, as an example of a simplified application, the outer layer 3, the intermediate layer 5 and the inner layer 4 can be made of the same material (new and/or recycled material) or the material with different grades or different levels. For example, the outer layer 3, the intermediate layer 5 and the inner layer 4 can be made of high density polyethylene. In addition, the outer layer 3 can be made of material having high hardness level and bright color, the intermediate layer 5 can be a composite layer, and the inner layer 3 can be made of recycled materials and a predetermined proportion of structural filling materials. These configurations can save the material cost and allow quick color changing capability.

[0170] As shown in FIG. 6, an alternative mode of the preferred embodiment of the present invention is illustrated. According to this alternative mode, the upper panel member 1 and the lower panel member 2 each having a double-layer structure. In other words, each of the upper panel member 1 and the lower panel member 2 includes an outer layer 3 and an inner layer 4, wherein the lower panel member 2 is recessed in a direction toward the upper panel member 1 until the inner layer of the lower panel member and the inner layer of the upper panel member 1 are fused with each other to form a predetermined number of joint supporting structures 6 distributed in a predetermined manner.

[0171] The raw material structure of the double-layer multi-layer hollow fusion panel 1 is as follows: the outer layers 3 of the upper panel member 1 and the lower panel member 2 are both made of high density polyethylene, and the inner layers 4 of the upper panel member 1 and the lower panel member 2 are made of a mixture selected from high density polyethylene, metallocene polyethylene and calcium carbonate, or both made of a mixture of high-density polyethylene, metallocene polyethylene and glass fiber.

[0172] As a result, the outer layer 3 has the properties of high surface strength, scratch resistance, and oil resistance. The inner layer 4 has a low thermoplastic shrinkage ratio and provides rigid frame structure support which also has a predetermined elasticity and energy absorption and high strength, and provides an effective buffering effect to any impact and drop which may damage the panel.

[0173] According to this alternative mode of the preferred embodiment of the present invention, for the inner layer 4, the mass percentage of the metallocene polyethylene is 10% to 15%, the mass percentage of calcium carbonate is 15% to 20%, and the rest is high density polyethylene. Alternatively, for the inner layer 4, the mass percentage of the metallocene polyethylene is 10% to 15%, the mass percentage of the glass fiber is 15% to 25%, and the rest is high density polyethylene.

[0174] Also, when the outer layer 3 of the upper panel member 1 is an exterior portion that is being exposed to outside, only the outer layer 3 of the upper panel member 1 is required to be made of new material of high density polyethylene. The inner layer 4 of the upper panel member 1 is an interior portion that can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the inner layer 4 of the upper panel member 1 can be recycled materials.

[0175] Similarly, if the outer layer 3 of the lower panel member 2 is also an exterior portion that is being exposed to outside, the outer layer 3 of the lower panel member 1 is made of new material of high density polyethylene, and the raw materials of the inner layer 4 of the lower panel member 2 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the inner layer 4 of the lower panel member 2 can be recycled materials.

[0176] Further, when the hollow fusion panel 1 of the present invention is used to construct as the storage container C10 that the lower panel member 2 does not require to be exposed to outside, the outer layer 3 and the inner layer 4 of the lower panel member 2 can all be made of recycled materials or a mixture of new and recycled materials.

[0177] Same as the preferred embodiment, the mass percentage of the high density polyethylene, calcium carbonate, glass fiber mentioned above can be applied to both the new material or recycled material thereof. Preferably, since the high density polyethylene is the major content of the intermediate layer 5 and the inner layer 4, it can be made that only the high density polyethylene is recycled material.

[0178] In addition, the parameter performance of the high density polyethylene and metallocene polyethylene used in this alternative mode can refer to the above preferred embodiment, which will not be further described here.

[0179] The above descriptions are for the preferred embodiment and its alternative mode of the present invention. It should be pointed out that for a person who skilled in the art, without departing from the principle of the present invention, various modifications or improvements can be made to the present invention. For example, the outer layer 3, the intermediate layer 5, and the inner layer 4 of the upper layer member 1 and the outer layer 3, the intermediate layer 5, and the inner layer 4 of the lower layer member 2 can be configured to have more than one layer structure, which should be within the scope of the present invention.

[0180] Referring to FIGS. 7A to 8C, according to the preferred embodiment of the present invention, a hollow fusion panel 1 is exampled and illustrated as, but not limited to, a construction panel or a wall of the storage container C10.

[0181] The hollow fusion panel 1 can be constructed as a panel having a relatively thinner thickness with excellent performance. The hollow fusion panel 1 may include a first panel member 30 and a second panel member 40, wherein at least a portion of the first panel member 30 and at least a portion of the second panel member 40 is configured to maintain a predetermined distance to define at least one cavity 100 therebetween and surroundingly to form a hollow panel structure.

[0182] A plurality of portions of the second panel member 40 is extended toward the first panel member 30 to form a predetermined number of supporting structures 41 arranged in predetermined patterns, wherein the supporting structures 41 are respectively extended to the first panel member 30 until being fused with the first panel member 30 during thermal blow molding.

[0183] At least portions of the second panel member 40 are stretched and recessed towards the first panel member 30 to form the supporting structures 41. In other words, without increasing the overall weight of the hollow fusion panel 1, the supporting structures 41 are formed with respect to the first panel member 30 to provide supporting effect so as to enhance the overall strength of the entire hollow fusion panel 1.

[0184] In addition, since the second panel member 40 is stretched and recessed to form the supporting structures 41, at least some portions of the second panel member 40 can be thinner in thickness, so that the thickness of the entire hollow fusion panel 1 can be reduced. In other words, comparing with the conventional blow-molded panels, the hollow fusion panel 1 of the present invention can provide better structural strength while having a thinner thickness.

[0185] Further, since the second panel member 40 has the supporting structures 41 formed and extended to the first panel member 30 and the inner side of the first panel member 30 and at least portions of the second panel member 40 are fused with each other, during the using of the hollow fusion panel 1, the overall impact resistance of the entire hollow fusion panel 1 is improved accordingly while subjected to an external collision or impact due to the mutual contact and fusion between the first panel member 30 and the second panel member 40.

[0186] Due to the fusion of the supporting structures 41 and the first panel member 30, the thickness of the fusion positions where the supporting structures 41 fuse and connect with the first panel member 30 can be reduced that facilitates heat dissipation at these positions. In detail, if the second panel member 40 forms the supporting structures 41 that extend to only attach to the first panel member 30, then the thickness at each attaching position of the first panel member 30 and the second panel member 40 is equal to the sum of the thickness of the first panel member 30 and the second panel member 40 at the corresponding attaching position. For the first panel member 30, since the thickness at each of the attaching positions is greater than that of other adjacent positions, heat may accumulate in these attaching positions during the manufacturing process, that will affect the quality of the final product, such as uneven shrinkage problem caused by uneven heat dissipation.

[0187] However, the fusion of the supporting structure 41 and the first panel member 30 can improve the above problem. By means of the fusion of the supporting structures 41 of the second panel member 40 and the first panel member 30, the material of the second panel member 40 forming the supporting structures 41 merges into the first panel member 30, and the material of the first panel member 30 merges into the supporting structures 41. It is understood that gaps between the materials forming the first panel member 30 and the supporting structures 41 of the second panel member 40 are eliminated due to the mutual fusion of the supporting structures 41 and the first panel member 30, so that the thickness of each of the fusion positions of the first panel member 30 and the supporting structures 41 would be less than the sum of the thickness of the first panel member 30 and the thickness of the supporting structure before fusion, such that the heat dissipation problem can thus be improved.

[0188] In addition, due to the mutual fusion of materials, the structure between the supporting structure 41 and the first panel member 30 is more tight and rigid.

[0189] Furthermore, the hollow fusion panel 1 is configured as a multilayer structure. However, in the conventional art, the entire plastic panel is usually made of the same material while being required to achieve the desired structural strength, scratch resistance, impact resistance, and etc. A high performance plastic panel needs to achieve a variety of excellent performance through the same material, which undoubtedly requires the material itself to have higher requirements, so that it is often necessary to use more expensive modified materials, or that it is often necessary to redesign the structure of the plastic panel, expecting to obtain panels with excellent performance through structural improvements other than the materials.

[0190] In the preferred embodiment, the hollow fusion panel 1 is designed as a multilayer structure, so different materials can be used to composite and meet different performance requirements, thereby lowering the demands and requirements of the materials to be used as a whole.

[0191] In detail, in this embodiment, the hollow fusion panel 1 may include a first layer 10 and a second layer 20, wherein the first layer 10 and at least a portion of the second layer 20 are overlapped and composited. The first panel member 30 may include one or two selected from a combination of a portion of the first layer 10 and at least a portion of the second layer 20, and the second panel member 40 may include one or two selected from a combination of other at least a portion of the first layer 10 and the other portion of the second layer 20.

[0192] The hollow fusion panel 1 can be implemented as that the first panel member 30 includes at least a portion of the first layer 10, and the second panel member 40 includes at least the other portion of the first layer 10 and the entire second layer 20.

[0193] The hollow fusion panel 1 can also be implemented as that the first panel member 30 includes at least a portion of the first layer 10 and the entire second layer 20, and the second panel member 40 includes at least the other portion of the first layer 10.

[0194] The hollow fusion panel 1 can also be implemented as that the first panel member 30 includes at least a portion of the first layer 10 and at least a portion of the second layer 20, and the second panel member 40 includes at least the other portion of the first layer 10 and at least the other portion of the second layer 20. In this embodiment, the first layer 10 and the second layer 20 are overlapped and composited to form both the first panel member 30 and the second panel member 40.

[0195] It is worth mentioning that the term layer in the disclosure does not refer that the first layer 10 or the second layer 20 must have an apparent boundary therebetween. The first layer 10 and the second layer 20 can be made of the same material, and the connecting boundary between the first layer 10 and the second layer 20 can be obvious or can also be blurred, such as a fusion, bonding, superimposed, or laminated integral composite structure. The first layer 10 and the second layer 20 may also be made of different materials. In particular, the first panel member 30 includes at least portion of the first layer 10 and at least portion of the second layer 20, wherein at least portions of the first layer 10 and the second layer 20 can be overlapped and composited with each other to form the first panel member 30.

[0196] In the preferred embodiment, the first layer 10 and the second layer 20 are fused with each other at the overlapping junction thereof as an example for description.

[0197] Further, in this embodiment, the first layer 10 and the second layer 20 of the hollow fusion panel 1 are both arranged to be continuous layers, and the first layer 10 and the second layer 20 are completely overlapped. The first layer 10 is an outer layer located outside and the second layer 20 is an inner layer located inside. The second layer 20 surrounds to define the cavity 100 and the first layer 10 is arranged around the second layer 20.

[0198] While only the first layer 10 of the first panel member 30 is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30 is required to be made of a new material of high density polyethylene. The second layer 20 of the first panel member 30 are interior portions and thus the second layer 20 of the first panel member 30 can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 of the first panel member 30 can be recycled materials.

[0199] Similarly, if the first layer 10 of the second panel member 40 is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40 is made of new material of high density polyethylene, and the raw materials of the second layer 20 of the second panel member 40 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 of the lower panel member 2 can be recycled materials. It is appreciated that when the second panel member 40 does not require to be exposed to outside, the first layer 10 and the second layer 20 of the second panel member 40 can all be made of recycled materials or a mixture of new and recycled materials.

[0200] Further, the hollow fusion panel 1 may further include a third layer 50, wherein the second layer 20 is located between the first layer 10 and the third layer 50, wherein the third layer 50 and at least portion of the second layer 20 are overlapped and fused with each other.

[0201] The first panel member 30 may include one or more selected from a combination of at least portion of the first layer 10, at least portion of the second layer 20, and at least portion of the third layer 50. The second panel member 40 may include one or more selected from a combination of at least the other portion of the first layer 10, at least the other portion of the second layer 20, and at least the other portion of the third layer 50.

[0202] It is understandable that the first panel member 30 can be a single-layer, double-layer, triple-layer, or multi-layer structure, and the second panel member 40 can also be a single-layer, double-layer, triple-layer, or multi-layer structure, for example, referring to FIGS. 9A to 9C.

[0203] In this embodiment, the first panel member 30 includes at least portion of the first layer 10, at least portion of the second layer 20, and at least portion of the third layer 50. The second panel member 40 includes at least the other portion of the first layer 10, at least the other portion of the second layer 20, and at least the other portion of the third layer 50. An inner wall of the third layer 50 defines the cavity 100.

[0204] The supporting structure 41 may each includes one or more selected from a combination of at least portion of the first layer 10, at least portion of the second layer 20 and at least portion of the third layer 50. It can be understood that the number of layers of the supporting structure 41 and other portion of the second panel member 40 may be the same or may be different. In this embodiment, the supporting structures 41 each includes at least portion of the first layer 10, at least portion of the second layer 20 and at least portion of the third layer 50. In other words, the first layer 10, the second layer 20, and the third layer 50 of the second panel member 40 extend inwardly at predetermined positions to form the predetermined number of supporting structures 41 respectively.

[0205] The first layer 10 of the hollow fusion panel 1 is configured to have an excellent first performance, the second layer 20 is configured to have an excellent second performance, and the third layer 50 is configured to have excellent third performance. While the first layer 10 has the excellent first performance, the requirements of the second performance and the third performance can be lowered. While the second layer 20 has the excellent second performance, the requirements of the first performance and the third performance can be lowered. While the third layer 50 has the excellent third performance, the requirements of the first performance and the second performance can be lowered.

[0206] Accordingly, the hollow fusion panel 1 including the first layer 10, the second layer 20 and the third layer 50 finally has the excellent first performance, second performance and third performance overall, but does not need to rely on any material that meets the requirements of the first performance, the second performance and the third performance at the same time.

[0207] The layers of the hollow fusion panel 1 are designed to have different performances. For example, the first layer 10 is designed to be scratch-resistant and has better scratch-resistant performance than the second layer 20 and the third layer 50. For example, the second layer 20 is designed to be impact resistant and has better impact resistance performance than the first layer 10 and the third layer 50. For example, the third layers 30 is designed to have better supporting strength and has better supporting strength performance than the first layer 10 and the second layer 20.

[0208] Optionally, the first layer 10 may be made of high density polyethylene, the second layer 20 may be made of high density polyethylene plus or high density polyethylene plus glass fiber, and the third layer 50 may be made of metallocene polyethylene.

[0209] When the first layer 10 of the hollow fusion panel 1 is made of high density polyethylene, the relative parameters of the high density polyethylene may be melting fat: 1.5 g/10 min, bending strength: 900 MPa, and Shore D69.

[0210] When the second layer 20 of the hollow fusion panel 1 is made of high density polyethylene plus calcium carbonate, the mass percentage of calcium carbonate can be 15% to 30%, and the mass percentage of high density polyethylene can be 70% to 85%. In addition, the relative parameters of the high density polyethylene can be melting fat: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.

[0211] When the second layer 20 of the hollow fusion panel 1 is made of high-density polyethylene and glass fiber, the mass percentage of glass fiber can be 15% to 40%, and the mass percentage of high density polyethylene can be 60% to 85%. Also, the relative parameters of high density polyethylene can be melting fat: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.

[0212] When the third layer 50 of the hollow fusion panel 1 is made of metallocene polyethylene, the relative parameters of the metallocene polyethylene can be melting fat: 2.0 g/10 min, elongation at break: 420% in longitudinal direction, 830% in transverse direction, tensile strength at break: 62 MPa in longitudinal direction, 25 MPa in transverse direction, dart impact strength <48 g, Eikmandorf tear strength: 21 C. in longitudinal direction, 430 C. in transverse direction.

[0213] Further, the first panel member 30 and a portion of each of the supporting structures recessed from the second panel member 40 can be fused with each other for producing more beneficial effects. In particular, in this embodiment, portions of the third layer 50 of the first panel member 30 and portions of the third layer 50 of the supporting structures 41 are fused with each other. It is worth mentioning that the fusion of the first panel member 30 and the second panel member 40 does not necessarily require that the materials of the two fusing positions of the first panel member 30 and the second panel member 40 be the same before the fusion, wherein person skilled in the art is capable of selecting suitable materials according to requirements.

[0214] In addition, when only the first layer 10 of the first panel member 30 is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30 is required to be made of a new material of high density polyethylene. The second layer 20 and third layer 50 of the first panel member 30 are interior portions and thus the second layer 20 and the third layer 50 of the first panel member 30 can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 and the third layer 50 of the first panel member 30 can be recycled materials.

[0215] Similarly, if the first layer 10 of the second panel member 40 is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40 is made of new material of high density polyethylene, and the raw materials of the second layer 20 and the third layer 50 of the second panel member 40 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the second layer 20 and the third layer 50 of the lower panel member 2 can be recycled materials.

[0216] It is worth mentioning that when the hollow fusion panel 1 of the present invention is used to construct as a wall of the storage container C10, the second panel member 40 does not require to be exposed to outside, the first layer 10, the second layer 20 and the third layer 50 of the second panel member 40 can all be made of recycled materials or a mixture of new and recycled materials.

[0217] Alternatively, the first layer 10 can be made of a material or a combination of materials selected from nylon and high density polyethylene, the third layer 50 can be made of a material or a combination of materials selected from high density polyethylene, glass fiber, calcium carbonate and metallocene polyethylene, and the second layer 20 can be a bonding layer made of bonding adhesive adapted to better connecting the first layer 10 and the third layer 50 to form an integral body. In such configuration, the mass percentage of the first layer 10 can be 5-6%, the mass percentage of the second layer 20 can be 2-3%, and the mass percentage of the third layer can be as much as 90% or more. In this case, when only the first layer 10 of the first panel member 30 is an exterior portion that is being exposed to outside, only the first layer 10 of the first panel member 30 is required to be made of new material, i.e. new nylon and/or high density polyethylene. The third layer 50 of the first panel member 30 is interior portions and thus the third layer 50 of the first panel member 30 can be made of recycled material or a mixture of new material and recycled material. In other words, the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the third layer 50 of the first panel member 30 can be recycled materials.

[0218] Similarly, if the first layer 10 of the second panel member 40 is also an exterior portion that is being exposed to outside, the first layer 10 of the second panel member 40 is made of a new material of high density polyethylene, and the raw materials of the third layer 50 of the second panel member 40 can be made of recycled materials or a mixture of new materials and recycled materials as interior portions. That is the high density polyethylene, the calcium carbonate and/or glass fiber to be used to manufacture the third layer 50 of the lower panel member 2 can be recycled materials. It is appreciated that when the second panel member 40 does not require to be exposed to outside, the first layer 10 and the third layer 50 of the second panel member 40 can all be made of recycled materials or a mixture of new and recycled materials.

[0219] Appreciated to the fusion configuration of the present invention, at least 30% of the raw material for producing the hollow fusion panel 1 of the present invention can be recycled materials. In favor to the global environment, the hollow fusion panel 1 of the present invention may contains up to 90% recycled materials. Preferably, 65% recycled material can be used to produce the hollow fusion panel 1 of the present invention.

[0220] Before the first panel member 30 and the second panel member 40 where is closed thereto are fused with each other, the largest thickness of the hollow fusion panel 1 is the contact position where the supporting structure contacting the first panel member 30, that is such maximum thickness is the sum of a total thickness of the first layer 10, the second layer 20, and the third layer 50 of the first panel member 30, and at total thickness of the first layer 10, the second layer 20, and the third layer 50 of the second panel member 40.

[0221] After the first panel member 30 and the second panel member 40 are fused with each other, for example, two opposing third layers 30 of the first panel member 30 and the supporting structure 41 of the second panel member 40 are at least partially fused with each other, wherein a maximum thickness of the hollow fusion panel 1 is less than the sum of the thickness of the first panel member 30 and the thickness of the second panel member 40, and is greater than or equal to a total thickness of partial thickness of the first layer 10, partial thickness of the second layer 20, and partial thickness of the third layer 50 of the first panel member 30 plus partial thickness of the first layer 10 and partial thickness the second layer 20 of the second panel member 40. The reason is that the third layer 50 part of the second panel member 40 may be completely fused with the third layer 50 part of the first panel member 30.

[0222] Accordingly, a thickness of the maximum thickness position of the hollow construction fusion panel 1 can be decreased, thereby facilitating heat dissipation thereat.

[0223] In addition, since the second layer 20 and the third layer 50 can be made of different materials, the fusion of the first panel member 30 and the supporting structure 41 may render the heat dissipation of portions of the third layer 50 of the first panel member 30 at those fusing positions being more difficult than that of before fusion with the supporting structure 41, which may lead to different shrinkage rates at various positions of the third layer 50 of the first panel member 30, which may further affect the corresponding portions of the second layer 20 and the first layer 10 of the first panel member 30, resulting in uneven surface of the first panel member 30. However, due to the multi-layer configuration of the first panel member 30, the heat transfer efficiency and shrinkage rates of the first layer 10, the second layer 20 and the third layer 50 may be different. The heat dissipation may have a certain influence on the third layer 50, but this influence can be compensated or reduced as much as possible by selecting the right material to be used for the first layer 10 or the second layer 20.

[0224] Further, in the conventional art, relevant technicians would generally try to avoid any contact between the second panel member 40 and the first panel member 30 which are made of the same material as to reduce the defective rate of the product. Therefore, under the framework of the conventional art, it is necessary to arrange as many supporting structures 41 as possible for supporting the first panel member 30 as much as possible under the premise of smaller contact area. In the preferred embodiment, since the supporting structures 41 can each maintain a certain contact area with the first panel member 30, it is beneficial to the structural strength of the hollow fusion panel 1 of the present invention while without affecting the product yield thereof. Accordingly, the number of the supporting structures 41 does not need to be arranged as much as the conventional art does. In other words, the total number of the supporting structures 41 can be reduced and the distance between the adjacent supporting structures 41 can be reasonably enlarged to facilitate manufacturing, such as to facilitate demolding, and also to reduce the possibility of collateral influence of the adjacent supporting structures 41 during the manufacturing process.

[0225] Further, in the conventional art, relevant technicians would try to avoid any contact between the second panel member 40 and the first panel member 30 to reduce product defective rate, especially when the first panel member 30 is made thinner, wherein the increasing of the thickness at the inner side of the first panel member 30 would cause adverse effect in heat dissipation for the first panel member 30. Therefore, the thinner the panel thickness, the smaller the contact area between the first panel member 30 and the second panel member 40. However, according to the preferred embodiment of the present invention, larger contact area between the first panel member 30 and the second panel member 40 can be arranged, especially when a thinner first panel member 30 is used, that is beneficial, on the one hand, to the support of the first panel member 30, and on the other hand, to the firmness and rigidness of the integration of the first panel member 30 and the second panel member 40. In the conventional art, the contact area of the first panel member 30 and the second panel member 40 should be arranged as little as possible, or even have to avoid any contact of the first panel member 30 and the second panel member 40 other than the edge connection position of the first panel member 30 and the second panel member 40. In the preferred embodiment of the present invention, the total contact area of the supporting structures 41 of the first panel member 30 and the second panel member 40 is relatively larger. When the first panel member 30 is impacted, the impact force applied thereon can be quickly transmitted to the second panel member 40, while the cavity 100 formed between the first panel member 30 and the second panel member 40 can serve as a buffer and provide shock absorption effect.

[0226] According to the preferred embodiment of the present invention, the thickness of the first panel member 30 of the hollow fusion panel 1 may be referred as t, and this value would be an average thickness of the first panel member 30. The contact area between the first panel member 30 of the hollow fusion panel 1 and the corresponding supporting structure 41 at this fusing position is referred as s, and this value may be a mean value of the contact area between the plurality of supporting structures 41 and the first panel member 30. The ratio of the thickness of the first panel member 30 of the hollow fusion panel 1 to the contact area is x=s/t.sup.2. According to one embodiment of the present invention, t may be 2 mm and s may be 0.5 mm.sup.2, where x is 0.5/4-0.125. According to the preferred embodiment of the present invention, x may be greater than 0.1.

[0227] According to one embodiment of the present invention, the thickness of the first panel member 30 of the hollow fusion panel 1 may be referred as t, and the area of the first panel member 30 occupied by the corresponding contact peak 43 is referred as s. Then, t can be 3 mm and s can be 6 mm.sup.2, where x=s/t.sup.2=6/9, which is greater than 0.1.

[0228] Furthermore, each of the supporting structures 41 can form a recessed cavity 400, having a W-shaped cross-section, in a direction toward the first panel member 30. The recessed cavity 400, having an elongated oval shape, has a bottom portion with two arc-shape end peaks, and is defined by a surrounding peripheral edge wall inclinedly extending upwards and inwards to form the supporting structure 41 for strengthening the second panel member 40. Each of the supporting structures 41 is provided with at least one reinforcing rib 42. In this embodiment, each of the supporting structures 41 is provided with a pair of the reinforcing ribs 42, transversally extended across the bottom portion of the recessed cavity 400, that is the relative top portion of the supporting structure 41. It is worth mentioning that a wave-shaped structure is an ideal reinforcing structure, so the pair of wave-shaped reinforcing ribs 42 also forms the above-mentioned three-peak wave supporting structure 41, which greatly strengthens the impact resistance and robustness of the second panel member 40.

[0229] The supporting structure 41 can extend toward the first panel member 30 to form at least one contact peak point 43, wherein the first panel member 30 fuses with the second panel member 40 at the contact peak point 43. In this example, each of the supporting structures 41 forms three contact peak points 43, such that when the first panel member 30 is impacted, the combining of the contact peak points 43 with the first panel member 30 provide an enforcement effect to the first panel member 30. Accordingly, the impact force applied to the first panel member 30 is more evenly transmitted to the second panel member 40, while the first panel member 30 and the cavity 100 formed on the second panel member 40 can provide buffering and shock absorbing effects.

[0230] Further, the hollow fusion panel 1 can be manufactured by blow molding technology, such as extrusion blow molding, injection blow molding and injection stretch blow molding. The melted materials used to manufacture the first layer 10, the second layer 20 and the third layer 50 can be co-extruded through a mold head to form a mold blank in a parison mold, wherein the first layer 10, the second layer 20, and the third layer 50 are fused with each other and define a cavity surrounded by the first layer 10, the second layer 20 and the third layer 50. The parison mold provides an exterior extrusion pressure to the mold blank and air blow in the mold blank with in the parison mold provides interior extrusion pressure to press the mold blank against the parison mold until the hollow fusion panel 1 is blow-molded from the mold blank. Those skilled in the art can understand that this is one blow molding method selected from various blow molding producing methods for the hollow fusion panel 1.

[0231] During the manufacturing process, portions of the first layer 10, portions of the second layer 20 and portions of the third layer 50 used to form the second panel member 40 are stretched to protrude toward the first panel member 30 to form the supporting structures 41 while the second panel member 40 simultaneously forms the recessed cavities 400 with respect to the supporting structures 41 respectively.

[0232] At least a portion of the second panel member 40 is stretched, so the thickness of at least a portion of the second panel member is thinner than the thickness of the first panel member 30. For example, a thickness of the portion of the first layer 10 forming the supporting structure 41 is generally thinner than that of the portion of the first layer 10 forming the first panel member 30.

[0233] Referring to FIG. 9A, another alternative mode of the hollow fusion panel 1 according to the above preferred embodiment of the present invention is illustrated. In this alternative mode, the first panel member 30 includes at least portion of the first layer 10 and at least portion of the second layer 20, and the second panel member 40 includes at least portion of the first layer 10, at least portions of the second layer 20 and the third layer 50. In other words, the first panel member 30 is arranged in a two-layer structure and the second panel member 40 is arranged in three-layer structure.

[0234] Referring to FIG. 9B, another alternative mode of the hollow fusion panel 1 according to the above-mentioned preferred embodiment of the present invention is illustrated. In this alternative mode, the first panel member 30 includes at least portion of the first layer 10 and at least portion of the second layer 20, and the second panel member 40 includes the other portion of the first layer 10 and the other portion of the second layer 20. In other words, each of the first panel member 30 and the second panel member 40 is arranged in a double-layer structure.

[0235] Referring to FIG. 9C, another alternative mode of the hollow fusion panel 1 according to the above preferred embodiment of the present invention is illustrated. In this alternative mode, the first panel member 30 includes the first layer 10 and at least portion of the second layer 20, and the second panel member 40 includes the other portion of the second layer 20. In other words, the first panel member 30 is arranged in a double-layer structure and the second panel member 40 is arranged in a single-layer structure.

[0236] It should be understood by those skilled in the art that the number of layers of the first panel member 30 and the second panel member 40 can be the same or different, and the first panel member 30 and the second panel member 40 can be selectively arranged according to requirements.

[0237] Referring to FIG. 10A, it is a partial perspective view of the hollow fusion panel 1 according to another alternative mode of the above preferred embodiment of the present invention.

[0238] In this alternative mode, at least one of the supporting structures 41 is formed to have two contact peak points 43 and is arranged with one reinforcing rib 42.

[0239] The contact area between the corresponding supporting structure 41 and the first panel member 30 can be 4*3 mm.sup.2, and the thickness of the first panel member 30 can be 3 mm, so that x can be 12/9, which is greater than 0.1.

[0240] Referring to FIG. 10B, it is a partial perspective view of the hollow fusion panel 1 according to another alternative mode of the above preferred embodiment of the present invention.

[0241] In this alternative mode, at least one of the supporting structures 41 is formed to have a single contact peak 43.

[0242] The contact area between the single supporting structure 41 and the first panel member 30 may be 4*4 mm.sup.2, and the thickness of the first panel member 30 can be 4 mm, so that x can be 16/16, which is greater than 0.1.

[0243] FIG. 11 is a sectional view illustrating the storage container C10 of the present invention, which comprises a bottom wall C11 and a surrounding wall C12 extended from a periphery edge of the bottom wall C11 defining the storage cavity C13 therein and having at least one opening C14. The bottom wall C11 can be made of one board type hollow fusion panel 1. The surrounding wall C12, which can be constructed with a plurality of board type hollow fusion panels 1 connected side to side, is connected to the sides of the bottom wall C11. It is appreciated that the entire storage container C10 can be made of a box type hollow fusion panel 1 to integrally form the bottom wall C11 and the surrounding wall C12 by blow molding. It is worth mentioning that the shape of the hollow fusion panel 1, such as planar board type, curved board type, circular box type, polygon box type, and the like, depends on the shape and configuration of the blow mould.

[0244] Referring to FIG. 12 of the drawings, a producing method of the board type or box type blow-molded hollow fusion panel 1 according to the above-mentioned preferred embodiment of the present invention is illustrated.

[0245] First, heat the first polymer, such as high density polyethylene, of the first polymer layer 10, the second polymer, such as high density polyethylene or a combination of high density polyethylene, calcium carbonate and/or glass fiber, of the second polymer layer 20, and the third polymer, such as high density polyethylene or a combination of high density polyethylene, glass fiber, calcium carbonate, and/or metallocene polyethylene, of the third polymer layer 50 respectively at a predetermined temperature to obtain the first polymer, the second polymer and the third polymer in fluid form. When new material is used, the new material, in form of small pellets or granules, is received in the corresponding chamber A1, A2 or A3 and heated to melt by the feeding unit 201. When recycled material is used, the recycled material, in form of small pellets or granules, is contained in the corresponding chamber A1, A2 or A3 and heated to melt by the feeding unit 201. When a mixture of new and recycled materials is used, the new and recycled materials, in form of small pellets or granules, are contained in the corresponding chamber A1, A2 or A3 and heated to melt by the heater B.

[0246] Then, co-extrude the first polymer, the second polymer and the third polymer to form the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 respectively, wherein an inner surface of the first polymer layer 10 and an outer surface of the second polymer layer 20 are fused with each other, and an inner surface of the second polymer layer 20 and an outer surface of the third polymer layer 50 are fused with each other.

[0247] It is worth mentioning that, alternatively, in the co-extrusion step, the first polymer layer 10 and an outer surface of the second polymer layer 20 are fused with each other and are surrounded to form the cavity 100. The first polymer layer 10 is a continuous material layer to surround the second polymer layer 20, and the second polymer layer 20 is a continuous material layer to surround the third polymer layer 50. In other words, after co-extruding the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50, surrounding the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 to form the cavity 100.

[0248] Then, the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are fused with each other and placed in a mold for molding. A flow of gas can be blown into the mold, such that the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are biased against an inner wall of the mold, Therefore, the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 can be molded along the inner wall of the mold.

[0249] The molded first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 are then cooled and demolded to form the blow-molded hollow fusion panel 1.

[0250] It should be understood that the method of cooling the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 can be achieved by the introduction of gas. The gas can be any commercially available gas in a pressurized tank, or it can be air. The gas itself should not be harmful to the first polymer, the second polymer, and the third polymer, and should not damage the mold. The gas can be, but should not be limited to, air, helium, neon, argon, or any combination of the foregoing. Of course, it should be understood that the cooling method of the blow-molded hollow fusion panel 1 after molding should not be limited to the above-mentioned air cooling method.

[0251] It should be understood that the first polymer, the second polymer and the third polymer are preferably formed in a melting state before they are extruded, wherein the first polymer, the second polymer, and the third polymer can be heated separately to maintain their fluidities. The extrusion step is performed during the heating process, such that the first polymer, the second polymer and the third polymer are heated uniformly, so as to enhance uniformity of the first polymer, the second polymer, and the third polymer.

[0252] It should be understood that when the first polymer, the second polymer and the third polymer are respectively extruded to form the first polymer layer 10, the second polymer layer 20, the second polymer layer 20 and the third polymer layer 50, wherein the first polymer layer 10, the second polymer layer 20, the second polymer layer 20 and the third polymer layer 50 are fused with each other. A person who skilled in the art can select the first polymer, the second polymer, and the third polymer, so that the first polymer, the second polymer and the third polymer have good viscosity after being heated.

[0253] As shown in FIG. 13 and FIG. 14, a blow molding process and the related blow molding equipment 2 according to the preferred embodiment of the present invention are illustrated.

[0254] The blow molding equipment 2 comprises a feeding unit 201, an extrusion unit 202, and a blow molding unit 203, wherein the first polymer, the second polymer, and the third polymer are respectively fed to the feeding unit 201.

[0255] The feeding unit 201 comprises a first feeding screw rod 2011, a second feeding screw rod 2012, and a third feeding screw rod 2013, wherein the first polymer is fed through the first feeding screw rod 2011, the second polymer is fed through the second feeding screw rod 2012, and the third polymer is fed through the third feeding screw rod 2013.

[0256] The first feeding screw rod 2011, the second feeding screw rod 2012, and the third feeding screw rod 2013 can be configured to heat up the first polymer, the second polymer, and the third polymer respectively to ensure the first polymer, the second polymer, and the third polymer in a fluid state. It should be understood that before respectively feeding the first polymer, the second polymer and the third polymer into the first feed screw rod 2011, the second feed screw rod 2012 and the third feeding screw rod 2013, a mixing step may be performed, for example, the raw material and the plastic additive such as catalyst are mixed and then fed to the feeding unit 201.

[0257] The first feed screw rod 2011, the second feed screw rod 2012, and the third feed screw rod 2013 are arranged for heat treating the first polymer, the second polymer and the third polymer respectively. In one embodiment, the operating temperatures of the first feeding screw rod 2011, the second feeding screw rod 2012, and the third feeding screw rod 2013 are set with a range from 160 C. to 180 C. It should be understood that according to the transformation of the first polymer, the second polymer, and the third polymer, the heating temperatures thereof can be adjusted correspondingly, such that the first polymer, the second polymer and the third polymer are respectively heated to a desired fluid state, so as to maintain a desired flow speed and viscosity.

[0258] Furthermore, in one embodiment, the first polymer layer 10 of the blow-molded hollow fusion panel 1 is can be implemented to have the properties of high surface strength, scratch resistance, and oil stain resistance. The second polymer layer 20 can be implemented to have an energy absorbing structure or a material with high rigid ability and can effectively provide a buffering effect of the blow-molded panel due to any external impact or drop. The third polymer layer 50 can be implemented to have a low thermoplastic shrinkage ratio and to provide frame support.

[0259] For example, the first polymer is implemented as high-density polyethylene, and the parameters related to the high density polyethylene may be melting rate: 1.5 g/10 min, bending strength: 900 MPa, and Shore D69.

[0260] The second polymer is implemented as a mixture of high density polyethylene and calcium carbonate or a mixture of high density polyethylene and glass fiber. For the first example of the second polymer made of the mixture of high-density polyethylene and calcium carbonate, the mass percentage of calcium carbonate is 15-30%, the mass percentage of high-density polyethylene is 70-85%, and the parameters related to high-density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63. For the second example of the second polymer made of the mixture of high-density polyethylene and glass fiber, the mass percentage of glass fiber is 15-40%, the mass percentage of high density polyethylene is 60-85%, and the related parameters of high-density polyethylene are melting rate: 0.35 g/10 min, bending strength 1050 MPa, Shore D63.

[0261] The third polymer can be implemented as metallocene polyethylene. The related parameters of the metallocene polyethylene are melting rate: 2.0 g/10 min, elongation at break: longitudinal 420%, transverse 830%, tensile strength at break: longitudinal 62 MPa, transverse 25 MPa, dart impact strength <48 g, Elmendorf tear strength: longitudinal 21 C., transverse 430 C.

[0262] It should be understood that the materials of the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 are not limited to the aforementioned materials. A person who skilled in the art can select suitable materials for each layer of the blow-molded panel 1 according to the characteristics of the materials.

[0263] The second polymer layer 20 can be embodied as a micro-foam layer to provide a cushioning effect. Since the second polymer layer 20 is located and sandwiched between the first polymer layer 10 and the third polymer layer 50, the second polymer layer 20 can be selected in different colors, such as black color. The second polymer layer 20 can also be made of recycled plastic, such as recycled high density polyethylene, to reduce material cost.

[0264] The second polymer layer 20 is embodied as an intermediary layer. Via the second polymer layer 20, the first polymer layer 10 and the third polymer layer 50 are bonded or adhered together. For example, at least a portion of the first polymer layer 10 and at least a portion of the second polymer layer 20 are fused with each other, and at least a portion of the second polymer layer 20 and the third polymer layer 50 are fused with each other. However, the first polymer layer 10 and the third polymer layer 50 are difficult to adhere to or fuse with each other. It should be understood that the intermediate layer does not have to be made of polymer, and it can be an inorganic adhesive or other types of connecting media as mentioned above.

[0265] The extrusion unit 202 is operatively connected to the first feeding screw rod 2011, the second feeding screw rod 2012, and the third feeding screw rod 2013 of the feeding unit 201. The extrusion unit 202 has a first extrusion channel 2020A, a second extrusion channel 2020B and a third extrusion channel 2020C. The first extrusion channel 2020A is operatively connected to a first feeding channel 2011A of the first feeding screw rod 2011. The second extrusion channel 2020B is operatively connected to a second feeding channel 2012A of the second feeding screw rod 2012. The third extrusion channel 2020C is operatively connected to a third feeding channel 2013A of the third feeding screw rod 2013.

[0266] The number of the feeding channels of the feeding unit 201 and the number of the extrusion channels of the extrusion unit 202 can be set and modified according to requirements.

[0267] The sizes and shapes of first extrusion channel 2020A, the second extrusion channel 2020B, and the third extrusion channel 2020C are selectively configured to form the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50 with predetermined thicknesses and shapes.

[0268] It is worth mentioning that the size of each of the first extrusion channel 2020A, the second extrusion channel 2020B, and the third extrusion channel 2020C is adjustable to control the thickness of the first polymer layer 10, the second polymer layer 10 and the third polymer layer 50.

[0269] In this embodiment, the second extrusion channel 2020B is coaxially aligned within the first extrusion channel 2020A, and the third extrusion channel 2020C is coaxially aligned within the second extrusion channel 2020B. After the third polymer is extruded from the third extrusion channel 2020C to form the third polymer layer 50, at the same time, the second polymer is extruded from the second extrusion channel 2020B to form the second polymer layer 20, the third polymer layer 50 is circumferentially encircled with and fused to the second polymer layer 20. Similarly, the second polymer layer 20 is circumferentially encircled with and fused to the first polymer layer 10.

[0270] After the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 are extruded and fused with each other at a predetermined length, an end thereof is sealed, such that the fused body has a closed end and an opened end for air ventilation.

[0271] It should be understood that the location of the opening should not be limited to the above example. The first polymer, the second polymer, and the third polymer can be extruded from top to bottom, wherein the opening, i.e. the opened end, can be formed on the upper side of the fused body. Alternatively, the opening can be formed on the lateral side or lower side of the fused body. A person who skilled in the art can select the location of the opening according to requirements.

[0272] Preferably, in this embodiment, the end of the fused body is sealed when 20% to 40% of the fused body is formed by extruding the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50. Then, a step of pre-blowing the air into the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50 to form the cavity 100.

[0273] The blow molding unit 203 comprises a molding die 2031 and an air blower 2032, wherein the air blower 2032 is configured to blow an air flow into the molding die 2031. The air blower 2032 comprises at least one blowing needle 20321 and an air tank 20322, wherein the blowing needle 20321 is communicably connected to the air tank 20322.

[0274] The air blower 2032 can be operatively installed in the extrusion unit 202, or can be independently connected to the extrusion unit 202.

[0275] During the extrusion of the first polymer layer 10, the second polymer layer 20 and the third polymer layer 50, a left mold 20311 and a right mold 20312 of the molding die 2031 are moved toward each other to left and right sides of the fused body respectively. The fused body is gradually extruded into a molding space of the molding die 2031 between the left and right molds 20311, 20312, at the same time, the left and right molds 20311, 20312 are moved closer to each other until the fused body is completed formed within a molding space 20310 of the molding die 2031.

[0276] It should be understood that, according to the amount of material being fed, different numbers of fused body can be manufactured at one time. If small amount of material is fed in the feeding unit 201 for a single feeding manner, the extrusion unit 202 is configured to extrude all the first polymer, the second polymer, and the third polymer in a single feeding manner so as to form one single fused body. After the fused body is placed in the molding die 2031 for processing, the blow-molded hollow fusion panel 1 is formed.

[0277] Furthermore, at least one of an inner wall of the left mold 20311 and the right mold 20312 of the molding die 2031 is configured to have a predetermined shape, such as a wave form. At least a portion of the fused body is biased against the inner wall of the left mold 20311, and at least a portion of fused body is biased against the inner wall of the right mold 20312 to form the first panel member 10 and the second panel member 20 of the blow molding hollow fusion panel 1 respectively. In this process, since the first panel member 30 and the second panel member 40 are blown to maintain a relatively high pressure, the first polymer layer 10 and the second polymer layer 20 and the third polymer layer 50 can be fused closely.

[0278] For example, the left mold 20311 of the molding die 2031 is configured to mold the second panel member 20, and the right mold 20312 of the molding die 2031 is configured to mold the first panel member 10.

[0279] The molding die 2031 further comprises at least one protrusion 203111 integrally formed at the left mold 20311, wherein the protrusion 203111 is correspondingly aligned with the supporting structure 60 of the second panel member 40. When the fused body is biased against the left mold 20311, the fused body is stretched to form the second panel member 40 with the supporting structure 60. Through this configuration, the overall weight of the second panel member 40 will not increased, but the structural strength of the blow-molded hollow fusion panel 1 can be enhanced. In other words, the weight of the second panel member 40 will not be changed, but the material thereof is stretched to form the supporting structure 60 so as to ensure no additional material of the second panel member 40 being added to form the supporting structure 60. Thus, since the supporting structure 60 is stretched, the thickness becomes thinner, so as to enhance the heat dissipation in the subsequent steps.

[0280] The blowing operation to the molding die 2031 can be maintained during the closing and molding process of the molding die 2031. The blow time can be set with a range from 65 to 70 seconds. Then, the gas is discharged and the molding die 2031 is cooled for demolding. This process will take 15-20 seconds to complete. Finally, the molded blow-molded hollow fusion panel 1 can be removed from the molding die 2031 once the molding die 2031 is opened.

[0281] Edges of the first panel member 30 and the second panel member 40 are connected to each other. During the closing process of the molding die 2031, some material may overflow and leak at the edge position, such that edges of the blow-molded hollow fusion panel 1 can be trimmed after the blow-molded hollow fusion panel 1 is formed.

[0282] It should be understood that in the above example, the blow-molded hollow fusion panel 1 is constructed to have the first polymer layer 10, the second polymer layer 20, and the third polymer layer 50, wherein the second polymer layer 20 is encircled by the first polymer layer 10, and the third polymer layer 50 is encircled by the second polymer layer 20.

[0283] In another embodiment of the present invention, the first panel member 30 and/or the second panel member 40 of the blow-molded hollow fusion panel 1 can be constructed to have a double-layer structure.

[0284] Referring to FIG. 15, a bottom view of the hollow fusion panel 1 is illustrated, wherein the part J is illustrated in FIG. 7A. When the hollow fusion panel 1 is embodied as a construction panel or a wall of the storage container, the hollow fusion panel 1 may further has two side recesses 401, 402 formed along two outer bending walls 11 for mounting a pair of runners for mounting with another hollow fusion panel 1.

[0285] The hollow fusion panel 1 can be made of any shape that blow molding producing method as disclosed in the present invention is processable, such as a circular shape as shown in FIG. 16 to FIG. 18B. Referring to FIG. 16, the plurality of elongated support members 41 is arranged in a concentric circle, and the length direction of the support member 41 is located in a circumferential direction of the circle.

[0286] When the second panel member 40 is folded along the surface and through a center of the circle, the second panel member 40 has at least a part of the support member 41 while the direction of force is crossed, thereby facilitating the inner support strength of hollow fusion panel 1.

[0287] Referring to FIG. 17A and FIG. 17B, an alternative mode of the hollow fusion panel 1 is illustrated, wherein the number of the contact peak points 43 of the support member 41 formed by the second panel member 40 is one, and that when viewed from outside of the second panel member 40, a shape of the support member 41 is circular. The support members 41 are arranged at a certain interval distance.

[0288] Referring to FIG. 18A and FIG. 18B, alternatively, the number of reinforcing rib 42 of each of the plurality of support members 41 is two, and the number of contact peak points 43 of the plurality of support members 41 is three. From outside view of the second panel member 40, the shapes of some of the support members 41 are circular, and the shapes of the other of support members 41 are elongated. The elongated support member 41 and the circular support member 41 are arranged at intervals.

[0289] Referring to FIG. 19, a combined hollow fusion panel 1, which is able to be constructed as the construction panel S131, made by coupling two symmetrical hollow fusion panels 1 side by side is illustrated, wherein the two hollow fusion panels 1 can be coupled overlappedly by thermal bonding, adhering or other coupling means such that the second panel members 40 of the two hollow fusion panels 1 are preferred to face inwards with each other and the first panel members 30 of the two hollow fusion panels 1 are facing outwards. For example, as shown in FIG. 18B, such combined hollow fusion panel 1 is good in applying to construct a partition panel 2000 by mounting the combined hollow fusion panel 1 with a panel frame 2010.

[0290] Referring to FIG. 19, the combined hollow fusion panel 1, which can be constructed as the bottom wall C11 or the surrounding wall C12 of the storage container C10 (as shown in FIG. 11), is embodied that that the two hollow fusion panels 1 have different configurations, wherein both the first panel member 30 and the second panel member 40 of the upper hollow fusion panel 1 is a triple-layer structure as shown in FIG. 8B, while the first panel member 30 of the lower hollow fusion panel 1 is a two-layer structure and the second panel member 40 of the lower hollow fusion panel 1 is single-layer structure as shown in FIG. 9C.

[0291] Referring to FIG. 21, an alternative mode of the combined hollow fusion panel 1, which can be constructed as the bottom wall C11 or the surrounding wall C12 of the storage container C10 (as shown in FIG. 11), is illustrated, wherein two symmetrical hollow fusion panels 1 are coupled side by side overlappedly by thermal bonding, adhering or other coupling means such that the second panel members 40 of the two hollow fusion panels 1 are preferred to face outwards and the first panel members 30 of the two hollow fusion panels 1 face inwards with each other. This configuration of the combined hollow fusion panel 1 is stronger.

[0292] Referring to FIG. 22, a first embodiment of an engagement joint unit 1000 at side edges 111, 112 of the hollow fusion panel 1 is illustrated, wherein the hollow fusion panel 1 is constructed as the hollow fusion panel as described in the present invention.

[0293] The engagement joint unit 1000 includes a protruding engaging joint 1001 configured along a first longitudinal side edge 111 of the hollow fusion panel 1 and a recessed engageable joint 1002 configured along a second longitudinal side edge 112 of the hollow fusion panel. Accordingly, the protruding engaging joint 1001 is configured to be fittingly inserted in the recessed engageable joint 1002 so as to securely engaging the first side edge 111 of one hollow fusion panel 1 with the second side edge 112 of another adjacent hollow fusion panel 1.

[0294] Referring to FIG. 23, a second embodiment of the engagement joint unit 2000 at side edges 111, 112 of a combined hollow fusion panel 1 of two construction panels 1 is illustrated, wherein the combined hollow fusion panel 1 is constructed by two hollow fusion panels as shown in the FIG. 19 to FIG. 20. The engagement joint unit 2000 includes a protruding engaging joint 2001 at a first longitudinal side edge 111 of the combined hollow fusion panel 1 and a recessed engageable joint 2002 configured along a second longitudinal side edge 112 of the combined hollow fusion panel . Accordingly, the protruding engaging joint 2001 is configured to be fittingly inserted in the recessed engageable joint 2002 so as to securely engaging the first side edge 111 of one combined hollow fusion panel 1 with the second side edge 112 of another adjacent combined hollow fusion panel 1.

[0295] FIG. 24 illustrates a third embodiment of the engagement joint unit 3000 at two opposing side edges 111, 112 of the hollow fusion panel 1, wherein the hollow fusion panel 1 is constructed as the bottom wall C11 or the surrounding wall C12 of the storage container C10 (as shown in FIG. 11) as described in the present invention. The engagement joint unit 3000 includes a protruding engaging joint 3001 at a first longitudinal side edge 111 of the hollow fusion panel 1 and a recessed engageable joint 3002 configured along a second longitudinal side edge 112 of the hollow fusion panel. Accordingly, the protruding engaging joint 3001 is configured to be fittingly inserted in the recessed engageable joint 3002 so as to securely engaging the first side edge 111 of one hollow fusion panel 1 with the second side edge 112 of another adjacent hollow fusion panel 1.

[0296] FIG. 25 illustrates a fourth embodiment of the engagement joint unit 4000 at two opposing side edges 111, 112 of the hollow fusion panel 1, wherein the hollow fusion panel 1 is constructed as the bottom wall C11 or the surrounding wall C12 of the storage container C10 (as shown in FIG. 11) as described in the present invention. The engagement joint unit 4000 includes a protruding engaging joint 4001, having a pair of protruding ribs 40010, at a first longitudinal side edge 111 of the hollow fusion panel 1 and a recessed engageable joint 4002, having a pair of recesses 40020, configured along a second longitudinal side edge 112 of the hollow fusion panel. Accordingly, the protruding engaging joint 4001 is configured to be fittingly inserted in the recessed engageable joint 4002 so as to securely engaging the first side edge 111 of one hollow fusion panel 1 with the second side edge 112 of another adjacent hollow fusion panel 1.

[0297] Referring to FIG. 26, a mounting device 600 configured for mounting the hollow fusion panels 1 on a wall 6000 is illustrated, wherein the mounting device 600 comprises a plurality of mounting rails 601 affixed on a wall 6000 in horizontal and parallel manner, and a plurality of mounting slots 101 is formed in a side surface of the hollow fusion panel, such that the hollow fusion panel 1 is able to be mounted on the wall 6000 by engaging the mounting rails 601 with the mounting slots 101 respectively.

[0298] Referring to FIG. 27, a corner connection device 700 configured for connecting two jointing side edges 1110, 1120 of two hollow fusion panels 1 to form a connection corner 701 is illustrated, wherein the corner connection device 700 comprises a pair of connection rails 701, 702 and a corner cover 703. The two connection rails 701, 702 are secured along a jointing side edge 1110 of one hollow fusion panel 1 and another jointing side edge 1120 of another hollow fusion panel 1 and the corner cover 703 are configured to mount on the two connection rails 701, 702 so as to connect the two jointing side edges 1110, 1120 together firmly in position.

[0299] It is appreciated that, referring to FIG. 3B, to facilitate the attachment of the auxiliary component and/or accessory elements to the hollow fusion panel 1, a filler material, such as resin, patching powder or filling slurry, can be applied to fill up the recess cavity 400 of the second panel member 40, such that after the filler material is dried and turns hard, one or more filler portions 404 is formed so that the predetermined auxiliary components and accessory elements can be mounted to the second panel member 40 by screwing. If the entire surface of the second panel member 40 is covered with a layer of filler material to fill up all recess cavities 400 thereof, a filler layer 404 is formed for fastening the predetermined auxiliary components and accessory element, such as leg posts to form a chair or a desk, mounting braces for mounting the hollow fusion panel 1 to a surface, the mounting rails 601, or the connection rails 701, 702.

[0300] Referring to FIG. 29 to FIG. 50, an exemplary storage container made with the hollow fusion panel of the present invention is illustrated.

[0301] As shown in FIGS. 29 to 33, along the direction indicated by arrow D in FIG. 29, the storage container of the present invention is embodied as a square storage box and the hollow fusion panels of the present invention are embodied as a bottom panel A1, a front panel A2, a rear panel A3, and a left panel A4, a right panel A5 and a cover panel A6. In other embodiments, the front panel A2, the rear panel A3, the left panel A4, the right panel A5 and the cover panel A6 are made of the blow-molded hollow fusion panels each of which is integrally formed in one-piece, and the bottom panel A1 can be an injection-molded panel that is integrally formed in one-piece.

[0302] According to the preferred embodiment, the bottom panel A1, the front panel A2, the rear panel A3, the left panel A4 and the right panel A5 can adopt screw-free, plug-in coupling structures with their respective adjacent panels, which is convenient for installation and disassembly. The screw-free, plug-in coupling structure can adopt strip-shaped ribs and strip-shaped grooves that can be interlocked with each other.

[0303] The cover panel A6 can be pivotably or rotatably connected to the rear panel A3. A spring A9 connected to the cover panel A6 can be installed on both the left panel 4 and the right panel 5. A spring A9 can enable the cover panel A6 to open and close more easily.

[0304] A transverse support rod A73 can be installed on a front edge of the cover panel 6. A lock A64 can be installed on the transverse support rod A73. The transverse support rod 73 can strengthen the cover panel A6 and prevent it from bending. A lock hole 21 can be installed at a corresponding position of the front panel A2. When the storage container is closed, the lock catch A64 can pass through a lock hole A21 of the front panel A2.

[0305] A vertical partition panel A7 can be made of the hollow fusion panel and arranged inside the storage container. The vertical partition panel A7 can divide the storage container into two storage areas. A bottom of the vertical partition panel A7 can be fixed on the bottom panel A1. Front and rear sides of the vertical partition panel A7 can be respectively mated with the front panel A2 and the rear panel A3. In particular, the vertical partition panel A7 can have pins configured to be inserted into corresponding sockets provided in the front panel A2 and the rear panel A3.

[0306] An inner bottom surface of the bottom panel A1 has protruding limiting ribs A11 that are distributed in left and right directions. The bottom of the vertical partition panel A7 has one or more limiting grooves A71 to couple with the limiting ribs A11. An inner side of the cover panel A6 has strip-shaped ribs A613 corresponding to the vertical partition panel A7. When the cover panel A6 is closed, the strip-shaped ribs A613 is configured to abut against the vertical partition panel A7. As such, the vertical partition panel A7 can support the cover panel A6 to increase the load-bearing capacity of the cover panel A6 and to enhance the stability of the storage container.

[0307] In one embodiment, the vertical partition panel A7 can comprise two small partition panels that can be assembled together. According to some embodiments, multiple vertical partition panels A7 can be used not only to strengthen the storage box but also to provide more organized storage space.

[0308] In one embodiment, as shown in FIG. 32 and FIG. 49, one or more fixation hole A12 can be presented in the bottom panel A1. The storage container can be fastened to the ground by screws via fixation hole A12.

[0309] In one embodiment, the storage container can have waterproof features. The cover panel A6 can have an arched structure with an uneven top. For example, cover panel A6 can have a high rear portion and a low front portion or a high central portion and a low side portion. When the cover panel A6 is closed, the uneven top can allow water to flow away from the container and not flow into the container.

[0310] As shown in FIG. 34 to FIG. 39, according to the preferred embodiment, an embedded groove hinge A63 can be formed in the inner side of the cover panel A6. The embedded groove hinge A63 can have two openings respectively located on opposite sides of the cover panel A6, thus dividing the cover panel A6 into rotatable upper folding portion 61 and lower folding portion A62. The lower turning portion A62 can be detachably connected to the rear panel A3 to form a full rear panel of the storage container.

[0311] Furthermore, the full rear panel A3 comprises an upper part and a lower part, whereas the upper part is the lower turning portion A62 and the lower part is the rear panel A3. The rear panel construction is novel and unique. In one embodiment, the two-part panel can be adopted by the cover panel, instead of the rear panel. Accordingly, an embedded groove hinge on the rear panel can divide it into two turning portions as described herein.

[0312] When the cover panel A6 is coupled to the rear panel A3, the lower folding portion A62 is mated with the rear panel A3 so that the upper folding portion A61 is pivotable or rotatable in relation to the full rear panel by the embedded groove hinge A63. The embedded groove hinge A63 can eliminate the need for a traditional hinge. It has a simple structure that is easy to assemble. Without any metal components, the integrated hinge structure has a relatively low manufacturing cost.

[0313] As shown in FIG. 40 and FIG. 41, the lower turning portion A62 of the cover panel 6 and the rear panel A3 can adopt a plug-in coupling to form a detachable connection. The specific structure can be: first pins A621 and second sockets A622 disposed on the lower side of the lower turning portion A62, and first sockets A31 and second pins A32 disposed on the upper side of the rear panel A3. The first pins A621 can be inserted into the corresponding first sockets A31, and the second pins A32 can be inserted into the corresponding second sockets A622.

[0314] According to the preferred embodiment, the first sockets A31 and/or the second sockets A622 can further comprise ribs A625. The first pins A621 and/or the second pins A32 can further comprise grooves A33. The ribs A625 can be snapped into the corresponding grooves A33 when the lower turning portion A62 is connected to the rear panel A3 to form the full rear panel.

[0315] According to the preferred embodiment, the inner side of the upper turning portion A61 can have an upper inclined surface A611 connected with one side of the embedded groove hinge A63. The inner side of the lower turning portion A62 can have a lower inclined surface A623 connected with the other side of the embedded groove hinge A63.

[0316] According to the preferred embodiment, the upper inclined surface A611 can abut against the lower inclined surface A623 to prevent the upper turning portion 61 and the lower turning portion A62 from collapsing into each other when the upper turning portion A61 and the lower turning portion A62 are perpendicular to each other.

[0317] According to the preferred embodiment, the inner surface of the upper turning portion A61 can further comprise inwardly extending stopper stripes A612. The inner surface of the lower turning portion A62 can further comprise stopper bars A624.

[0318] According to the preferred embodiment, the inwardly extending stopper stripes A612 can abut against the stopper bars A624 to prevent the upper turning portion A61 and the lower turning portion A62 from collapsing into each other when the upper turning portion A61 and the lower turning portion A62 are perpendicular to each other.

[0319] As shown in FIG. 32 to FIG. 37, when the storage box is in the packaged state, the lower turning portion A62 of the cover panel A6 can be installed on the rear side of the bottom panel A1, and the upper turning portion A61 of the cover panel A6 can be folded to the top of the bottom panel A1. The package structure has an installation cavity A10 formed between the upper turning portion A61, the lower turning portion A62, the bottom panel A1, and the front side panel A2. The rear panel A3, the left panel A4, and the right panel A5 can be stacked in the installation cavity A10 in the storage container packaging state.

[0320] As shown in FIG. 48 and FIG. 49, limiting ribs A11 can be provided between the vertical partition panel A7 and the bottom panel A1. The limiting ribs A11 can be distributed at intervals from front to back. As shown in FIG. 33, a second limiting slot A72 can be formed on the side of the vertical partition panel A7. During the storage box packaging state, the limiting ribs A11 can be locked into the second limiting slot A72, thereby locking the vertical partition panel A7 on the bottom panel A1. It can prevent the vertical partition panel A7 from moving forward and backward during transportation.

[0321] As shown in FIG. 49, a limit element can be provided between the lower turning portion A62 of the cover panel A6 and the bottom panel A1. It can be sockets A13 located on the bottom panel A1, and first pins A621 located on the lower turning portion A62 of the cover panel A6. As shown in FIG. 40, the first pins A621 can insert into the corresponding sockets A13 during the storage packaging state.

[0322] As shown in FIG. 50, a limiting element can be provided for the left panel A4, the right panel A5, the lower turning portion A62 of the cover panel A6. It can be lateral limiting grooves A626 provided on the inner side wall of the lower turning portion A62 and water resisting stripes A8 provided on the left panel A4 and right panel A5. As shown in FIG. 31, when the storage box is packed, the water resisting stripes A8 are embedded in the corresponding lateral limiting grooves A626. The left panel A4 and the right panel A5 can be placed horizontally.

[0323] As shown in FIG. 43 and FIG. 44, the front panel A2 can be arranged horizontally. As shown in FIG. 31, the top of the front panel A2 can have a water-retaining strip A8 that can abut the lock A64 on the transverse support rod A73, meaning the abutted parts would limit the rotation of the upper turning portion A61. Furthermore, in the package state, referring to FIG. 37 and FIG. 38, the upper inclined surface A611 can abut against the lower inclined surface A623, the inwardly extending stopper stripes (A612) can abut against the stopper bars A624. This would prevent the upper turning portion A61 of the cover panel A6 from further inward turning.

[0324] As shown in FIG. 51, the front panel A2, the rear panel A3, the left panel A4, the right panel A5 and the cover panel A6 of the storage container can be blow-molded hollow fusion panels with touchpoints on the inner surface. Such touchpoints can enhance the structural strength of the storage container.

[0325] It is appreciated that, according to the above-described embodiments and producing methods of the blow-molded hollow fusion panel 1 of the present invention, the first panel member 1, 10, 30 and the second panel member 2, 20, 40 can be respectively configured as the outer panel member 1, 10, 30 and the inner panel member 2, 20, 40 of the supporting furniture. Please referring to FIG. 52, a melted fluid form first material and a melted fluid form second material are fed into a blow mold M through a first feeding unit 201-1 and a second feeding unit 201-2 to form the outer panel member 1, 10, 30 and the inner panel member 2, 20, 40 respectively.

[0326] As mentioned above, the parison mold of the blow molding unit 203 (as shown in FIG. 12 and FIG. 13) provides the exterior extrusion pressure to the mold blank and the air blow in the mold blank within the blow mold provides the interior extrusion pressure to press the mold blank against the parison mold until the inner panel member 2, 20, 40 and the outer panel member 1, 10, 30 form the blow-molded hollow fusion panel 1 with predetermined shape and size, wherein an inner side of the outer panel member 1, 10, 30 is fused with an inner side of the inner panel member 2, 20, 40. Similarly, either the outer panel member 1, 10, 30 or the inner panel member 2, 20, 40 can be constructed with one or more layers 10, 20, 50.

[0327] After the formation of the inner panel member 2, 20, 40 within and fused with the outer panel member 1, 10, 30, a feeding opening 201-21 of the second feeding unit 201-2 is shut such that the continuous feeding of the first material through the first feeding unit 201-1 fills the feeding opening 201-21 and ensures the inner panel member 2, 20, 40 being surrounded and covered by the outer panel member 1, 10, 30, completely.

[0328] It is worth mentioning that the outer panel member 1, 10, 30 can be made of new material and the inner panel member 2, 20, 40 can be made of recycled material. The material or a combination of the materials used to construct the outer panel member 1, 10, 30 can be made of strengthened and anti-scratching durable material, such as nylon and high density polyethylene. Also, the material or a combination of the materials used to construct the inner panel member 2, 20, 40 can be made of shock absorbing and supporting materials, for example, elected from high density polyethylene, glass fiber, calcium carbonate and metallocene polyethylene.

[0329] It is further appreciated that, according to the above-described embodiments, and producing methods of the blow-molded hollow fusion panel 1 of the present invention, the first panel member 1, 10, 30 and the second panel member 2, 20, 40 can be respectively configured as the upper or outer panel member 1, 10, 30 and the lower or inner panel member 2, 20, 40 of the storage container. For example, when the hollow fusion panel is a blow-molded storage container wall, the first panel member is embodied as an upper or outer panel member 1, 10, 30 and the second panel member is embodied as a lower or inner panel member 2, 20, 40. Also, when the blow-molded hollow fusion panel 1 is a partition panel, a shelf panel, a cabinet wall panel, the first panel member is embodied as a first side panel member 1, 10, 30 and the second panel member is embodied as a second side panel member 2, 20, 40, wherein the first side and second side panel members 1, 10, 30, 2, 20, 40 can be embodied as left side and right side panel members or, alternatively, outer and inner side panel members. Please referring to FIG. 53 to FIG. 54, a melted fluid form first material and a melted fluid form second material are fed into a blow mold M through a first feeding unit 201-1 and a second feeding unit 201-2 respectively to form the first side panel member 1, 10, 30 and the inner panel member 2, 20, 40.

[0330] Referring to FIG. 53, the blow molding unit 203 has a first portion and a second portion allowing the first material and the second material filling in through the first feeding unit 201-1 and the second feeding unit 201-2 respectively, wherein the parison mold of the blow molding unit 203 (as shown in FIG. 12 and FIG. 13) provides the exterior extrusion pressure to the mold blank and the air blow in the mold blank within the blow mold provides the interior extrusion pressure to press the mold blank against the parison mold until the first side panel member 1, 10, 30 and the second side panel member 2, 20, 40 form the blow-molded hollow fusion panel 1 with predetermined shape and size, wherein edges of the first and second side panel members 1, 10, 30, 2, 20, 40 are fused with each other. It is worth mentioning that the first portion and the second portion are formed from two side fluid channels connected with the first and second feeding units 201-1 and 201-2 respectively without isolation gap. In other words, the first material and the second material being fed in the two side fluid channels of the first and second portions through the first and second feeding units 201-1, 201-2 respectively and simultaneously with predetermined speeds and the first material of the first side panel member 1, 10, 30 and the second material of the second side panel member 2, 20, 40 will meet edge to edge and fuse with each other to form the blow-molded hollow fusion panel 1.

[0331] Referring to FIG. 55, the first side panel member 1, 10, 30 and the second side panel member 2, 20, 40 can be made to have different colors. In addition, the material or a combination of the materials used to construct the first and second side panel members 1, 10, 30, 2, 20, 40 can be made of different properties, for example, can be made of strengthened and anti-scratching durable material, such as nylon and high density polyethylene, or can be made of shock absorbing and supporting materials, such as elected from high density polyethylene, glass fiber, calcium carbonate and metallocene polyethylene. Therefore, if the blow-molded hollow fusion panel 1 of the invention is configured as a shelf panel or cabinet wall panel, the outer (first) side panel member 1, 10, 30 can be made to have a lighter color such as white for decorative purpose and the inner (second) side panel member 2, 20, 40 can be made have a darker color for anti-dirty purpose.

[0332] Referring to FIG. 54, the configuration of the blow molding unit 203 as illustrated in FIG. 52 and FIG. 53 can be combined to configure a combined blow molding unit 203 to make both the first side panel member 1, 10, 20 and second side panel member 2, 20, 40 each having an inner panel member and an outer panel member a blow-molded hollow fusion panel 1. Similarly, each of the inner and outer panel members of the first side panel member 1, 10, 30 and the inner and outer panel members of the second side panel member 2, 20, 40 can be constructed with one or more layers 10, 20, 50.

[0333] Those skilled in the art should understand that the above description and the embodiments of the present invention shown in the drawings are only examples and do not limit the present invention.

[0334] 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.