Shelter Apparatus with Hollow Fusion Panel

Abstract

The present invention provides a shelter apparatus, wherein at least one of a construction panel of the shelter apparatus is constructed with a hollow fusion panel, which 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 shelter apparatus, which includes: a base; a roof; and an enclosure housing, comprising a plurality of construction panels engaged side by side to form a surrounding wall, supported between the base and the roof to define an enclosed space therein, wherein at least one of the plurality of construction panels, the base and the roof is a hollow fusion panel, which includes: 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 shelter apparatus, as recited in claim 1, further including 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, as recited in claim 3, further including 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, wherein a filler layer is formed on said second panel member by filling a predetermined number of said recessed cavities with a filler material.

8. The shelter apparatus, as recited in claim 4, further including 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, wherein a filler layer is formed on said second panel member by filling a predetermined number of said recessed cavities with a filler material.

9. The shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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 shelter apparatus, 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, wherein a mass percentage of said one or more recycled materials is ranged between 30% and 90%.

20. The shelter apparatus, 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 are made of one or more recycled materials, wherein a mass percentage of said one or more recycled materials is ranged between 30% and 90%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0084] FIG. 1A to FIG. 1D are schematic views illustrating various conventional sheds.

[0085] FIG. 2A to FIG. 2F are schematic views illustrating various conventional sheds construction with one or more plastic construction panels.

[0086] 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.

[0087] 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.

[0088] FIG. 4 is an enlarged view of encircled part A in FIG. 1.

[0089] FIG. 5 is an enlarged view of encircled part B in FIG. 1.

[0090] FIG. 6 is a partial sectional perspective view of an alternative mode of the above preferred embodiment of the present invention.

[0091] FIG. 7A is an elevation view of a hollow fusion panel adapted for constructing a shed according to the above preferred embodiment of the present invention.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] FIG. 11 is a flow diagram illustrating a manufacturing method of the blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0104] FIG. 12 illustrates a blow molding equipment for manufacturing the blow-molded construction panel according to the above preferred embodiment of the present invention.

[0105] FIG. 13 is a schematic diagram of the blow molding equipment for manufacturing a blow-molded hollow fusion panel according to the above preferred embodiment of the present invention.

[0106] FIG. 14 is a bottom view of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0107] FIG. 15 is a bottom view of an alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0108] FIG. 16A is a bottom view of another alternative mode of the hollow fusion panel according to the above preferred embodiment of the present invention.

[0109] FIG. 16B is an enlarged sectional view of a portion along E-E sectional line in FIG. 16A according to the preferred embodiment of the present invention.

[0110] 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.

[0111] FIG. 17B is an enlarged sectional view of a portion along F-F sectional line in FIG. 17A according to the preferred embodiment of the present invention.

[0112] FIG. 18 is a partial sectional perspective view illustrating a combined construction panel according to the above preferred embodiment of the present invention.

[0113] FIG. 19 is a sectional view with enlarged sectional views of the combined construction panel according to the above preferred embodiment of the present invention.

[0114] FIG. 20 is a sectional view of an alternative mode of the combined construction panel according to the above preferred embodiment of the present invention.

[0115] FIG. 21 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.

[0116] FIG. 22 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.

[0117] FIG. 23 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.

[0118] FIG. 24 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.

[0119] FIG. 25 is a schematic view illustrating a mounting device to be utilized for mounting the hollow fusion panels on a wall according to the above preferred embodiment of the present invention.

[0120] FIG. 26 is a schematic view illustrating a corner connection device to be utilized between two construction panels according to the above preferred embodiment of the present invention.

[0121] FIG. 27A is a perspective view of a shed construction with one or more hollow fusion panels according to the above preferred embodiment of the present invention.

[0122] FIG. 27B is a perspective view of the shed construction with opened doors according to the above preferred embodiment of the present invention.

[0123] FIG. 28A is a front perspective view of another shed constructed with one of more of the hollow fusion panel according to the preferred embodiment of the present invention.

[0124] FIG. 28B is a rear perspective view of the shed shown in FIG. 28A according to the preferred embodiment of the present invention.

[0125] FIG. 29 is a perspective view of a shelter apparatus constructed with the hollow fusion panel according to the above preferred embodiment of the present invention.

[0126] FIG. 30 is a front view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0127] FIG. 31 is a first side view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0128] FIG. 32 is a second side view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0129] FIG. 33 is a rear view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0130] FIG. 34 is a top plan view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0131] FIG. 35 is an exterior view of a floor of the shelter apparatus according to the above preferred embodiment of the present invention.

[0132] FIG. 36 is an interior view of the floor of the shelter apparatus according to the above preferred embodiment of the present invention.

[0133] FIG. 37 illustrates multiple uninstalled floor panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0134] FIG. 38 illustrates multiple installed floor panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0135] FIG. 39 is an exploded view of the shelter apparatus according to the above preferred embodiment of the present invention.

[0136] FIG. 40 illustrates partial exploded views of the shelter apparatus according to the above preferred embodiment of the present invention.

[0137] FIG. 41 illustrates multiple installed floor panels via connectors of the shelter apparatus according to the above preferred embodiment of the present invention.

[0138] FIG. 42 illustrates multiple installed floor panels via connectors and interlocked teeth couplings of the shelter apparatus according to the above preferred embodiment of the present invention.

[0139] FIG. 43 is a partial enlarged schematic view illustrating a connecting of the floor panels with the connector of the shelter apparatus according to the above preferred embodiment of the present invention.

[0140] FIG. 44 is partial enlarged schematic view illustrating the connecting of the floor panels with the interlocked teeth couplings of the shelter apparatus according to the above preferred embodiment of the present invention

[0141] FIG. 45 illustrates back strengthening ribs of the hollow fusion panel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0142] FIG. 46 is a front view illustrating flat wall panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0143] FIG. 47 is a rear view illustrating the flat wall panels and foldable corner panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0144] FIG. 48 is a rear view illustrating the flat wall panels and foldable corner panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0145] FIG. 49 is a schematic view illustrating the flat wall panels with stored supporting beams of the shelter apparatus according to the above preferred embodiment of the present invention.

[0146] FIG. 50 is a schematic view illustrating the supporting beams and components thereof of the shelter apparatus according to the above preferred embodiment of the present invention.

[0147] FIG. 51 is a schematic view illustrating foldable corner panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0148] FIG. 52 is a front view illustrating a foldable corner panel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0149] FIG. 53 is a rear view illustrating the foldable corner panel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0150] FIG. 54 is another rear view illustrating the foldable corner panel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0151] FIG. 55 is a schematic view illustrating the foldable corner panel coupled to the floor panel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0152] FIG. 56 are multiple exploded and enlarged views illustrating the foldable corner panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0153] FIG. 57 is an enlarged view illustrating the foldable corner panel(s) of the shelter apparatus according to the above preferred embodiment of the present invention.

[0154] FIG. 58 are exploded and enlarged views illustrating two coupling mechanisms of foldable corner panel(s) of the shelter apparatus according to the above preferred embodiment of the present invention.

[0155] FIG. 59 are enlarged views illustrating two coupling mechanisms of foldable corner panel(s) of the shelter apparatus according to the above preferred embodiment of the present invention.

[0156] FIG. 60 are schematic views illustrating interlocking teeth couplings between two connected wall panels of the shelter apparatus according to the above preferred embodiment of the present invention.

[0157] FIG. 61 are schematic and enlarged views illustrating the foldable corner panel with a concave door frame of the shelter apparatus according to the above preferred embodiment of the present invention.

[0158] FIG. 62 is a schematic view illustrating the foldable corner panel with shelf grooves of the shelter apparatus according to the above preferred embodiment of the present invention.

[0159] FIG. 63 is a schematic view illustrating the foldable corner panel coupled with a door of the shelter apparatus according to the above preferred embodiment of the present invention.

[0160] FIG. 64 is a schematic view illustrating an assembled lintel for the shelter apparatus according to the above preferred embodiment of the present invention.

[0161] FIG. 65 is an enlarged view illustrating a roof connected with a lintel of the shelter apparatus according to the above preferred embodiment of the present invention.

[0162] FIG. 66 is an enlarged view illustrating a foldable roof panel for the roof of the shelter apparatus according to the above preferred embodiment of the present invention.

[0163] FIG. 67 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.

[0164] FIG. 68 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.

[0165] FIG. 69 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.

[0166] FIG. 70 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. 68 and FIG. 69.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0167] 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.

[0168] 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.

[0169] 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.

[0170] The present invention will be further described in detail below with reference to the preferred embodiment of the drawings.

[0171] Referring to FIG. 27A and FIG. 27B, a shelter apparatus S10, embodied as an outdoor storage shed as shown in FIG. 27A and FIG. 27B and an outdoor storage shelter as shown in FIG. 28A and FIG. 28B, comprises a base S11, a roof S12, and an enclosure housing S13 supported between the base and the roof to define an enclosed space therein, wherein the enclosure housing S13 comprises a plurality of construction panels S131 engaged side by side to form a surrounding wall and a door S132, wherein at least one of the plurality of construction panels S131 is a hollow fusion panel 1.

[0172] Referring to FIG. 3A, FIG. 4 and FIG. 5, the hollow fusion panel 1, according to a preferred embodiment of the present invention, adapted for constructing the shelter apparatus S10 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.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] It is worth mentioning that when the hollow fusion panel 1 of the present invention is used to construct as, for example, a tabletop, a shed, a storage container, a construction panel, and etc. that the lower panel member 2 does not require to be exposed to outside, the outer layer 3, the inner layer 4 and the intermediate layer 5 of the lower panel member 2 can all be made of recycled materials or a mixture of new and recycled materials.

[0180] 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.

[0181] 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%.

[0182] 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%.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] The multi-panel multi-layer hollow fusion panel 1 can be applied to many different applications. For example, it can be used to build structural wall, interior wall, compartment wall to construct interior room, partition panel, exterior wall, partition room wall, work station partition wall, temporary housing, desk partition wall, temporary storage compartment, outdoor fence, bed frame, bed back panel, bed board, bench, floor panel for truck and pickup, garden planter, bench, screen panel, garage door, shed, storage container, tray, trash container, dumpster, camper, table, desk, stool, shelf, rack, and etc. In other words, the hollow fusion panel 1 is preferred to be applied to products where the panel is not easy to break, such as wall partition, wall panel, door panel, fence panel, outdoor floor, insulation panel, screen panel, and partition panel.

[0188] 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: [0189] melting fat: 1.5 g/10 min, bending strength: 900 MPa, Shore D69.

[0190] 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: [0191] melting fat: 0.35 g/10 min, bending strength: 1050 MPa, Shore D63.

[0192] 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<48g; and Eikmandorf tearing strength: 21 C. in longitudinal direction, 430 C. in transverse direction.

[0193] 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.

[0194] 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.

[0195] 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.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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 nner layer 4 of the lower panel member 2 can be recycled materials.

[0200] Further, when the hollow fusion panel 1 of the present invention is used to construct as a shelter apparatus 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] 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.

[0205] 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.

[0206] 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.

[0207] 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.

[0208] 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.

[0209] 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.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] 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.

[0215] 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.

[0216] 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.

[0217] 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.

[0218] 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.

[0219] 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.

[0220] 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.

[0221] 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.

[0222] 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.

[0223] 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.

[0224] 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.

[0225] 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.

[0226] 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.

[0227] 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.

[0228] 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.

[0229] 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.

[0230] 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.

[0231] 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.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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: 2.0g/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<48g, Eikmandorf tear strength: 21 C. in longitudinal direction, 430 C. in transverse direction.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] It is worth mentioning that when the hollow fusion panel 1 of the present invention is used to construct as shelter apparatus that the second panel member 40 does not require to be exposed to outside, the first layer 10, the second layer 20 and the third layer 50 of the second panel member 40 can all be made of recycled materials or a mixture of new and recycled materials.

[0241] 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.

[0242] 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.

[0243] 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.

[0244] 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.

[0245] 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.

[0246] Accordingly, a thickness of the maximum thickness position of the hollow construction fusion panel 1 can be decreased, thereby facilitating heat dissipation thereat.

[0247] 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.

[0248] 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.

[0249] 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.

[0250] 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.

[0251] 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.

[0252] 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 .

[0253] 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.

[0254] 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.

[0255] 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.

[0256] 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.

[0257] 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.

[0258] 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.

[0259] 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.

[0260] 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.

[0261] 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.

[0262] 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.

[0263] 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.

[0264] 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.

[0265] In this alternative mode, at least one of the supporting structures 41 is formed to have a single contact peak 43.

[0266] 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.

[0267] Referring to FIG. 11 of the drawings, a producing method of the blow-molded hollow fusion panel 1 according to the above-mentioned preferred embodiment of the present invention is illustrated.

[0268] 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.

[0269] 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.

[0270] 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.

[0271] 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.

[0272] 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.

[0273] 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.

[0274] 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.

[0275] 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.

[0276] As shown in FIG. 12 and FIG. 13, a blow molding process and the related blow molding equipment 2 according to the preferred embodiment of the present invention are illustrated.

[0277] 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.

[0278] 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.

[0279] 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.

[0280] 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.

[0281] 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.

[0282] 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.

[0283] 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.

[0284] 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<48g, Elmendorf tear strength: longitudinal 21 C., transverse 430 C.

[0285] 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.

[0286] 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.

[0287] 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.

[0288] 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.

[0289] 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.

[0290] 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.

[0291] 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.

[0292] 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.

[0293] 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.

[0294] 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.

[0295] 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.

[0296] 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.

[0297] The air blower 2032 can be operatively installed in the extrusion unit 202, or can be independently connected to the extrusion unit 202.

[0298] 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.

[0299] 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.

[0300] 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.

[0301] 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.

[0302] 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.

[0303] 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.

[0304] 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.

[0305] 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.

[0306] 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.

[0307] Referring to FIG. 14, 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 planar board type 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 connection with another hollow fusion panel 1.

[0308] The hollow fusion panel 1 can be made of any shape that blow molding manufacturing method as disclosed in the present invention is processable, such as a circular shape as shown in FIG. 15 to FIG. 17B. Referring to FIG. 15, 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.

[0309] 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.

[0310] Referring to FIG. 16A and FIG. 16B, 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.

[0311] Referring to FIG. 17A and FIG. 17B, 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.

[0312] Referring to FIG. 18, a combined 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 panel 1 is good in applying to construct a partition panel 2000 by mounting the combined panel 1 with a panel frame 2010.

[0313] Referring to FIG. 19, the combined panel 1, which can be constructed as the construction panel S131, 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.

[0314] Referring to FIG. 20, an alternative mode of the combined construction panel 1, which can be constructed as the construction panel S131, 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 construction panel 1 is stronger for constructing as structural wall panel, compartment wall and the like.

[0315] Referring to FIG. 27, it is appreciated that the base S11, the roof S12, and each of the construction panels S131 and the door S132 of the enclosure housing S13 can be constructed by the hollow fusion panel 1 as shown in FIG. 3A to FIG. 10B.

[0316] Referring to FIG. 21, 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.

[0317] 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 construction panel 1 with the second side edge 112 of another adjacent construction panel 1.

[0318] Referring to FIG. 22, a second embodiment of the engagement joint unit 2000 at side edges 111, 112 of a combined panel 1 of two construction panels 1 is illustrated, wherein the combined panel 1 is constructed by two hollow fusion panels as shown in the FIG. 18A and FIG. 19. The engagement joint unit 2000 includes a protruding engaging joint 2001 at a first longitudinal side edge 111 of the combined panel 1 and a recessed engageable joint 2002 configured along a second longitudinal side edge 112 of the combined 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 panel 1 with the second side edge 112 of another adjacent combined panel 1.

[0319] FIG. 23 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 hollow fusion panel 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 construction panel 1 with the second side edge 112 of another adjacent construction panel 1.

[0320] FIG. 24 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 hollow fusion panel as described in the present invention and covered by a panel shell 110. 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 construction panel 1 with the second side edge 112 of another adjacent construction panel 1.

[0321] Referring to FIG. 25, 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 the 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.

[0322] Referring to FIG. 26, a corner connection device 700 configured for connecting two jointing side edges 1110, 1120 of two construction 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 construction panel 1 and another jointing side edge 1120 of another construction 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.

[0323] 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.

[0324] It is worth mentioning that the shelter apparatus S10 as disclosed in the present invention is embodied as a shed as an example, which can also be a trailer, a camper, a tiny house, a cabin, a loft, a pet house, a portable outdoor toilet, a toy shed and the like. The hollow fusion panel 1 is good for building structural wall, interior wall, compartment wall to construct interior room, partition panel, exterior wall, partition room wall, floor, roof, and door of the shelter apparatus S10.

[0325] Referring to FIG. 29 to FIG. 66, a shelter apparatus constructed with the hollow fusion panels according to the above preferred embodiment of the present invention is illustrated, wherein, as shown in FIG. 29, the shelter apparatus is embodied as an outdoor storage shed A10 which comprises a plurality of construction panels made of the blow-molded hollow fusion panels of the present invention. The plastic construction panels can be configured and manufactured in a substantially similar shape and size. This way, the package of the construction panels is more compact, resulting in reduced transportation cost. FIG. 30 is a front view of the outdoor storage shed A10. FIG. 31 is a first side view of the outdoor storage shed A10. FIG. 32 is a second side view of the outdoor storage shed A10. FIG. 33 is a rear view of the outdoor storage shed A10. FIG. 34 is a top view of the outdoor storage shed A10.

[0326] Referring to FIG. 35, the storage shed (shelter apparatus) A10 comprises a floor A100 constructed by assembling a predetermined number of construction panels. An exterior floor surface of the floor A100 is illustrated in FIG. 35, which provides a ground covering for the storage shed A10, which can not only provide an even surface but also prevent rain and dirt to enter the storage shed A10.

[0327] As shown in FIG. 36, an interior floor surface A102 of the floor A100 is illustrated, wherein evenly spaced and symmetrically arranged back strengthening ribs are arranged in the interior floor surface A102 to provide enhanced stability of the construction panel. According to the preferred embodiments, the reinforcing ribs 61, 42, as shown in FIG. 3A, FIG. 4 and FIG. 7A to FIG. 10B, each provides the recessed cavity 400 having vertical support grooves and horizontal support grooves. In particular, each vertical support groove can be encircled by a plurality of horizontal support grooves. In addition, each horizontal support groove can be surrounded by a plurality of vertical support grooves.

[0328] FIG. 37 illustrates multiple uninstalled individual floor panels A1001, A1002, A1003 of the storage shed A10 according to the preferred embodiment of the present invention. The individual floor panels include a first corner edge floor panel A1001, a second corner edge floor panel A1002, and a transitional floor panel A1003. The corner edge floor panel, serving as the corner of a floor, can have two sides that can be coupled with wall panels. A transitional floor panel, which can be positioned in a non-corner location, may have one or none side available for connection to the wall panel(s).

[0329] As shown in FIG. 38, the first corner edge floor panel A1001 and the second corner edge panel A1002 can function as corners of a floor, while the transitional floor panel A1003 can be inserted in between the corner panels to constitute a portion of the floor. According to other embodiments, additional transitional floor panels can be added to extend the size of the floor to render a customizable-sized storage room. To make such extensions and adjustments possible, each floor panel can be substantially identical in shape and size, thereby further enhancing the efficiency of product packaging and transportation.

[0330] As shown in FIG. 39, the first corner edge floor panel A1001 can be joined to the transitional floor panel A1003 using interlocked teeth couplings and supplementary connectors. In one embodiment, a first side of the transitional floor panel A1003 has a first slider rail A1004, which could feature an L-shaped groove or rail A1005 designed to accommodate an L-shaped slider located on a wall panel. In one embodiment, the slider rail can incorporate a T-shaped or differently-shaped groove designed to house a corresponding slider for connecting with a wall panel.

[0331] The first corner edge floor panel A1001 can be coupled to transitional floor panel A1003 via interlocked teeth couplings and additional connectors. According to the preferred embodiment, a first side of transitional floor panel A1003 has a first slider rail A1004, which could comprise the L-shaped groove or rail A1005 configured to receive a L-shaped groove arranged on a wall panel. According to some embodiments, the slider rail could be a T-shaped or differently-shaped groove configured to receive a corresponding slider for coupling with a wall panel.

[0332] As shown in FIG. 40, a first side of the corner edge floor panel A1001 has a second slider rail A1006 designed to continue from the first slider rail A1004. The second slider rail A1006 can comprise a L-shaped groove A1005 that is configured to receive the same L-shaped slider arranged on a wall panel. In addition, the first side of the corner edge floor panel A1001 further has one or more clips A1008 configured to engage with clip slots arranged in the wall panel.

[0333] According to the preferred embodiment, the corner edge floor panel A1001 can incorporate two distinct coupling mechanisms on the same side. For example, a slider coupling, such as A1006, can be positioned adjacent to and in alignment with the clips A1008. Consequently, a wall panel that couples to the corner edge floor panel can possess two corresponding coupling structures, such as a slider bar and clip slots, on the same side. Furthermore, these two different coupling mechanisms can each employ a contrasting engagement style, i.e., projecting vs. receiving, to enhance the connecting force and stability between the panels. For example, a panel can feature a projected coupling portion, like clips, on one side, and a receiving coupling portion, such as a slider rail, on another side.

[0334] According to the preferred embodiments, a second side of the corner edge floor panel A1001 has a third slider rail A1007 that comprises another L-shaped groove A1005 for coupling to another wall panel. According to the preferred embodiment, the second side of the corner edge floor panel A1001 can have a different coupling portion, such as clips or clip slots.

[0335] Referring to FIG. 41, multiple installed floor panels via connectors are illustrated, wherein the floor A100 can comprise the corner edge floor panels and transitional floor panels that are connected by more than one coupling mechanism. For example, butterfly connector A1009 can fix two coupled panel boards, whereas one or more cross connectors A1010 can secure four coupled panel boards.

[0336] As shown in FIG. 42, multiple installed floor panels via connectors and interlocked teeth couplings are illustrated, wherein a plurality of interlocked teeth couplings A1011 can securely connect two neighboring panels, e.g., the first corner edge floor panel A1001 and the transitional floor panel A1003, the first corner edge floor panel A1001, and the second corner edge floor panel A1002. The interlocked teeth couplings can have corresponding ledged portions that match each other to provide more surface contact and support, as shown in FIG. 42. Furthermore, the interlocked teeth couples can create a straight and simple seam on the exterior side of the connected panels.

[0337] As shown in FIG. 43, a butterfly connector A1009 can be inserted into the pre-manufactured slot formed by the two joined panels, which can be further affixed to the panels using a screw or another fastening tool.

[0338] As shown in FIG. 44, a cross connector or a double-butterfly connector A1010 can be inserted into the pre-manufactured slot formed by four neighboring panels, which can be further affixed using a screw A1012 or another fastening tool.

[0339] Referring to FIG. 45, back strengthening ribs of a molded plastic panel according to the preferred embodiment of the present invention are illustrated, wherein each of the hollow fusion panels comprises the number of back strengthening ribs A1013, which can be embodied as the reinforcing ribs 61, 42 as shown in FIG. 3A, FIG. 4 and FIG. 7A to FIG. 10B, each comprising vertical support grooves and horizontal support grooves that form the recessed cavity 400. The vertical or horizontal support groove can create an indent and touch point (such as contact peak 43) for the upper and lower layers of the blow molded hollow fusion panel, which increases its durability and stability. In particular, each vertical support groove can be encircled by a plurality of horizontal support grooves. In addition, each horizontal support groove can be surrounded by a plurality of vertical support grooves. Such a balanced switch between the two orientations of the oval support grooves can maximize the intended benefits of the grooves, where an enlarged perspective view A and an enlarged plan view B illustrate the arrangement of the back strengthening ribs A1013.

[0340] Referring to FIG. 46, side walls of the outdoor storage shed can comprise both flat panels and foldable corner panels, which can form four corners of the outdoor storage shed. Alternatively, according to other embodiments, the side walls of the storage shed can include only foldable corner panels, thereby omitting any flat panels. As shown in FIG. 46, the flat panel A200 may include a basic flat panel A201, which has symmetrical interlocking teeth or portions on both sides. There is also an extension flat panel A202 that can be optional and can be used for enlarging the storage shed. A slider rail A2021 for coupling with one or more floor panels can be arranged on the bottom side of the basic flat panel A201 and the extension flat panel A202.

[0341] FIG. 47 illustrates the rear sides of the flat wall panel(s) and the foldable corner panel(s) according to the preferred embodiment. A base flat panel A201 can have pre-manufactured integrated slots to store metal supporting beams during transportation. These metal support beams, once assembled and installed, can provide support for a designated section of the outdoor storage shed, such as the roof. As shown in FIG. 47, the base flat panel can be coupled to two foldable corner panels A300 via at least the interlocked teeth couplings.

[0342] FIG. 48 illustrates alternative mode of the rear sides of the flat wall panel(s) and the foldable corner panel(s), wherein via interlocked teeth couplings, a basic flat panel A201 can be coupled with an extension flat panel A202 on a first side, and a foldable corner panel A300 on a second side. Additional extension flat panel A202 can be added to expand or customize the size of the storage shed. Another foldable corner panel A300 can be coupled to extension flat A202 to form a second corner of the shed. As shown in FIG. 48, during transportation, two sets of supporting beams can be stored within matching grooves embedded in the back of the plastic panels, which can save packaging space. Such supporting beams can be installed on-site to reinforce the shed's roofing assembly.

[0343] Referring to FIG. 49, the flat wall panels with stored supporting beams are illustrated, wherein multiple supporting beams A2001 can be stored within the rear layer of a plastic molded panel, e.g., A201 and A202. As shown in this example, supporting beams can be split into two portions and connected via fastening tools during installation. To enable convenient retrieval by the user, the pre-manufactured beam slots that are integrated within the plastic layer can have a depth shallower or smaller than the depth of the supporting beams, e.g., half the depth. During transportation, a second panel, securely laying on top of the beam slots, can function as a fastener for the stored beams to prevent them from scratching and damaging other molded plastic panels in the package.

[0344] As shown in FIG. 50, supporting beams and their components are illustrated, wherein an exemplary supporting beam A2001 can consist of multiple components of the supporting beam A2001. The components A2002 are shorter and take less space than a completed supporting beam, thus further reducing package space and cost.

[0345] FIG. 51 illustrates the foldable corner panels according to the preferred embodiment, wherein the wall panels can comprise one or more foldable corner panels A300. Examples shown in this drawing include a first foldable corner panel A301 for the front right corner of the storage shed and a second foldable corner panel A302 for the left right corner, which constitute mirror images to each other.

[0346] Traditionally, the corner assembly of a storage shed comprises two separate panels joined by fasters, leaving a seamed connection that could cause instability. Also, water/rain can enter the shed through the joint/seam and cause damage. The foldable corner panel solves these issues by eliminating the joint between two panels. A foldable corner panel can comprise a folding groove that divides the panel into a first leaf and a second leaf. In addition, each leaf of the foldable panel has a size and shape similar to other wall panels and floor panels. The embedded folding groove can be formed by blow-molding with less or thinner plastic material than the rest of the panel, thus rendering a soft area that is flexible and turnable.

[0347] During transportation, the two leaves are folded and closed at the groove. Prior to the installation, the foldable molded plastic model can unfold and form a flat surface. During installation, the two leaf panels of the foldable panel can be fixed at a fixed angle, e.g., 90, to constitute a seamless corner. According to some embodiments, depending on the intended use of the final product, the two leaf panels can form a corner at other angles, such as 60. According to some embodiments, multiple folding grooves can be integrated into a single panel to create multiple turning areas. Furthermore, the one-piece foldable corner can reduce manufacturing cost and also reduce installation complexity and time for the user.

[0348] FIG. 52 illustrates a front side of the foldable corner panel and FIG. 53 illustrates a rear side of the foldable corner panel according to the preferred embodiment. As shown in FIG. 52, the second foldable corner panel A302 can be unfolded at the folding groove and form a flat surface prior to the installation. After the installation, the foldable panel can be affixed to the corner edge floor panels to form a corner. A similar process is shown in FIG. 53 from the rearview.

[0349] Referring to FIG. 54, a folding groove A3021 can enable the turning of a foldable corner panel, e.g. second foldable corner panel A302.

[0350] As shown in FIG. 55, the foldable corner panel coupled to a floor panel is illustrated, wherein after installation, the second foldable corner panel A302 can be fixed along two edges of floor A100. According to the preferred embodiment, the floor 100 can be a corner edge floor panel that comprises two types of coupling mechanisms, e.g., a slider coupling and a clip coupling, on each edged side. According to the preferred embodiment, seam lines between side wall panels can offset with seam lines between floor panels, which means avoiding aligning two seam lines substantially. This way, the connected floor panels and the wall panels can reinforce each other.

[0351] Referring to FIG. 56, the second foldable corner panel A302 can have a top side A3027 configured to be coupled to a lintel or a roof for the storage shed. A door hinge slot A3024 can be pre-manufactured so that a door can be connected to the hollow fusion type construction panel. The bottom two sides along the two leaves of the panel A302 can be equipped with one or more coupling mechanisms.

[0352] According to the preferred embodiment, each leaf can have a different coupling structure from each other so that the installation is easier, and the structural stability is enhanced. For example, clip slots A3023 on first leaf can be coupled to clips arranged on a floor panel; an L-shaped slider A3025 on a second leaf can be coupled to a L-shaped rail on the floor panel.

[0353] In addition, the rear layer of second foldable corner panel A302 can comprise back strengthening ribs A3022 (e.g. the reinforcing ribs 61, 42). As shown in FIG. 56, evenly spaced and symmetrically arranged back strengthening ribs are arranged to provide enhanced stability of the plastic panel. According to some embodiments, back strengthening ribs A3022 can comprise vertical support grooves and horizontal support grooves. In particular, each vertical support groove can be surrounded by a plurality of horizontal support grooves. In addition, each horizontal support groove can be surrounded by a plurality of vertical support grooves.

[0354] Referring to FIG. 57, the second foldable corner panel A302 can have another type of slider, e.g., a T-shaped slider A3026, to engage with a T-shaped rail of a floor panel.

[0355] FIG. 58 illustrates two coupling mechanisms of the foldable corner panel(s) according to the preferred embodiment, wherein the second foldable corner panel A302 can be divided by an embedded folding groove into a first leaf A30231 and a second leaf A30232, wherein the first leaf 30231 can consist of an L-shaped slider A3025 and the second leaf A30232 can comprise clip slots A3023. According to the preferred embodiment, the two leaves can incorporate two different coupling mechanisms. The two coupling mechanisms can adopt a contrasting engagement style, i.e. projecting v. receiving, to increase the binding force and stability between the panels. For example, a construction panel can have a protruding coupling portion, e.g., L-shaped slider A3025, arranged on one leaf, and a receiving coupling portion, e.g., clip slots A3023, arranged on another leaf.

[0356] FIG. 59 illustrates two coupling mechanisms of the foldable corner panel(s) according to the preferred embodiment, wherein a clip coupling structure A3027 is arranged on a first side of the turnable corner panel, whereas a slider coupling structure A3028 is arranged on a second side of the corner panel.

[0357] FIG. 60 illustrates interlocking teeth couplings between two connected wall panels according to the preferred embodiment, wherein interlocked teeth couplings A3011 can comprise a plurality of protrusions/lips on the left wall panel and corresponding recesses arranged on the right wall panel. It is further noted that each protrusion and recess can have varied depths of plastic material, forming varied ledges based on the design and contour of the teeth couplings. Such varied, multi-level engagement can increase the contact surface between the two panels. According to the preferred embodiment, the protrusions/lips and the recesses are distributed asymmetrically along with connecting line. For example, the interlocked teeth portions can be placed closer to or within the upper half region A3013, instead of the lower half region A3015. This way, the installation can take less careful alignment as the lower half region shall be coupled with the floor panels.

[0358] One advantage of interlocked teeth couplings A3011 is to increase the binding and unity of any two coupled panels. The increased contact surface resulting from the teeth couplings, protrusions and recesses at varied depths, can share any force applied to the panels, thus improving the stability of the structure. Such couplings can be used between the wall panels, the floor panels, or any other plastic panels. Furthermore, one or more additional fastening tools, such as screws, can be adopted to further secure the connected panels.

[0359] As shown in FIG. 60, the interlocked teeth couplings A3011 are illustrated, wherein after the assembly, there is a straight seam line formed by the interlocked teeth couplings A3011. Thus, the interlocked teeth couplings can increase the structure stability without sacrificing the aesthetic appeal of the product.

[0360] Referring to FIG. 61, the foldable corner panel with a concave door frame are illustrated according to the preferred embodiment, wherein traditionally, a door of the storage shed is flush with the wall surface. According to the preferred embodiment, the edge of second foldable corner panel A302 can transition into a concave door frame A3030, generating an inwardly concave surface A3031. This concave surface A3031 can be sloped towards a door. As shown in FIG. 61, the concave surface A3031 can be broader than a standard door frame, thus enhancing the stability of the door-wall structure. Moreover, the concave surface A3031 can also serve as a door stopper or brake when the shed door is opened, preventing the door from harshly hitting the wall panels. The design of the concave door frame also can permit the door to recess below the surface of the wall, offering protection to the door from weather elements such as rain, sunlight, or wind.

[0361] FIG. 62 illustrates the foldable corner panel with shelf groove(s) according to the preferred embodiment, wherein the foldable corner panel, e.g. the second foldable corner panel A302, can comprises a number of shelf grooves A3032 that are manufactured and embedded into the interior surface of the two panel leaves. One or more plastic shelfs A3033 can be slotted into shelf grooves A3032. Such shelves can offer not only additional storage space within the shed but also increase the structural stability of the corner panel assembly.

[0362] FIG. 63 illustrates the foldable corner panel coupled with a door according to the preferred embodiment, wherein the storage shed can comprise a door A400 that further consists of a first door panel A401 and a second door panel A402. Such door A400 can be connected to a foldable corner panel, such as second foldable corner panel A302. According to some embodiments, the shed storage structure can comprise a front door and a back door. According to some embodiments, the shed storage structure can have only a front door.

[0363] FIG. 64 illustrates an assembled lintel for the outdoor storage shed according to the preferred embodiment, wherein a lintel A500 can function as a supporting component between the wall panels and the roof of the storage shed. The lintel A500 can comprise a front lintel A501, a rear lintel A502, a front foldable lintel panel A503 and a rear foldable lintel panel A504. The lintel A500 can be fixed to wall panels and roof via connectors such as screws A5011.

[0364] FIG. 65 illustrates a roof connected with the lintel for the outdoor storage shed according to the preferred embodiment, wherein the roof with lintel A600 can comprise a roof A601 that is fixed to lintel A500 via various connectors such as screws A6011.

[0365] FIG. 66 illustrates a foldable roof panel for a roof according to the preferred embodiment, wherein a foldable roof panel A6012 can be utilized to reduce the storage space and cost. As shown in FIG. 66, a folding groove A6013 can be manufactured by injecting less or thinner plastic than the rest of the roof panel. During transportation, foldable roof panel A6012 can be folded into half size at folding groove A6013, which is similar sized with the other panels. During installation, foldable roof panel A6012 can unfold and form a flat surface.

[0366] It is appreciated that, according to the above-described embodiments 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 shelter apparatus. Please referring to FIG. 67, 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.

[0367] As mentioned in producing method of the hollow fusion panel 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.

[0368] 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.

[0369] 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.

[0370] 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 construction panel. For example, when the construction panel is a blow-molded hollow fusion panel embodied to construct a shelter apparatus, the first panel member is embodied as an upper or outer panel member 1, 10, 30 and the second panel member is embodied as a lower or inner panel member 2, 20, 40. When the blow-molded hollow fusion panel 1 is a partition panel, a shelf panel, or a shelter 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. 68 to FIG. 69, 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.

[0371] Referring to FIG. 68, 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.

[0372] Referring to FIG. 70, 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 shelter 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.

[0373] Referring to FIG. 69, the configuration of the blow molding unit 203 as illustrated in FIG. 67 and FIG. 68 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.

[0374] It is worth mentioning that the storage shed can be an outdoor shed or indoor shed. Furthermore, some or all features of the present subject matter can be incorporated into other types of molded plastic assembly.

[0375] 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.

[0376] 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.