Blow-Molded Panel with Double-Layer Flange to Reduce Edge Cracking

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Solution Overview

Problem

Blow-molded panels used in furniture, such as tables, often have weak and thin edges that are prone to cracking, and the existing solutions to enhance strength, like thickening the panels, result in increased weight and cost, while the parting line at the flange is also vulnerable to damage.

Innovation Solution

A hollow blow-molded panel with reinforced edges featuring a flange design with an inner and outer layer fusion at the lower portion, crisscross recessed support touch points, and strategically placed grooves for beam installation, which enhances structural strength and rigidity, and a folding table design that embeds beams and feet into these grooves for improved stability and ease of folding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the panel thickness is increased to enhance structural strength, then the strength is improved, but the weight increases and cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The flange is segmented into inner and outer layers that are separated by a hollow space, with the parting line positioned only on the outer flange layer. This segmentation allows the panel to maintain structural strength through the layered configuration without requiring increased overall thickness, thereby avoiding weight increase while preserving strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flange structure uses a composite configuration of inner and outer flange layers forming a hollow sandwich structure. This composite design enhances structural strength and rigidity through the layered architecture without increasing material volume or weight, as the hollow space provides structural efficiency similar to I-beam construction.

Inventive Principle:

Principle #40Composite materials

2Strength

If the panel thickness is increased to enhance structural strength, then the strength is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the structural parameters of the flange by creating a hollow space between inner and outer layers, and by repositioning the parting line to only the outer flange layer. These parameter changes enhance structural strength without increasing material consumption, thereby reducing manufacturing cost while maintaining or improving strength.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the parting line is located at the bottom of the outer flange layer, then the molding process is simplified, but the firmness at the parting line area is lowest and it is easy to be broken

Engineering Contradiction:

Improvemolding processVSAvoidfirmness at parting line

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The flange is segmented into inner and outer layers with the parting line positioned only on the outer flange layer. This segmentation isolates the parting line to a specific location where it does not compromise the overall structural integrity, as the inner flange layer remains continuous and provides structural support. The hollow space between layers further distributes stress away from the parting line area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow space between the inner and outer flange layers acts as an intermediary that distributes and absorbs stress, preventing stress concentration at the parting line location. This intermediary space allows the parting line to exist on the outer layer without becoming a weak point, as the hollow structure provides structural reinforcement around the parting line area.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3000353B1Blow molding panel with strengthened edge and folding table applying same

Publication Date: 2020.07.08 JIANG YIXIANG

Figure 1
Figure 2~3
Figure 4

AI summary

The invention relates to a blow-molded panel with reinforced edges and a folding table. The flange (1) is extended downward on the periphery of the panel and surrounding the reinforced edge. The flange (1) comprises an inner flange layer (11) and an outer flange layer (12). A hollow space is formed between the upper portion of the inner flange layer (11) and the upper curvy portion of the outer flange layer (12), and the lower portion of the inner flange layer (11) is attached to the lower straight portion of the outer flange layer (12). In the present invention, the flange (1) has two layers, and the lower portion of the inner flange layer (11) is attached to the lower straight portion of the outer flange layer (12), so that the firmness and the shock resistance of the fragile parts on the periphery of the panel are remarkably improved. Due to the first strip-shaped grooves (4), the second strip-shaped grooves (5) and the strip-shaped grooves (6), the set of foots can be conveniently and firmly installed, a high flatness can be kept after the panel and the set of foots are completely folded, and a plurality of folding tables can be easily stacked up after being folded accordingly.