Blow-molded plastic structure
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Solution Overview
Problem
Conventional tables with large tabletops and folding legs are often heavy due to materials like wood or metal, making them difficult to move and store, and requiring additional reinforcing members that increase weight and manufacturing costs.
Innovation Solution
A blow-molded plastic structure featuring a tabletop with a lip that forms part of the sidewall, integrally formed as a unitary, one-piece structure during the blow-molding process, which includes inwardly extending portions to enhance strength and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If tabletops are constructed from lightweight materials such as plastic, then the weight of the table is decreased, but the strength and structural integrity of the tabletop deteriorates
Solution Approach 1:
The tabletop is divided into multiple structural components including a rim structure with inwardly extending portions, recesses, and attachment features that are integrally formed into the plastic structure. This segmentation provides localized reinforcement without requiring additional heavy parts.
Solution Approach 2:
The patent uses plastic material with specific properties (high impact resistance, rigidity) and combines it with structural design elements to create a composite effect that achieves both lightweight construction and high strength. The integral formation of reinforcing features within the plastic structure creates a composite-like performance.
2Strength
If reinforcing members or structural parts such as braces and brackets are added to strengthen the tabletop, then the strength of the tabletop is improved, but the weight of the table increases
Solution Approach 1:
The reinforcing members, braces, and structural support elements are merged with the tabletop itself through integral formation. The rim structure, inwardly extending portions, and attachment features are all formed as one piece with the main tabletop body, eliminating the need for separate reinforcing parts and their associated fasteners.
Solution Approach 2:
The rim structure and inwardly extending portions serve multiple functions simultaneously: they provide structural reinforcement, create attachment points for legs and aprons, define the perimeter of the tabletop, and provide mounting surfaces for other components. This multi-functionality eliminates the need for separate reinforcing members.
3Strength
If additional parts and fasteners are used to assemble the table, then the strength and structural integrity are improved, but the manufacturing complexity and assembly time increase
Solution Approach 1:
Multiple components that would traditionally be separate parts (tabletop surface, rim structure, reinforcing members, attachment features) are merged into a single integrally formed plastic structure. This eliminates the need for multiple fasteners, joints, and assembly steps while maintaining structural integrity.
Solution Approach 2:
The tabletop structure includes self-contained attachment features and mounting points that are built into the integral structure. The inwardly extending portions and recesses automatically provide alignment and attachment capabilities without requiring separate fastening components or complex assembly procedures.
4Strength
If conventional materials such as wood or metal are used for the tabletop, then the strength and durability are improved, but the cost of shipping and transportation increases due to increased weight
Solution Approach 1:
The patent changes the material parameter from traditional heavy materials (wood, metal) to lightweight plastic material with specific properties (high impact resistance, rigidity). This parameter change is compensated for by optimizing the structural design with integral reinforcing features, achieving the desired strength-to-weight ratio.
Data Source
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AI summary
A molded plastic structure may comprise a tabletop with an upper surface and a lower surface. A lip may extend downwardly relative to the lower surface of the tabletop, and the lip may include an outer surface and an inner surface. An inwardly extending portion may extend inwardly from the inner surface of the lip. A frame may be connected to the table top and the frame may include a side rail of a frame. The side rail may include a receiving portion that receives the inwardly extending portion. The side rail may also include a portion that supports the lower surface of the table top and a portion that supports the lip.