Composite Table Top Structure for Lightweight Strength

Solution Overview

Problem

Traditional wood table tops are not environmentally friendly, require constant maintenance, and may not be suitable for all applications, while synthetic materials like fiberboard or flake board have similar drawbacks, and blow molding results in heavy, overused materials due to the need for thickness for strength.

Innovation Solution

A composite table top design featuring a top plate with an outer and inner surface, a bottom plate with projections and reinforcement inserts, manufactured through vacuum forming, which reduces material usage and weight while enhancing mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If blow molding is used to manufacture synthetic table top, then the table top can be made of synthetic material, but the material overuse and heavy weight occur due to the need for sufficient thickness for strength

Engineering Contradiction:

Improvesynthetic material applicabilityVSAvoidtable top weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The table top is divided into multiple layers with distinct functions: a decorative top layer, a core layer with honeycomb or rib structure for strength, and a bottom layer. This segmentation allows each layer to be optimized independently, reducing overall material usage and weight while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite structures combining different materials and geometries - such as plastic layers with foam cores, or rigid frames with flexible panels - to achieve high strength-to-weight ratios. The composite design provides the necessary mechanical properties without requiring excessive thickness of single materials.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If blow molding is used to manufacture synthetic table top, then the table top can be made of synthetic material, but material overuse occurs due to the need for sufficient thickness for strength

Engineering Contradiction:

Improvesynthetic material applicabilityVSAvoidmaterial usage

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The table top is divided into multiple layers with distinct functions: a decorative top layer, a core layer with honeycomb or rib structure for strength, and a bottom layer. This segmentation allows each layer to be optimized independently, reducing overall material usage and weight while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs thin-walled structures and shell-like geometries that provide strength through shape rather than material thickness. The hollow or cellular cross-sections act as structural shells that resist bending and buckling loads with minimal material.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If traditional wood is used for table top, then the table top can be made, but consumption of large amount of wood is not environmentally friendly

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the material parameter from natural wood to synthetic polymers and composites, maintaining manufacturability through established plastic forming processes while eliminating the environmental depletion associated with large-scale wood consumption.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite structures combining different materials and geometries - such as plastic layers with foam cores, or rigid frames with flexible panels - to achieve high strength-to-weight ratios. The composite design provides the necessary mechanical properties without requiring excessive thickness of single materials.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If wood is used for table top, then the table top can be made, but wood needs constant maintenance

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidmaintenance requirement

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The invention changes the material parameter from natural wood to synthetic polymers and composites, maintaining manufacturability through established plastic forming processes while eliminating the environmental depletion associated with large-scale wood consumption.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite table top achieves improved durability, reduced maintenance, and environmental friendliness by optimizing material distribution and manufacturing processes, resulting in a lightweight and strong synthetic material alternative.

Implementation Method 1

the bottom plate is produced through a vacuum forming process

Methodology Applied

Scientific EffectVacuum forming:

Data Source

PatentUS9808081B2Composite table top

Publication Date: 2017.11.07 NEW TEC INTEGRATION (XIAMEN) CO LTD

AI summary

A composite table top including a top plate and a bottom plate. The top plate has an outer and an inner surface. The bottom plate has a plurality of projections, each of the plurality of projections has a top defining a top surface. The composite table top has at least a pair of reinforcement inserts disposed at two opposite edges of the bottom plate. The sum of the top surfaces of the plurality of projections is 30%-70% of the upper surface of the bottom plate.