Polyurethane Foam Marine Table Assembly

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Solution Overview

Problem

Current marine furniture is expensive, limited in color and options, heavy, non-buoyant, and difficult to repair when damaged, with most components being made from expensive plastic molds or wood that deteriorates quickly.

Innovation Solution

A table assembly with a polyurethane foam top that includes integrated, integral accessories and a method for producing it using a silicon mold with a wood-grain textured surface, resulting in a lightweight, water-resistant, and buoyant product with improved aesthetics and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If marine furniture is made from expensive plastic molds, then manufacturing precision and durability are improved, but cost increases and weight increases

Engineering Contradiction:

ImprovedurabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent uses polyurethane foam as a composite material that combines lightweight properties with durability. The foam material provides both structural integrity and buoyancy, replacing traditional heavy plastic molds while maintaining reliability and extending service life in marine environments.

Inventive Principle:

Principle #40Composite materials

2Shape

If marine furniture is made from wood, then aesthetics and natural appearance are improved, but durability deteriorates due to deterioration and discoloration over time

Engineering Contradiction:

ImproveaestheticsVSAvoiddurability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent incorporates wood grain patterns and various color options directly into the polyurethane foam material through pigments and surface treatments. This allows the furniture to maintain aesthetic appeal with natural wood appearances while the synthetic foam material provides resistance to deterioration and discoloration in marine conditions.

Inventive Principle:

Principle #32Color changes

3Strength

If traditional marine furniture is manufactured, then structural integrity is achieved, but buoyancy is lost and water resistance is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidwater resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent utilizes the cellular structure of polyurethane foam as a porous material that provides inherent buoyancy. The closed-cell foam structure resists water absorption while maintaining structural integrity, allowing the furniture to float and remain water-resistant without sacrificing strength or requiring additional buoyancy components.

Inventive Principle:

Principle #31Porous materials

4Adaptability or versatility

If marine furniture is made with integrated accessories, then versatility and functionality are improved, but manufacturing complexity increases

Engineering Contradiction:

ImprovefunctionalityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates accessories such as cup holders, storage compartments, and mounting brackets directly into the polyurethane foam structure during the molding process. This combining of multiple functions into a single molded piece eliminates the need for separate assembly steps, reducing manufacturing complexity while enhancing versatility and functionality of the marine furniture.

Inventive Principle:

Principle #5Merging (Combining)

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 solution provides a durable, aesthetically pleasing, and cost-effective marine table assembly that is buoyant and resistant to water, reducing repair costs and suitable for recreational boating applications.

Implementation Method 1

allowing the mixture of polyol and isocyanate to set into a substantial homogenous body portion of a table top comprising polyurethane foam

Methodology Applied

Scientific EffectPolymerization: Chemical Bonding

Implementation Method 2

providing a mold comprising silicon, the mold including a wood grain textured surface... wherein one or more of the top surface and the plurality of side surfaces includes an integral wood-grain pattern

Methodology Applied

Scientific EffectImpression transfer: Deposition (physical)

Implementation Method 3

are water resistant, are water buoyant

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS11260941B2Table assembly for a watercraft and method for producing the same

Publication Date: 2022.03.01 CATES KIRT

AI summary

A table top assembly for a watercraft table assembly includes an upwardly-disposed top surface, a downwardly-disposed bottom surface spaced vertically from the top surface, and a plurality of side surfaces extending between the top and bottom surfaces and cooperating with the top and bottom surfaces to form a body portion, wherein the body portion comprises polyurethane foam having a density within a range of between about 20 lbs/ft3 and about 25 lbs/ft3, and wherein the body portion has a substantially homogeneous composition throughout, and wherein one or more of the top surface and the plurality of side surfaces includes an integrally molded textured surface.