High strength blow-molded structure

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Solution Overview

Problem

Blow-molded plastic structures face a trade-off between weight reduction and load-bearing strength, as hollow interiors for lightness compromise structural integrity, and traditional strengthening methods like metal ribs increase weight and create stress points.

Innovation Solution

A blow-molded plastic structure with a hollow interior and a pattern of tripodal depressions in rows and columns on the outer surface, providing structural stiffening without significant weight increase, by integrating these features into the blow-molding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If hollow interior is used to reduce weight, then weight is reduced, but load-bearing strength deteriorates

Engineering Contradiction:

ImproveweightVSAvoidload-bearing strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The hollow interior is segmented into multiple compartments by partition walls, creating a cellular structure that enhances load-bearing capability while maintaining light weight. The partition walls divide the single hollow space into multiple smaller hollow spaces, distributing structural loads more effectively throughout the structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Rounded corners are provided at the intersections of partition walls and outer walls, replacing sharp corners with curved surfaces. This curvature distributes stress more evenly throughout the structure, preventing stress concentration at corner points and enhancing overall structural strength without adding significant weight.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Strength

If metal strengthening ribs are added to increase load-bearing strength, then load-bearing strength is improved, but weight increases significantly

Engineering Contradiction:

Improveload-bearing strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Instead of adding metal ribs throughout the structure, strengthening features are localized to specific regions where load-bearing requirements are highest. The partition walls and rounded corners provide targeted reinforcement at critical stress points while leaving other areas lightweight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The structure uses a composite approach by combining the hollow plastic structure with integrated partition walls made of the same material, creating a unified composite structure that provides strength without the weight penalty of metal reinforcements.

Inventive Principle:

Principle #40Composite materials

3Strength

If integrally formed ribs are used to increase load-bearing capability, then load-bearing capability is improved, but wall thickness increases adding weight

Engineering Contradiction:

Improveload-bearing capabilityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The partition walls function as thin film structures that provide structural reinforcement without requiring significant thickness. These thin partition walls create the cellular configuration that strengthens the overall structure while maintaining minimal material usage and weight.

Inventive Principle:

Principle #30Flexible shells and thin films

4Strength

If integrally formed ribs are used to provide load-bearing support, then load-bearing support is improved, but production time increases

Engineering Contradiction:

Improveload-bearing supportVSAvoidproduction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The partition walls and strengthening features are merged into the blow-molding process itself, allowing the structural reinforcements to be formed simultaneously with the main structure in a single production cycle. This eliminates separate manufacturing steps and reduces overall production time.

Inventive Principle:

Principle #5Merging (Combining)

5Strength

If integrally formed ribs are used to increase structural strength, then structural strength is improved, but structure complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The structure is segmented into multiple standardized compartments using repeating partition wall patterns. This segmentation creates a modular design that, while providing enhanced strength, follows a regular repeating pattern that simplifies the blow-molding process and mold design compared to custom complex rib structures.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11564493B2High strength blow-molded structure

Publication Date: 2023.01.31 DONGGUAN SHICHANG METALS FACTORY LTD

AI summary

A blow-molded plastic structure has a hollow interior portion formed during a blow-molding process, and includes first and second outer portions that are spaced apart from each other, with the hollow interior portion disposed there between. The structure includes a pattern of structural stiffening features that are integrally formed in the second outer portion. The pattern of structural stiffening features includes a plurality of tripodal depressions disposed in rows and columns and a plurality of convex regions disposed in rows and columns between the plurality of tripodal depressions. Each convex region has a maximum height between the first and second outer portions. Each of the tripodal depressions extends into the hollow interior portion, includes three indentations disposed adjacent the first outer portion, and includes an island spaced away from the first outer portion. The island has three sides, each of which is disposed adjacent one of the three indentations.