U.S. patent application number 11/372515 was filed with the patent office on 2006-10-19 for high-strength, lightweight blow-molded plastic structures.
Invention is credited to Thayne B. Haney, Rich Howe.
Application Number | 20060230989 11/372515 |
Document ID | / |
Family ID | 37107246 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060230989 |
Kind Code |
A1 |
Haney; Thayne B. ; et
al. |
October 19, 2006 |
High-strength, lightweight blow-molded plastic structures
Abstract
Blow-molded plastic structures may include a plurality of
depressions and the depressions may have different characteristics
depending, for example, upon the particular configuration of the
depression. For example, a depression may have an elongated length
and it may have increased strength along its length. The
depressions may be arranged into a pattern in order to take
advantage of particular characteristics of the depressions. For
example, the depressions may be arranged to maximize the strength
and/or minimize the weight of the structure. The depressions may
also be arranged to create a structure with generally uniform
characteristics. Significantly, the depressions may be arranged
into a number of different patterns depending, for example, upon
the intended use of the structure. For instance, the depressions
may be arranged into a pattern with one or more rows and columns,
and the depressions may be disposed in particular positions or
orientations within the rows or columns.
Inventors: |
Haney; Thayne B.; (Syracuse,
UT) ; Howe; Rich; (Pleasant View, UT) |
Correspondence
Address: |
WORKMAN NYDEGGER;(F/K/A WORKMAN NYDEGGER & SEELEY)
60 EAST SOUTH TEMPLE
1000 EAGLE GATE TOWER
SALT LAKE CITY
UT
84111
US
|
Family ID: |
37107246 |
Appl. No.: |
11/372515 |
Filed: |
March 9, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60659982 |
Mar 9, 2005 |
|
|
|
Current U.S.
Class: |
108/57.25 |
Current CPC
Class: |
B65D 11/24 20130101;
B29L 2031/448 20130101; A47B 13/08 20130101; B65D 71/70 20130101;
B29C 49/52 20130101; B29C 49/00 20130101 |
Class at
Publication: |
108/057.25 |
International
Class: |
B65D 19/00 20060101
B65D019/00 |
Claims
1. A structure constructed from blow-molded plastic, the structure
comprising: a first surface; a second surface that is spaced apart
from the first surface; a hollow interior portion formed during the
blow-molding process; a plurality of depressions formed in the
second surface and extending towards the first surface, each of the
plurality of depressions having generally the same general shape,
the plurality of depressions comprising: a first depression, a
second depression, a third depression and a fourth depression
positioned in a generally parallelogram shaped configuration; and a
fifth depression positioned proximate a central portion of the
generally parallelogram shaped configuration, the fifth depression
being orientated at first angle, the first depression being
disposed at an angle that is oblique to the first angle, the second
depression being disposed at an angle that is oblique to the first
angle, the third depression being disposed at an angle that is
oblique to the first angle, the fourth depression being disposed at
an angle that is oblique to the first angle.
2. The structure constructed from blow-molded plastic as in claim
1, wherein the first depression is oriented generally perpendicular
to the second depression, the first depression is oriented
generally perpendicular to the fourth depression, the second
depression is oriented generally perpendicular to the first
depression, the second depression is oriented generally
perpendicular to the third depression, the third depression is
oriented generally perpendicular to the second depression, the
third depression is oriented generally perpendicular to the fourth
depression, the fourth depression is oriented generally
perpendicular to the first depression, and the fourth depression is
oriented generally perpendicular to the third depression.
3. The structure constructed from blow-molded plastic as in claim
1, wherein the first depression, the second depression, the third
depression and the fourth depression positioned in a generally
rectangular shaped configuration.
4. The structure constructed from blow-molded plastic as in claim
1, wherein the first depression, the second depression, the third
depression and the fourth depression positioned in a generally
square shaped configuration.
5. The structure constructed from blow-molded plastic as in claim
1, wherein the first, second, third, and fourth depressions each
include a major axis that intersects a portion of the fifth
depression.
6. The structure constructed from blow-molded plastic as in claim
1, wherein the first, second, third, and fourth depressions each
include a minor axis that intersects a portion of the fifth
depression.
7. The structure constructed from blow-molded plastic as in claim
1, wherein the depressions have a generally oblong
configuration.
8. A structure constructed from blow-molded plastic, the structure
comprising: a first surface; a second surface that is spaced apart
from the first surface; a hollow interior portion that is formed
during the blow-molding process; a plurality of depressions formed
in the second surface and extending towards the first surface, each
of the plurality of depressions having generally the same shape,
the plurality of depressions comprising: a first depression, a
second depression, a third depression and a fourth depression
positioned in a generally parallelogram shaped configuration, the
first depression being disposed proximate the second and fourth
depressions, the second depression being disposed proximate the
first and third depressions, the third depression being disposed
proximate the second and fourth depressions, the fourth depression
being disposed proximate the first and third depressions; the first
and third depressions being positioned at opposing corners of the
generally parallelogram shaped configuration, the second and fourth
depressions being positioned at opposing corners of the generally
parallelogram shaped configuration; the first and third depressions
being oriented generally perpendicular to each other; the second
and fourth depressions being oriented generally perpendicular to
each other; the third depression being orientated at a first angle,
the second depression being orientated at angle that is oblique to
the first angle, the fourth depression being orientated at angle
that is oblique to the first angle.
9. The structure constructed from blow-molded plastic as in claim
8, wherein the second depression is orientated at angle that is
between about 35 degrees to about 55 degrees from the first angle,
and the fourth depression is orientated at angle that is between
about 35 degrees to about 55 degrees from the first angle.
10. The structure constructed from blow-molded plastic as in claim
8, wherein the second depression is orientated at angle that is
about 45 degrees from the first angle, and the fourth depression is
orientated at angle that is about 45 degrees from the first
angle.
11. The structure constructed from blow-molded plastic as in claim
8, wherein the first depression, the second depression, the third
depression and the fourth depression positioned in a generally
rectangular shaped configuration.
12. The structure constructed from blow-molded plastic as in claim
8, wherein the first depression, the second depression, the third
depression and the fourth depression positioned in a generally
square shaped configuration.
13. The structure constructed from blow-molded plastic as in claim
8, wherein the depressions have a generally oblong
configuration.
14. A structure constructed from blow-molded plastic, the structure
comprising: a first surface; a second surface that is spaced apart
from the first surface; a hollow interior portion formed during the
blow-molding process; a plurality of depressions formed in the
second surface and extending towards the first surface, each of the
plurality of depressions having generally the same shape, the
plurality of depressions comprising: a first row of depressions,
the depressions of the first row alternating between a first
orientation and a second orientation, the first and second
orientations being generally perpendicular to each other; and a
second row of depressions adjacent the first row of depressions,
the depressions of the second row alternating between a third
orientation and a fourth orientation, the third and fourth
orientations being generally perpendicular to each other, the first
orientation being at an angle that is oblique to the third and
fourth orientations, the second orientation being at an angle that
is oblique to the third and fourth orientations, the third
orientation being at an angle that is oblique to the first and
second orientations, the fourth orientation being at an angle that
is oblique to the first and second orientations.
15. The structure constructed from blow-molded plastic as in claim
15, wherein the first orientation is between about 35 degrees to
about 55 degrees from the third orientation, and the second
orientation is between about 35 degrees to about 55 degrees from
the third orientation.
16. The structure constructed from blow-molded plastic as in claim
15, wherein the first orientation is about 45 degrees from the
third orientation, and the second orientation is about 45 degrees
from the third orientation.
17. The structure constructed from blow-molded plastic as in claim
15, wherein the depressions of the second row are offset from the
depressions of the first row.
18. The structure constructed from blow-molded plastic as in claim
15, wherein the plurality of depressions further comprises: a third
row of depressions adjacent the second row of depressions, the
depressions of the third row alternating between the first
orientation and the second orientation; and a fourth row of
depressions adjacent the third row of depressions, the depressions
of the fourth row alternating between the third orientation and the
fourth orientation.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and the benefit of,
U.S. provisional patent application Ser. No. 60/659,982, filed Mar.
9, 2005, which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to structures
constructed from blow-molded plastic and, in particular, to
high-strength, lightweight blow-molded plastic structures.
[0004] 2. Description of Related Art
[0005] It is known to construct various objects and items, such as
tables, chairs, partitions, walls, and sports equipment, from
plastic. It is also known to construct some of these and other
objects from blow-molded plastic. As known to those skilled in the
art, blow-molded structures often include an outer wall that
encloses a hollow interior space. Because blow-molded structures
include a hollow interior space, many blow-molded structures are
not high-strength. In fact, many known blow-molded structures are
relatively low-strength and are unable to support a relatively
large amount of weight or force.
[0006] In order to increase the strength of conventional
blow-molded structures, it is known to add strengthening ribs. For
example, known tables with table tops constructed from blow-molded
plastic may include strengthening ribs attached to the underside of
the table top in an attempt to increase the strength of the table
top. The strengthening ribs are often constructed from metal
because metal ribs are high strength. Disadvantageously, the metal
ribs must be attached to the table top by mechanical fasteners such
as bolts or screws. The bolts or screws require holes in the table
top, which may create stress concentrations and/or potential
failure points in the table top. Alternatively, the metal ribs may
be attached to the table top by adhesives, but the adhesives may
also decrease the structural integrity of the table top and make
the table top very difficult to repair or replace. In addition, the
metal ribs may increase the number of components required to
construct the table and the time required to manufacture the table.
Thus, while it is known to use metal ribs to increase the strength
of a blow-molded table top, the metal ribs may undesirably increase
the time and costs to manufacture the table. Further, the
attachment of the metal ribs to the table top may decrease the
strength and/or structural integrity of the table top, and increase
the potential causes of failure of the table.
[0007] Conventional table tops constructed from blow-molded plastic
may also include strengthening ribs or beams that are integrally
formed in the table top. For example, strengthening ribs may be
formed in the underside of the center portion of the table top in
an effort to prevent sagging of that portion of the table top.
These strengthening ribs are generally large, elongated portions
that extend along the length or width of the table top. While the
strengthening ribs may increase the strength or structural
integrity of the table top, the ribs often require thicker outer
walls so that the large, elongated ribs are correctly formed in the
table top. The large, elongated strengthening ribs may also require
thicker outer walls so that the ribs do not undesirably sag or
deform during the manufacturing process. Disadvantageously, the
thicker outer walls of the ribs may require additional plastic
materials be used to create the table top, which may undesirably
increase the costs and weight of the table tops. In addition, the
thicker outer walls may retain more heat during the manufacturing
process. Thus, a longer cooling time may be required during the
manufacturing process in order to allow the thicker outer walls to
cool. This may undesirably increase the time of the manufacturing
process because the blow-molded table tops cannot be removed from
the mold until the tops are sufficiently cooled.
[0008] Known table tops constructed from blow-molded plastic may
also include strengthening ribs disposed in other portions of the
table top. For example, strengthening ribs may be placed near
opposing ends of the table top in an effort to increase the
strength of the ends of the table top. Additionally, these
strengthening ribs may be configured to help prevent the table top
from undesirably bending and to allow the table top to support
additional weight. The strengthening ribs, however, often protrude
outwardly from the underside of the table top and the ribs
frequently have relatively large profiles to help create relatively
strong supporting structures. Disadvantageously, the large,
protruding ribs may undesirably decrease the amount of room
underneath the table top, decrease the usefulness of the table and
limit potential design considerations and/or arrangements of the
table top.
[0009] Conventional table tops that are constructed from
blow-molded plastic and include strengthening ribs, however, may
still not have sufficient strength and may allow a portion of the
table top to sag. In order to increase the strength of these
conventional table tops, it is known to increase the number of
ribs. These additional ribs undesirably require a larger area on
the underside of the table top, which may limit the area that other
features may be formed in the table top. The numerous strengthening
ribs may also interfere with other features or components of the
table, such as interfering with the folding of the table legs into
a collapsed position. The ribs may also increase the cooling and
manufacturing time of the table top.
[0010] Additionally, while the large strengthening ribs may prevent
large portions of the table top from sagging, the ribs may allow
smaller, localized portions of the table top to sag. In particular,
because the distance between the table top and the bottom portion
of the rib is greater than the distance between the upper and lower
surfaces of the table top, this may allow localized portions of the
table top to sag. Additionally, because the strengthening ribs are
large and have an elongated length, they may support localized
portions of the table top differently than the other portions of
the table top. Thus, the upper surface of the table top may be
uneven because different portions of the table top are supported
differently.
BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION
[0011] A need therefore exists for structures constructed from
blow-molded plastic that eliminates or reduces some or all of the
above-described disadvantages and problems.
[0012] One aspect is a structure that can be constructed from
blow-molded plastic and have increased strength. Preferably the
blow-molded plastic structure has both increased strength and it is
lightweight, but the structure does not have to be lightweight and
high-strength.
[0013] Another aspect is a structure that can be constructed from
blow-molded plastic and include opposing surfaces. The opposing
surfaces may be separated by a generally constant or other
predetermined distances. For example, the opposing surfaces may
include one surface that is generally planar and the other surface
may include a plurality of depressions that are sized and
configured to increase the strength of the blow-molded structure.
The depressions may cover only a portion of the surface,
substantially all of the surface, or the entire surface.
[0014] Yet another aspect is a structure that can be constructed
from blow-molded plastic and the structure could have a variety of
suitable shapes and configurations, and the structures could be an
assortment of items and objects such tables, chairs, walls,
shelves, storage bins, boxes, containers, sheds, panels, fences,
playground equipment, sports equipment and the like. In particular,
the structures could be used to form all or a portion of a table
and basketball backboard. Desirably, the upper surface of the
tables and the front surface of the backboards are generally
planar, while the bottom or rear surfaces include a plurality of
depressions. It will be appreciated, however, that the structures
could have any desired arrangement or design.
[0015] Still another aspect is a structure that can be constructed
from blow-molded plastic and the structure can include a plurality
of depressions. Desirably the distance between the depressions may
be substantially decreased, which may substantially increase the
number of depressions formed in the blow-molded structure. This
increase in the number of depressions formed in the blow-molded
structure at first appears to increase the amount of plastic
material required to construct the structure because of the
increased surface area and number of depressions. The increased
number of depressions with the increased amount of plastic also
appears to increase the time the structure must be cooled during
the manufacturing process. In particular, the increased amount of
plastic may retain more heat and that would require a longer
cooling time before the structure could be removed from the mold.
Disadvantageously, if the structures cannot be removed as quickly
from the mold, then this would increase the cycle time required to
construct the blow-molded structures, which may increase costs and
time required to manufacture the structures. The increased number
of depressions and closer spacing of the depressions, however,
allows the outer wall of the blow-molded structure to be
constructed from thinner plastic. Thus, contrary to conventional
blow-molded structures, increasing the number of depressions allows
blow-molded structures with thinner walls to be constructed.
Significantly, the thinner walls allow less plastic to be used to
construct the blow-molded structure. The reduced amount of plastic
advantageously saves materials and resources. In addition, the
costs of the blow-molded structure may be decreased because less
plastic is required. Further, lightweight structures may be
constructed if less plastic is required to make the structure.
[0016] A further aspect is a structure that can be constructed from
blow-molded plastic with thinner outer walls and that may allow
heat to be dissipated more quickly during the manufacturing
process. Because the thinner outer walls allow heat to be
dissipated more quickly, the blow-molded structures may cool more
quickly and this may allow structures to be removed sooner from the
mold. Additionally, because the increased number of depressions may
provide more support for the opposing surfaces, the structures may
be removed from the mold at a higher temperature. Accordingly, the
manufacturing time and/or cycle time required to construct the
blow-molded structures may be reduced, which may increase the
output and/or efficiency of making the structures.
[0017] Yet another aspect is a structure that can be constructed
from blow-molded plastic and conventional reinforcing ribs and
beams are not required. In fact, reinforcing ribs or beams are
desirably not formed in the blow-molded structures because the ribs
may require thicker outer walls and increase the time of the
manufacturing process. The reinforcing ribs may also undesirably
interfere with other structures or features formed in the table
top. In addition, the structure may have a lower profile because
reinforcing ribs are not required. Advantageously, this may allow
the height or thickness of the blow-molded structures to be
decreased.
[0018] A further aspect is a structure that can be constructed from
blow-molded plastic and the depressions may be uniformly spaced to
create generally consistent and/or standardized arrangements. A
consistent arrangement of the depressions may help create a
structure with uniform characteristics. For example, a generally
constant pattern of depressions may create a structure with
generally uniform strength and structural integrity.
[0019] A still further aspect is a structure that can be
constructed from blow-molded plastic and the structure may include
one or more generally planar surfaces. Desirably the structure
includes a plurality of closely spaced depressions on one side and
a generally planar surface on the other side. This may allow
blow-molded structures with large generally planar surfaces, such
as tables and basketball backboards, to be quickly and efficiently
manufactured and constructed. In addition, the closely spaced
depressions may allow large planar surfaces to be created that do
not include significant sags, ripples or uneven surfaces.
[0020] Another aspect is a structure that may be constructed from
blow-molded plastic and include a plurality of depressions that are
formed in one surface and extended towards another surface. The
depressions may have different characteristics depending upon the
configuration of the depression. For example, the depressions may
have a length and a width and the characteristics of the
depressions may be different for the length and the width. In
particular, the depression may have increased strength along its
length in comparison to its width.
[0021] Still another aspect is a structure that may include a
plurality of depressions and the depressions may have a
non-circular configuration, such as rectangular, oblong, oval and
the like, and different characteristics. The depressions may also
have different characteristics depending upon the configuration of
the depression. For example, the depressions may have a
non-circular configuration with increased strength in one direction
in comparison to another direction. Advantageously, if the
depressions have different characteristics, then the depressions
can be arranged or configured so that the structure has certain
characteristics. In particular, the depressions may be arranged
into a pattern so that characteristics are maximized and/or the
structure has generally uniform characteristics. Thus, the
depressions may be aligned or otherwise formed into a pattern to
maximize or minimize one or more of these characteristics.
[0022] Yet another aspect is a structure that is constructed from
blow-molded plastic and includes depressions having the same
generally shape. Advantageously, the depressions may be arranged
into a pattern, such as a parallelogram. In particular, a first
depression may be disposed proximate second and fourth depressions.
The second depression may be disposed proximate the first and third
depressions. The third depression may be disposed proximate the
second and fourth depressions. The fourth depression may be
disposed proximate the first and third depressions. The first and
third depressions may be positioned at opposing corners of the
generally parallelogram shaped configuration, and the second and
fourth depressions may be positioned at the other opposing corners.
A fifth depression may be positioned proximate a central portion of
the generally parallelogram shaped configuration. The fifth
depression may be orientated at first angle. The first depression
may be disposed at an angle that is oblique to the first angle. The
second depression may be disposed at an angle that is oblique to
the first angle. The third depression may be disposed at an angle
that is oblique to the first angle. The fourth depression may be
disposed at an angle that is oblique to the first angle.
[0023] Still yet another aspect is a structure constructed from
blow-molded plastic with a plurality of depressions in a generally
parallelogram shaped configuration. The first depression may be
disposed proximate the second and fourth depressions. The second
depression may be disposed proximate the first and third
depressions. The third depression may be disposed proximate the
second and fourth depressions. The fourth depression may be
disposed proximate the first and third depressions. The first and
third depressions may be positioned at opposing corners of the
generally parallelogram shaped configuration. The second and fourth
depressions may be positioned at opposing corners of the generally
parallelogram shaped configuration. The first and third depressions
may be oriented generally perpendicular to each other. The second
and fourth depressions may be oriented generally perpendicular to
each other. The third depression may be orientated at a first
angle. The second depression may be orientated at angle that is
oblique to the first angle. The fourth depression may be orientated
at angle that is oblique to the first angle.
[0024] Yet another aspect is a structure constructed from
blow-molded plastic with a plurality of depressions formed into a
predetermined pattern, such as rows and/or columns. For example, a
first row of depressions may include depressions that alternate
between a first orientation and a second orientation. The first and
second orientations may be generally perpendicular to each other. A
second row of depressions, which may be adjacent the first row of
depressions, may alternate between a third orientation and a fourth
orientation. The third and fourth orientations may be generally
perpendicular to each other. The first orientation may be at an
angle that is oblique to the third and fourth orientations. The
second orientation may be at an angle that is oblique to the third
and fourth orientations. The third orientation may be at an angle
that is oblique to the first and second orientations. The fourth
orientation may be at an angle that is oblique to the first and
second orientations.
[0025] These and other aspects, features and advantages of the
present invention will become more fully apparent from the
following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The appended drawings contain figures of preferred
embodiments to further clarify the above and other aspects,
advantages and features of the present invention. It will be
appreciated that these drawings depict only preferred embodiments
of the invention and are not intended to limits its scope. The
invention will be described and explained with additional
specificity and detail through the use of the accompanying drawings
in which:
[0027] FIG. 1A is a bottom perspective view of an exemplary
embodiment of a structure constructed from blow-molded plastic, the
exemplary structure being a blow-molded plastic table top;
[0028] FIG. 1B is a bottom view of a portion of the blow-molded
structure shown in FIG. 1A, illustrating a plurality of depressions
formed in a portion of the blow-molded structure;
[0029] FIG. 2A is an enlarged view of an exemplary embodiment of a
depression;
[0030] FIG. 2B is an enlarged view of another exemplary embodiment
of a depression;
[0031] FIG. 2C is an enlarged view of yet another exemplary
embodiment of a depression;
[0032] FIG. 3A is a bottom view of the depression shown in FIG. 2C,
illustrating an exemplary orientation of the depression;
[0033] FIG. 3B is a bottom view of the depression shown in FIG. 2C,
illustrating another exemplary orientation of the depression;
[0034] FIG. 3C is a bottom view of the depression shown in FIG. 2C,
illustrating yet another exemplary orientation of the
depression;
[0035] FIG. 3D is a bottom view of the depression shown in FIG. 2C,
illustrating still another exemplary orientation of the
depression;
[0036] FIGS. 4, 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B, 8C, 8D, 9A, and 9B
illustrate exemplary patterns of depressions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] This invention is generally directed towards structures
constructed from blow-molded plastic. The principles of the present
invention, however, are not limited to blow-molded plastic
structures. It will be understood that, in light of the present
disclosure, the structures disclosed herein can be successfully
used in connection with structures constructed from other types of
materials and processes.
[0038] Additionally, to assist in the description of the
blow-molded plastic structures, words such as top, bottom, front,
rear, right and left are used to describe the accompanying figures.
It will be appreciated, however, that the blow-molded plastic
structures can be located in a variety of desired
positions--including various angles, sideways and even upside down.
A detailed description of the blow-molded plastic structures now
follows.
[0039] As shown in FIG. 1A, a table top 2 may be constructed from
blow-molded plastic. It will be appreciated, however, that a wide
variety of structures may be constructed from blow-molded plastic
including, for example, tables, chairs, walls, partitions, shelves,
basketball backboards, storage bins, boxes, containers, sheds,
sporting equipment, panels, fences and the like. One of ordinary
skill in the art will also appreciate that all or a portion of
these structures may be constructed from blow-molded plastic.
[0040] As shown in FIG. 1A, the table top 2 may include an upper or
working surface 4 and a lower or mounting surface 6. The table top
2 may be supported by one or more legs or support pedestals, which
are not shown in the accompanying figures. The table top preferably
includes a hollow interior portion, which is preferably disposed
between the upper surface 4 and the lower surface 6. The hollow
interior portion is preferably integrally formed in table top 2 as
part of a blow-molding process. It will be appreciated that the
hollow interior portion may be filled with a material, such as foam
or other suitable material.
[0041] The one or more legs or support pedestals are preferably
movable between a first position in which the legs extend outwardly
from the table top 2 and a second position in which the legs are
positioned near and generally parallel to the lower surface 6 of
the table top. In particular, the legs may each be pivotally or
otherwise movably connected to the table top 2 and/or a table
frame. Additionally, one or more support braces may be connected to
the one or more legs and table top 2 and/or the table frame to help
support the legs.
[0042] The table frame may include a first side rail and an
opposing second side rail. Preferably, the first side rail is
disposed substantially parallel to the second side rail, and the
side rails preferably extend generally along the length of the
table top 2. The length and configuration of the side rails may
depend, for example, upon the length and configuration of the table
top 2. In addition, the side rails may extend only a portion of the
length of the table top 2. The side rails and/or the table top may
include one or more apertures that are sized and configured to
facilitate attachment of the legs and/or one or more cross bars to
the frame and/or the table top. Advantageously, the frame may help
prevent bowing, twisting, or deformation of table top 2, but it
will be appreciated that table does not require the use of a frame
and/or side rails.
[0043] The frame may be attached to a downwardly extending lip 8
located near the outer periphery of the table top 2. For example,
the frame may be attached to an inner surface of the downwardly
extending lip 8 by one or more fasteners. It will be understood
that other suitable means or methods for attaching the frame to the
table top 2 may be employed, including, but not limited to, rivets,
screws, bolts, glues, epoxies, or other bonding materials.
[0044] It will be appreciated that the frame and the legs may be
configured in a variety of ways, and the frame and legs may have
other suitable designs, shapes and sizes. For example, the legs may
include only a single elongated support member or multiple
elongated support members, and the legs may be constructed as a
single component or multiple components that are connected
together. It will further be appreciated that the legs need not be
in pivotal engagement with table top 2 to be collapsible. For
example, the legs may be detachably connected to the table top 2
such that when it is desired to collapse the table for storage, the
legs are detached from the table top.
[0045] Tables with other suitable features and configurations are
disclosed in Assignee's U.S. Pat. No. 6,112,674, entitled PORTABLE
FOLDING UTILITY TABLE WITH CENTER SUPPORT ASSEMBLY; U.S. Pat. No.
6,431,092, entitled PORTABLE FOLDING UTILITY TABLE WITH CENTER
SUPPORT AND OFF-SET SUPPORT LEGS; U.S. Pat. No. 6,508,184, entitled
LIGHTWEIGHT FOLDING TABLE WITH SELF-FIXTURING LEG ATTACHMENT; U.S.
patent application Ser. No. 10/096,814 entitled PORTABLE FOLDING
UTILITY TABLE WITH INTEGRAL TABLE TOP AND LIP, filed on Mar. 12,
2002; U.S. patent application Ser. No. 10/097,037, entitled
PORTABLE FOLDING UTILITY TABLE WITH FRAME FASTENED TO INNER SURFACE
OF LIP, filed on Mar. 12, 2002; and U.S. patent application Ser.
No. 10/216,342, entitled TABLE WITH BLOW MOLDED TOP AND PIVOTALLY
ATTACHED LEGS, filed on Aug. 10, 2002; and U.S. patent application
Ser. No. 10/340,018, entitled PERSONAL TABLE, filed on Jan. 9,
2003. Each of these patents and applications are incorporated by
reference.
[0046] The table top 2 may include a number of features that
facilitate attachment of the legs, one or more cross bars, and/or
the table frame to the table top. For example, the table top 2 may
include mounting members and securing members that are preferably
integrally formed in the table top as part of a unitary, one-piece
structure. Preferred embodiments of suitable mounting members and
securing members are disclosed in Assignee's U.S. Pat. No.
6,530,331, entitled PORTABLE FOLDING UTILITY TABLE WITH INTEGRAL
RECEIVING MEMBERS, which is incorporated by reference.
[0047] As seen in FIGS. 1A and 1B, a portion 10 of the bottom
surface 6 of the table top 2 may include a plurality of depressions
12 that are preferably sized and configured to increase the
strength and structural integrity of the table top. The depressions
12 are preferably formed in the bottom surface 6 of the table top 2
and the depressions extend towards the upper surface 4 of the table
top. As discussed in more detail below, the ends of the depressions
12 may contact or engage the upper surface 4 of the table top 2, or
the ends of the depressions may be spaced from the upper surface of
the table top.
[0048] The depressions 12 preferably cover substantially the entire
bottom surface 6 of the table top, but it will be appreciated that
the depressions may cover only a portion of bottom surface of the
table top. Additionally, while the depressions 12 are shown and
described as being located in the bottom surface 6 of the table top
2, the depressions could be formed in any desired portion of the
table top and may cover only a portion of the table top.
[0049] The depressions 12 are preferably arranged into a
predetermined pattern or array, which may increase the strength
and/or structural integrity of the table top 2. In particular, the
depressions 12 are preferably spaced closely together and the
depressions may cover substantially the entire bottom surface 6 of
the table top 2. Advantageously, the closely spaced depressions 12
may eliminates the elongated ribs and beams that were required in
many conventional structures constructed from blow-molded
plastic.
[0050] As shown in FIG. 1B, the depressions 12 are desirably formed
into a predetermined pattern, such as rows. For example, the
pattern may include one row of depressions 12 staggered with
respect to an adjacent row of depressions. On the other hand, a row
of depressions 12 may be aligned with an adjacent row of
depressions 12. It will be appreciated that the depressions 12 may
be formed in any suitable pattern or arrangement, including
geometric, random, scattered, etc. depending, for example, upon the
size and configuration of the table.
[0051] Desirably, the depressions 12 are formed in a predetermined
pattern that minimizes or reduces the distance between the
depressions. Advantageously, reducing the distance between the
depressions may reduce the unsupported areas of the opposing
surface. Reducing the distance between the depressions 12 may also
increase the structural integrity and strength of the blow-molded
structure. In addition, reducing the distance between the
depressions 12 may increase the surface smoothness of the opposing
surface. Thus, the depressions 12 are desirably closely spaced on
the bottom surface 6 of the table top 2 such that the depressions
are separated by a reduced distance. This may creates a table top 2
with greater strength and structural integrity, and the upper
surface 4 of the table top may have increased smoothness.
[0052] Advantageously, the smaller distance between the depressions
12 may increase the structural integrity and strength of the
blow-molded structure, which may allows the thickness of the outer
wall of the blow-molded structure to be decreased. Accordingly,
less plastic may be used to construct the blow-molded plastic
structures because of the reduced outer wall thickness. Because
less plastic is required to construct the blow-molded structure,
that may allow the cost of the structure to be decreased. In
addition, the blow-molded structure may cool more quickly during
the manufacturing process because of the thinner outer walls. This
may allow the blow-molded structure to be removed from the mold
more quickly and it may allow the structure to be removed at a
higher temperature because it dissipates heat more rapidly.
Significantly, this may decrease the cycle time required to
construct blow-molded structures and it may increase manufacturing
efficiency.
[0053] Accordingly, increasing the number of depressions 12 and
decreasing the distance between the depressions may increase the
strength and structural integrity of blow-molded structures such as
the table top 2. This is contrary to previous blow-molded
structures that used strengthening ribs to increase the strength
and structural integrity of the structures. Specifically, it was
previously believed that stronger blow-molded structures were
created by making the walls of the structure thicker and/or adding
strengthening ribs. Disadvantageously, the thicker walls and
strengthening ribs often required additional plastic and longer
manufacturing times.
[0054] Increasing the number of depressions and decreasing the
distance between the depressions provides the surprising and
unexpected result that less plastic can be used to construct the
blow-molded structures. Specifically, it was previously thought
that a larger amount of plastic would be required because of the
increased number of depressions in the blow-molded structure. The
increased number of depressions, however, allows thinner outer
walls to be used and that allows the overall amount of plastic used
to construct the blow-molded structure to be decreased.
Additionally, the increased number of closely spaced depressions 12
may increase the structural integrity of the structure, despite the
fact that disruptions in the continuity of surface were previously
thought to weaken the structure.
[0055] The depressions 12 are preferably arranged in a
predetermined pattern to create a structure with generally uniform
characteristics. For example, the depressions 12 are preferably
arranged in staggered rows to decrease the distance between the
depressions. Additionally, the depressions 12 preferably have a
generally constant and uniform spacing across the surface of the
structure. In particular, even if other features, objects or items
are formed in the surface, the depressions 12 are preferably
arranged into a generally uniform and consistent pattern. Thus, one
or more depressions may be formed in the other features, objects or
items formed in the surface. For example, one or more depressions
12 may be formed in channels or receiving portions located in the
bottom surface 6 of the table top 2 in order to maintain a
generally uniform and consistent pattern. In addition, the
depressions 12 may be spaced about these other features, objects or
items formed in the surface to keep a generally uniform and
consistent pattern. Thus, the depressions are preferably spaced so
that the distance between the depressions is minimized or otherwise
reduced, substantially the entire surface is covered with
depressions, and the depressions are located in a generally uniform
and consistent pattern even if other features, objects or items are
formed in the blow-molded structure.
[0056] In order to obtain a generally uniform and consistent
pattern of depressions, it is generally desirable to eliminate or
minimize or reduce other features, objects or items formed in the
blow-molded structure. Thus, for example, strengthening ribs are
preferably eliminated so that they do not interfere or disturb the
generally uniform and consistent pattern of depressions.
[0057] As seen in FIG. 1B, the depressions 12 are preferably
closely spaced to minimize or otherwise reduce the distance between
the depressions. In particular, the depressions are formed in the
bottom surface 6 and the depressions extend towards the upper
surface 4 of the table top 2. Each of the depressions preferably
includes a side wall and an end. The ends of the depressions 12 may
contact or engage the upper surface 4 of the table top 2.
Advantageously, this may help support the upper surface 4 of the
table top 2 and the closely spaced depressions 12 may help to
minimize the unsupported areas of the upper surface of the table
top. The depressions 12 are preferably integrally formed in the
table top 2 as part of a unitary, one-piece structure. In
particular, the depressions 12 are preferably integrally formed in
the table top 2 during the blow-molding process.
[0058] The depressions 12 are preferably sized and configured to
allow the depressions to be closely spaced. In particular, the side
walls of the depressions 12 are preferably formed at a steep angle
to allow the depressions to be closely spaced. For example, the
side walls of the depressions 12 are preferably at an angle between
about 60.degree. and about 85.degree. relative to the lower surface
6 of the table top 2. More preferably, the side walls are
positioned at an angle of 75.degree. or greater with respect to the
lower surface 6 of the table top 2. It will be appreciated that the
side walls may be positioned at any desired angle relative to the
lower surface 6 of the table top 2 depending, for example, upon the
configuration of the depressions 12 formed in the table top 2.
[0059] The depressions 12 may have a height h generally equal to a
thickness t of the table top 2, where the thickness t is the
distance separating the lower surface 6 and the upper surface 4.
When the depressions 12 have a height h generally equal to the
thickness t of the table top 2, the ends of the depressions
desirably contact or engage the upper surface 4 of the table top at
a contact area. It will be appreciated that the size of the contact
area may vary, for example, upon the shape and configuration of the
depression. In addition, one or more of the depressions 12 may be
separated by a distance d. The distance d is preferably measured
from the center of one depression to the center of an adjacent
depression. Desirably, the distance d separating adjacent
depressions 12 is generally consistent so that a pattern of
depressions with generally uniform and constant spacing is
created.
[0060] It will be appreciated that the ends of the depressions 12
do not have to contact or engage the upper surface 4 of the table
top 2. For example, the ends of the depressions 12 may be disposed
proximate to and/or spaced part from the upper surface 4 of the
table top 2. Thus, the height h of depressions would be less than
the thickness t of the table top 2.
[0061] As discussed above, the distance d separating the
depressions 12 is preferably minimized (or otherwise reduced) and
the depressions are preferably located in a generally uniform and
consistent arrangement so that the table top 2 is lightweight,
high-strength structure with relatively uniform properties. In
particular, the depressions 12 are preferably arranged in a tightly
packed array that covers substantially all the lower surface 6 of
the table top 2. For example, in order to create a tightly packed
array of depressions 12, the distance d between adjacent
depressions is preferably less than or equal to three times the
thickness t of the table top 2. In order to create a more tightly
packed array of depression, the distance d between adjacent
depressions may be less than or equal to two times the thickness t
of the table top 2. The distance d between adjacent depressions 12
may also be equal to or less than the thickness t of the table top
2. Additionally, the distance d between adjacent depressions 12 may
be less than or equal to three times the height h of the table top
2. Further, the distance d between adjacent depressions may be two
or less times than the height h of the table top 2. Finally, the
distance d between adjacent depressions may be equal to or less
than the height h of the table top 2. For example, in an exemplary
embodiment, the distance d between adjacent depressions may be
between about 1 to 3 inches, such as about 1.5 inches. It will be
appreciated that the distance d may be larger or smaller depending,
for example, upon the size, configuration and/or intended use of
the table top 2.
[0062] As discussed above, conventional blow-molded structures
often incorporated one or more reinforcing ribs or beams in an
attempt to provide increased strength and support for blow-molded
structures such as a table top 2. The closely spaced depressions
12, however, provide for the surprising and unexpected result that
an increased number of depressions that are closely spaced together
can create a stronger and lighter weight table top 2. Preferably,
the depressions are consistently spaced over substantially all the
entire surface of table top 2 so that substantially the entire
surface of table top 2 is provided with increased strength and
structural integrity. Advantageously, reinforcing ribs or beams may
be eliminated so that the depressions can cover substantially the
entire surface. It will be appreciated, however, that only a
portion of the table top 2 may have a plurality of closely spaced
depressions, for example, in order to provide increased structural
strength to only those particular portions of table top 2. Further,
the table top 2 may include reinforcing ribs or beams in any
location, if desired.
[0063] The increased number of closely spaced depressions 12 may
also allow blow-molded structures to be created with smoother, more
planar surfaces. For example, the closely spaced depressions 12 may
more uniformly support a surface and/or the surface may have more
uniform characteristics. Thus, the surface may be smoother and
generally located in the same plane. Advantageously, planar
surfaces may be used to create a number of suitable objects, such
as the table tops described above.
[0064] The depressions 12 may have a variety of shapes and
configurations. For example, the depressions 12 may have a
non-circular configuration such as the depressions 12a shown in
FIG. 2A. The generally oblong depressions 12a may have a pair of
opposing generally linear sides extending between a pair of
opposing generally curvilinear ends. The depressions 12 may also
have other suitable shapes and configurations such as the generally
rectangular depression 12b with rounded corners shown in FIG. 2B or
the generally elliptical configuration shown in FIG. 2C. Of course,
the depressions 12 could have other suitable shapes and
configurations.
[0065] As shown in FIGS. 2A-2C, the depressions 12a, 12b, 12c
respectively may include a first axis 16a, 16b, 16c and a second
axis 18a, 18b, 18c. The first axes 16a, 16b, 16c are preferably
centrally located and they may define a width of the depression,
and the second axes 18a, 18b, 18c may define a length of the
depression. The widths 16a, 16b, 16c of the depressions 12a, 12b,
12c are preferably less than the lengths of the depressions 18a,
18b, 18c, and the widths may advantageously be about 40 to about 60
percent of the lengths. The lengths of the depressions may also be
about 1.5 to about 2.5 times the widths of the depressions, if
desired. When the length of the depression is longer than the width
of the depression, the axis 18a, 18b, 18c may be referred to as the
"major axis" and the axis 16a, 16b, or 16c may be referred to as
the "minor axis." The relative lengths and widths of the
depressions 12 may be larger, smaller, or the same depending, for
example, on the particular configuration of the depressions.
[0066] Preferably, the axes 16a, 16b, and 16c respectively
intersect and/or are generally perpendicular to the axes 18a, 18b,
and 18c as shown in FIGS. 2A-2C. The axes 16a, 16b, 16c and axes
18a, 18b, 18c, however, does not have to be generally
perpendicular. As shown in the accompanying figures, the
depressions 12a, 12b, and 12c respectively may also include a
central portion 20a, 20b, and 20c, which is preferably located at
or proximate an intersection of the axes 16 and 18 and/or a center
of the depression.
[0067] The depressions 12 may also have a generally symmetrical
configuration. For example, as shown in FIGS. 2A-2C, the
depressions 12a, 12b, and 12c may be respectively symmetrical about
the axes 16a, 16b, and 16c and/or the axes 18a, 18b, and 18c.
Advantageously, the generally symmetrical depressions 12a, 12b, and
12c may provide a more consistent, uniform strength, especially
when applied in a variety of desired patterns of depressions. The
depressions, however, do not have to be symmetrical.
[0068] It will be appreciated that the depressions 12 do not
require a non-circular configuration, a generally oblong
configuration or a generally symmetrical configuration. Further,
the depressions 12 may have other suitable dimensions, shapes,
and/or configurations, depending on the particular configuration of
the table top 2. Depressions and/or blow-molded structures with
other suitable features and configurations are disclosed in
Assignee's U.S. patent application Ser. No. 10/409,000, filed Apr.
8, 2003 and entitled HIGH STRENGTH, LIGHTWEIGHT BLOW-MOLDED PLASTIC
STRUCTURES, which is incorporated by reference.
[0069] As shown in FIGS. 3A-3D, the depressions 12 may be disposed
in a variety of orientations relative to a reference axis 22, and
these orientations may be used to arrange the depressions in a
variety of patterns. Advantageously, the depressions may be
arranged into patterns in order to increase the strength and/or
decrease the weight of the table top 2.
[0070] For example, in an orientation 24, as shown in FIG. 3A, the
axis 18 of the depression 12 may be generally aligned with the
reference axis 22 and/or at an about 0 degrees angle relative to
the reference axis. If desired, the axis 18 of the depression 12
may be spaced apart from the reference axis 22 and/or the
depression 12; and the axis 18 may be generally parallel to the
reference axis 22.
[0071] In another orientation 26, as shown in FIG. 3B, the axis 18
of the depression 12 may be at an oblique angle to the reference
axis 22. This oblique angle may be between about 35 and 55 degrees,
such as about 45 degrees.
[0072] In yet another orientation 28, as shown in FIG. 3C, the axis
18 of the depression 12 may be at an oblique angle to the reference
axis 22. For example, the angle could be between about 125 and
about 145 degrees, such as about a 135 degrees angle to the
reference axis 22.
[0073] In still another orientation 30, as shown in FIG. 3D, the
axis 18 of the depression 12 may be generally perpendicular to the
reference axis 22, so that it is at about a 90 degrees angle to the
reference axis 22.
[0074] As shown, the orientations 24 (FIG. 3A) and 30 (FIG. 3D) may
be generally perpendicular to each other, and the orientations 26
(FIG. 3B) and 28 (FIG. 3C) may be generally perpendicular to each
other. It will be appreciated that the depressions 12 may have
other suitable orientations depending on the particular
configuration of the table top 2.
[0075] As discussed above, the depressions 12 may have a variety of
shapes, configurations, dimensions, and/or orientations. As shown
in FIGS. 4-9B, the depressions 12 may be arranged in a variety of
exemplary patterns, for example, to increase the strength and/or to
decrease the weight of the table top 2. In addition, the
depressions 12 may have different characteristics such as strength,
rigidity, thickness and the like. Further, different portions of
the depressions 12 may have different characteristics. For example,
the depressions may be sized and configured to have increased
strength along the length of the depression in comparison to the
width of the depression. Thus, for instance, the depressions may
have greater strength along a major axis and lesser strength along
a minor axis. Advantageously, the depressions 12 may be arranged
and/or configured to take advantage of these characteristics. In
particular, the depressions 12 may be arranged to increase the
strength and/or decrease the weight of blow-molded plastic
structures.
[0076] As shown in FIG. 4, the depressions 12 may be arranged into
a pattern 32 and the pattern may include rows 34, 36, 38 and 40.
Each of the rows may include one or more depressions 12. For
example, the row 34 preferably includes a plurality of depressions
that alternate between the orientation 24 (as shown in FIG. 3A) and
the orientation 30 (as shown in FIG. 3D); the row 36 preferably
includes a plurality of depressions that alternate between the
orientation 26 (as shown in FIG. 3B) and the orientation 28 (as
shown in FIG. 3C); the row 38 preferably includes a plurality of
depressions that alternate between the orientation 30 (as shown in
FIG. 3D) and orientation 24 (as shown in FIG. 3A); and the row 40
preferably includes a plurality of depressions that alternate
between the orientation 26 (as shown in FIG. 3B) and the
orientation 28 (as shown in FIG. 3C). The pattern 32, as shown in
the rows 34, 36, 38, 40, may be partially or completely repeated
depending, for example, upon the size and configuration of the
table top.
[0077] As shown in FIG. 4, the depressions 12 in the rows 34 and 38
are generally aligned, and the depressions in the rows 36 and 40
are also generally aligned. In particular, the depressions of the
rows 34 are generally aligned with the depressions of the rows 38
in pairs along their center portions, and the depressions of the
rows 36 are generally aligned with the depressions of the rows 40
in pairs along their center portions. Also, the depressions of rows
36 and 40 are generally offset to the depressions of rows 34 and 38
along their center portions. In particular, the rows 36 and 40
preferably include depressions spaced about half the distance
between the depressions of the rows 34 and 38.
[0078] As shown, the generally aligned pairs of depressions 12 in
rows 34, 38 preferably have orientatior is that are generally
perpendicular to each other, and the generally aligned pairs of
depressions in rows 36, 40 preferably have orientations that are
generally perpendicular to each other. However, it will be
appreciated that the depressions in the rows 34 and 38 need not be
generally aligned or have particular relative orientations, and the
depressions in the rows 36 and 40 need not be generally aligned or
have particular relative orientations. In fact, the depressions
could have any suitable arrangement and pattern.
[0079] As shown in FIG. 5A, the depressions 12 may be arranged in a
pattern 42 with one or more rows and each row preferably includes
one or more depressions. For example, the pattern 42 may include a
first set of one or more rows (such as rows 44, 46) and second set
of one or more rows (such as rows 48, 50). The one or more rows of
the first set are preferably generally perpendicular to one or more
rows of the second set. In particular, the row 44 preferably
includes a plurality of depressions that alternate between the
orientation 24 (as shown in FIG. 3A) and the orientation 30 (as
shown in FIG. 3D); the row 46 preferably includes a plurality of
depressions that alternate between the orientation 30 (as shown in
FIG. 3D) and orientation 24 (as shown in FIG. 3A); the row 48
preferably includes a plurality of depressions that alternate
between the orientation 24 (as shown in FIG. 3A) and the
orientation 30 (as shown in FIG. 3D); and the row 50 preferably
includes a plurality of depressions that alternate between the
orientation 30 (as shown in FIG. 3D) and orientation 24 (as shown
in FIG. 3A).
[0080] As shown in FIG. 5A, the row 48 is preferably generally
perpendicular to the row 44 and/or the row 46, and the row 48 is
preferably generally parallel to the row 50. Also, the row 50 is
preferably generally perpendicular to the row 44 and/or the row 46,
and the row 50 is preferably generally parallel to the row 48.
Accordingly, the row 44 and/or the row 46 are preferably generally
perpendicular to the row 48 and/or the row 50.
[0081] As shown in FIG. 5A, the row 48 includes at least one
depression of the row 44 and/or at least one depression of the row
46, and the row 50 includes at least one depression of the row 44
and/or at least one depression of the row 46. Likewise, the row 44
includes at least one depression of the row 48 and/or at least one
depression of the row 50, and the row 46 includes at least one
depression of the row 48 and/or at least one depression of the row
50. It will be appreciated that the rows 44, 46, 48, 50 and the
corresponding depressions 12 could have other suitable arrangements
and configurations.
[0082] As shown in FIG. 5B, the pattern 42 may also include rows 52
and 54. The row 52 preferably includes a plurality of depressions
that alternate between the orientation 26 (as shown in FIG. 3B) and
the orientation 28 (as shown in FIG. 3C). The row 54 preferably
includes a plurality of depressions that alternate between the
orientation 28 (as shown in FIG. 3C) and the orientation 26 (as
shown in FIG. 3B). As shown in FIG. 5B, the depressions of the rows
44 and 46 are generally aligned in pairs, and the depressions of
the rows 48 and 50 are generally aligned in pairs along their
center portions. Also, the rows 44 and 46 are generally offset to
the row 52 along their center portions, and the rows 48 and 50 are
generally offset to the row 52 along their center portions.
[0083] As shown in FIG. 5B, the row 52 is preferably generally
parallel to the row 44 and/or the row 46, and the row 52 is
preferably generally perpendicular to the row 48, the row 50,
and/or the row 54. The row 54 is preferably generally parallel to
the row 48 and/or the row 50, and the row 54 is preferably
generally perpendicular to the row 44, the row 46, and/or the row
52.
[0084] As shown in FIG. 5B, the row 52 is preferably is preferably
positioned between the row 44 and the row 46, and the depressions
of the row 52 are generally offset to the depressions of rows 44
and 46 along their center portions. Also, the row 54 is preferably
is preferably positioned between the row 48 and the row 50, and the
depressions of the row 54 are generally offset to the depressions
of rows 48 and 50 along their center portions. One of ordinary
skill in the art will appreciate that the rows 44, 46, 48, 50, 52,
54 and the corresponding depressions 12 could also have other
suitable arrangements and configurations.
[0085] As shown in FIG. 6A and 7A, the depressions 12 could be
arranged into other suitable patterns. For example, the pattern 56
could include a plurality of rows including a first set of rows
with rows 58, 60 and second set of rows with rows 62, 64. Also, as
shown in FIG. 7A, the depressions 12 may be arranged a pattern 66
with a plurality of rows including a first set of rows with rows
68, 70 and second set of rows with rows 72, 74. As shown in FIG. 6A
and 7A, one or more rows of the first set are preferably generally
perpendicular to one or more rows of the second set, and one or
more rows of the first set may intersect one or more rows of the
second set to form a generally X-shaped configuration. Also, the
rows of the first set are preferably parallel to each other, and
the rows of the second set are preferably parallel to each other.
Further, the depressions 12 of the one or more rows of the first
set preferably have a first orientation, and the depressions of the
one or more rows of the second set preferably have a second
orientation that is generally perpendicular to the first
orientation.
[0086] In greater detail, the depressions 12 may be arranged into a
pattern of a plurality of rows with each row including a plurality
of depressions. For example, the depressions 12 may be arranged a
pattern 76 (as shown in FIG. 6B) including a first set of rows with
rows 78, 80 and second set of rows with rows 82, 84. The
depressions 12 may also be arranged a pattern 86 (as shown in FIG.
7B) including a first set of rows with rows 88, 90 and second set
of rows with rows 92, 94.
[0087] As shown in FIG. 6B and 7B, each row of the first set of
rows preferably includes a plurality of depressions that alternate
between a first orientation and a second orientation, and each row
of the second set of rows preferably includes a plurality of
depressions that alternate between the second orientation and a
third orientation. The first orientation and the third orientation
are preferably generally perpendicular to each other. The second
orientation is preferably at an oblique angle to the first
orientation and/or the third orientation, at an about 45 degrees
angle to the first orientation and/or the third orientation, and/or
at an about 35 to about 55 degrees angle to the first orientation
and/or the third orientation.
[0088] As shown in FIG. 6A and 7A, one or more rows of the first
set are preferably generally perpendicular to one or more rows of
the second set, and one or more rows of the first set may intersect
one or more rows of the second set to form a generally X-shaped
configuration. Also, the rows of the first set are preferably
parallel to each other, and the rows of the second set are
preferably parallel to each other. Further, one or more rows of the
first set may each include at least one depression from some or all
of the one or more rows of the second set, and one or more rows of
the second set may each include at least one depression from some
or all of the one or more rows of the first set. It will be
understood that the rows and depressions 12 could also have other
suitable arrangements and configurations.
[0089] As shown in FIG. 8A-8D, the depressions 12 may also be
arranged a pattern of a plurality of depressions and the pattern
could include a first depression, a second depression, a third
depression, a fourth depression and a fifth depression. The first
depression, the second depression, the third depression, and the
fourth depression may be arranged in a generally square shaped
configuration, a generally rectangular shaped configuration, and/or
a generally parallelogram shaped configuration. The fifth
depression may be disposed proximate the first, second, third, and
fourth depressions. For example, as shown in FIG. 8A, the
depressions 12 may be arranged a pattern 96 including a depression
98, a depression 100, a depression 102, a depression 104, and a
depression 106. As discussed above, the depressions 98, 100, 102,
and 104 could arranged in a generally square shaped configuration,
a generally rectangular shaped configuration, and/or a generally
parallelogram shaped configuration 108. As shown in FIG. 8B, the
depressions 12 could be arranged into other suitable patterns. For
example, the pattern 110 could include a depression 112, a
depression 114, a depression 116, a depression 118 and a depression
120. The depressions 112, 114, 116 and 118 may be arranged in a
generally square shaped configuration, a generally rectangular
shaped configuration, and/or a generally parallelogram shaped
configuration 122. In yet another example, as shown in FIG. 8C, the
depressions 12 may be arranged a pattern 124 including a depression
126, a depression 128, a depression 130, a depression 132, and a
depression 134; and the depressions 126, 128, 130, and 132 may be
arranged in a generally square shaped configuration, a generally
rectangular shaped configuration, and/or a generally parallelogram
shaped configuration 136. In still another example, as shown in
FIG. 8D, the depressions 12 may be arranged a pattern 138 including
a depression 140, a depression 142, a depression 144, a depression
146, and a depression 148; and the depressions 140, 142, 144, and
146 arranged in a generally square shaped configuration, a
generally rectangular shaped configuration, and/or a generally
parallelogram shaped configuration
[0090] As shown in FIG. 8A-8D, the fifth depression may be disposed
at or proximate the center portion of the generally square shaped,
rectangular shaped, and/or parallelogram shaped configuration. The
fifth depression may be substantially equally spaced from each of
the first, second, third, and fourth depressions. The fifth
depression preferably has an orientation at an oblique angle to, at
an about 45 degrees angle to, at an about 35 to about 55 degrees
angle to, and/or different from some or all of the respective
orientations of the first, second, third, and fourth depressions.
The patterns 96, 110, 124 and 138 may include the first, second,
third, and fourth depressions without the fifth depression.
[0091] As shown in FIG. 8A 8D, the first and second depressions may
have a first orientation and may form opposing corner portions of
the generally square shaped, rectangular shaped, and/or
parallelogram shaped configuration, and the third and fourth
depressions may have a second orientation and may form opposing
corner portions of the configuration. As shown in FIG. 8B, some or
all of the first, second, third, and fourth depressions may each
have a major axis intersecting the fifth depression and/or
intersecting the center portion of the fifth depression. As shown
in FIGS. 8A, 8C and 8D, some or all of the first, second, third,
and fourth depressions may each have a major axis not intersecting
the fifth depression. As shown in FIGS. 8A, some or all of the
first, second, third, and fourth depressions may each have a minor
axis intersecting the fifth depression and/or intersecting the
center portion of the fifth depression. As shown in FIGS. 8B, 8C
and 8D, some or all of the first, second, third, and fourth
depressions may each have a minor axis not intersecting the fifth
depression. One of ordinary skill in the art will appreciate that
the depressions could also have other suitable arrangements and
configurations.
[0092] As shown in FIG. 9A and 9B, the depressions 12 may be
arranged into other suitable patterns, such as patterns 152 and
154. These patterns 152, 154 may include a first depression, a
second depression, a third depression, and a fourth depression
preferably arranged in a generally square shaped configuration, a
generally rectangular shaped configuration, and/or a generally
parallelogram shaped configuration, such as configurations 156 and
158. The first and second depressions preferably are proximate each
other and form a first side of the generally square shaped,
rectangular shaped, and/or parallelogram shaped configuration. The
second and third depressions preferably are proximate each other
and form a second side of the generally square shaped, rectangular
shaped, and/or parallelogram shaped configuration. The third and
fourth depressions preferably are proximate each other and form a
third side of the generally square shaped, rectangular shaped,
and/or parallelogram shaped configuration. The fourth and first
depressions preferably are proximate each other and form a fourth
side of the generally square shaped, rectangular shaped, and/or
parallelogram shaped configuration. Accordingly, the first and
third depressions may form opposing corner portions of the
generally square shaped, rectangular shaped, and/or parallelogram
shaped configuration, and the second and fourth depressions may
form opposing corner portions of the configuration.
[0093] As shown in FIG. 9A and 9B, the first depression preferably
has a first orientation, the second depression has a second
orientation, the third depression has a third orientation, and the
fourth depression has a fourth orientation. The first and third
orientations are preferably generally perpendicular to each other,
and the second and fourth orientations are preferably generally
perpendicular to each other. In one embodiment, each of the first,
second, third, and fourth depressions may have a different
orientation. The first orientation and/or the third orientation may
be at an oblique angle to the second orientation and/or the fourth
orientation, at an about 45 degrees angle to the second orientation
and/or the fourth orientation, and/or at an about 35 to about 55
degrees angle to the second orientation and/or the fourth
orientation. Also, the second orientation and/or the fourth
orientation may be at an oblique angle to the first orientation
and/or the third orientation, at an about 45 degrees angle to the
first orientation and/or the third orientation, and/or at an about
35 to about 55 degrees angle to the first orientation and/or the
third orientation. One of ordinary skill in the art will appreciate
that the depressions could also have other suitable arrangements
and configurations.
[0094] The blow-molded plastic structure may include one pattern
that covers all or just a portion of the structure. In addition,
the structure may include different patterns, for example, on
different portions of the structure. Thus, one or more of the
patterns discussed above (such as patterns 32, 42, 56, 76, 66, 86,
96, 110, 124, 138, 152, and 154) may be used in connection with all
or a portion of the blow-molded structure.
[0095] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive.
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