Plastic blow-molded panel with improved structural geometry

• US 6,826,887 B2
• Filed: 02/28/2003
• Issued: 12/07/2004
• Est. Priority Date: 02/28/2003
• Status: Active Grant

• Current Assignee: Rubbermaid Incorporated (Newell Brands Inc.)
• Original Assignee: Rubbermaid Incorporated (Newell Brands Inc.)
• Inventors: Skov, Erik L.
• Primary Examiner(s): SLACK, NAOKO N
• Application Number:
  US10/376,803
• Publication Number:
  US 20040168394A1
• Time in Patent Office: 648 Days
• Field of Search: 526/30, 527/931, 523/091, 527/901, 521/79, 521/77, 108/57.28, 108/901, 428/167, 428/120, 428/178, 428/188
• US Class Current: 52/793.1
• CPC Class Codes: E04C 2/322 with parallel corrugations
• CPC Class Codes: Y10S 108/901 Synthetic plastic industrial platform, e.g. pallet
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells

Abstract

An improved plastic blow-molded panel structure is shown and described that is lightweight and provides superior resistance to sagging, warping and creeping under high stress loads, especially when used in a horizontal position. The disclosed panel structure includes a combination of transverse or lateral beams extending from the second panel towards the first panel and, in certain embodiments, a plurality of transverse ribs disposed within the lateral beams. The disclosed shelving units may be fabricated from conventional blow-molding processes.

Claims

1. A panel structure comprising:

a first panel,

a second panel spaced apart from the first panel,

the second panel comprising a plurality of lateral beams extending from the second panel towards the first panel and connecting the second panel to the first panel, each beam defining a lateral slot extending through the second panel and towards the first panel,

the second panel comprising a plurality of transverse ribs, each transverse rib extending through one of the lateral slots.

2. The panel structure of claim 1 wherein the first panel is further connected to the second panel by a front wall and a rear wall.

3. The panel structure of claim 1 wherein each transverse rib has an average lateral width, the average lateral width of the transverse ribs disposed toward a lateral center of the first panel being greater than an average lateral width of the transverse ribs disposed closer to the front or rear walls.

4. The panel structure of claim 1 wherein each transverse rib has a bottom edge that extends from one side of its respective lateral slot to an opposite side thereof, each bottom edge of each rib being arched upward towards the first panel.

5. The panel structure of claim 1 wherein each transverse rib has a top edge that extends from one side of its respective lateral slot to an opposite side thereof, each top edge of each rib being arched downwards away from the first panel.

6. The panel structure of claim 1 wherein the panel structure is blow molded.

7. The panel structure of claim 1 wherein the first panel further comprises a plurality of grooves, each groove being in alignment with one of the lateral beams.

8. The panel structure of claim 1 wherein the first panel is arched upward away from the second panel.

9. The panel structure of claim 8 wherein the second panel is flat.

10. The panel structure of claim 8 wherein the first panel is further connected to the second panel by two side walls, each sidewall further connecting the front wall to the rear wall.

11. The panel structure of claim 1 wherein the first panel is further connected to the second panel by a front wall and a rear wall.

12. The panel structure of claim 11 wherein the front wall is arched.

13. A panel structure comprising:

a first panel,

a second panel spaced apart from the first panel,

the second panel comprising a plurality of lateral beams extending from the second panel towards the first panel and connecting the second panel to the first panel, each beam defining a lateral slot extending through the second panel and towards the first panel, the first panel further comprising a plurality of grooves, each groove being in alignment with one of the lateral beams.

14. The panel structure of claim 13 wherein the second panel further comprises a plurality of transverse ribs, each transverse rib extending through one of the lateral slots.

15. The panel structure of claim 14 wherein each transverse rib has a bottom edge that extends from one side of its respective lateral slot to an opposite side thereof, each bottom edge of each rib being arched upward towards the first panel.

16. The panel structure of claim 14 wherein each transverse rib has a top edge that extends from one side of its respective lateral slot to an opposite side thereof, each top edge of each rib being arched downwards away from the first panel.

17. The panel structure of claim 13 wherein the first panel is arched upward away from the second panel.

18. The panel structure of claim 13 wherein each transverse rib has an average lateral width, the average lateral width of the transverse ribs disposed toward a lateral center of the first panel being greater than an average lateral width of the transverse ribs disposed closer to the front or rear walls.

19. The panel structure of claim 13 wherein the panel structure is blow molded.

20. A panel structure comprising:

a first panel,

a second panel spaced apart from the first panel,

the second panel comprising a plurality of lateral beams extending from the second panel towards the first panel and connecting the second panel to the first panel, each beam defining a lateral slot extending through the second panel and towards the first panel, the first panel is arched upward away from the second panel.

21. The panel structure of claim 20 wherein the second panel is flat.

22. The panel structure of claim 21 wherein the front wall is arched.

23. The panel structure of claim 21 wherein the first panel is further connected to the second panel by two side walls, each sidewall further connecting the front wall to the rear wall.

24. The panel structure of claim 20 wherein the second panel further comprises a plurality of transverse ribs, each transverse rib extending through one of the lateral slots.

25. The panel structure of claim 24 wherein each transverse rib has an average lateral width, the average lateral width of the transverse ribs disposed toward a lateral center of the first panel being greater than an average lateral width of the transverse ribs disposed closer to the front or rear walls.

26. The panel structure of claim 24 wherein each transverse rib has a bottom edge that extends from one side of its respective lateral slot to an opposite side thereof, each bottom edge of each rib being arched upward towards the first panel.

27. The panel structure of claim 24 wherein each transverse rib has a top edge that extends from one side of its respective lateral slot to an opposite side thereof, each top edge of each rib being arched downwards away from the first panel.

28. The panel structure of claim 20 wherein the first panel further comprises a plurality of grooves, each groove being in alignment with one of the lateral beams.

29. The panel structure of claim 20 wherein the second panel is flat.

30. The panel structure of claim 20 wherein the first panel is further connected to the second panel by a front wall and a rear wall.

31. The panel structure of claim 30 wherein the front wall is arched.

32. The panel structure of claim 30 wherein the first panel is further connected to the second panel by two side walls, each sidewall further connecting the front wall to the rear wall.

33. The panel structure of claim 20 wherein the panel structure is blow molded.

34. A panel structure comprising:

a first panel,

a second panel spaced apart from the first panel and connected to the first panel by a front wall, a rear wall and two opposing sidewalls,

the second panel comprising a plurality of lateral beams extending from the second panel towards the first panel and extending laterally between the sidewalls, the lateral beams further connecting the second panel to the first panel, each lateral beam defining a lateral slot extending through the second panel and towards the first panel,

the second panel further comprising a plurality of transverse ribs, each transverse rib extending through one of the lateral slots.

35. The panel structure of claim 34 wherein the first panel further comprises a plurality of grooves, each groove being in alignment with one of the lateral slots.

36. The panel structure of claim 34 wherein the first panel is arched upward away from the second panel.

37. The panel structure of claim 36 wherein the second panel is flat.

38. The panel structure of claim 34 wherein the front wall is arched.

39. The panel structure of claim 34 wherein each transverse rib has an average lateral width, the average lateral width of the transverse ribs disposed toward a lateral center of the first panel being greater than an average lateral width of the transverse ribs disposed closer to the front or rear walls.

40. The panel structure of claim 39 wherein each transverse rib has a bottom edge that extends from one side of its respective lateral slot to an opposite side thereof, each bottom edge of each rib being arched upward towards the first panel.

41. The panel structure of claim 39 wherein each transverse rib has a top edge that extends from one side of its respective lateral slot to an opposite side thereof, each top edge of each rib being arched downwards away from the first panel.

42. The panel structure of claim 34 wherein the panel structure is blow molded.

43. A panel structure comprising:

an arched first panel,

a flat second panel spaced apart from the first panel and connected to the first panel by a front wall, a rear wall and two opposing sidewalls,

the second panel comprising a plurality of lateral beams extending upward from the second panel towards the first panel and extending laterally between the opposing sidewalls, the lateral beams being spaced apart and generally parallel to the rear wall, the lateral beams further connecting the second panel to the first panel, each lateral beam defining a lateral slot extending through the second panel and towards the first panel,

the second panel further comprising a plurality of transverse ribs, each transverse rib extending through one of the lateral slots,

each transverse rib having an average lateral width, the average lateral width of the transverse ribs disposed toward a lateral center of the first panel being greater than an average lateral width of the transverse ribs disposed closer to the front or rear walls,

each transverse rib has a bottom edge that extends from one side of its respective lateral slot to an opposite side thereof, each bottom edge of each rib being arched upward towards the first panel,

the first panel further comprising a plurality of grooves, each groove being in alignment with one of the lateral slots.

44. The panel structure of claim 43 wherein the panel structure is blow molded.