Abstract: A molded article includes a rotationally-molded body of polymer material, and a reinforcing member substantially encased within and in direct contact with the polymer material. Both the polymer material and the reinforcing member have their own unique post-molding shrinkage characteristics. A slip zone, defining a void in the body of polymer material, is formed around the end of the reinforcing member, such that post-molding shrinkage of the polymer material imposes substantially no stress on the end of the reinforcing member. The reinforcing member has a surface coating that substantially eliminates adhesion with the polymer material, so as to enable displacement of the reinforcing member with respect to contacting polymer material, and thereby reduce post-molding deformation of the molded article.

Abstract: A decorative post includes an elongated outer polymer shell having at least one longitudinal groove extending a majority of a length of the elongated shell sized and shaped to hold a decorative fence panel. The decorative fence post also includes an elongated reinforcing member disposed in the outer polymer shell, and substantially extending a length of the fence post. A foam filler is disposed inside the outer polymer shell between the shell and the reinforcement member. An aperture is disposed in the outer polymer shell near an end of the reinforcing member, and a void extends from the aperture into the foam filler adjacent to and exposing an end of the reinforcing member. The void defines a slip zone at the end of the reinforcing member into which the reinforcing member extends as the outer shell shrinks longitudinally during post mold cooling.

Abstract: A chair foot device for a wire frame chair stackable with other wire frame chairs includes a lower surface disposable on a support surface. An upper surface, opposite the lower surface is sized and shaped to carry the lower surface of an adjacent foot from an adjacently stacked upper chair. The chair foot also includes an alignment protrusion disposed on one of the lower and upper surfaces and an alignment indentation disposed on the other of the lower and upper surfaces. The alignment protrusion is sized and shaped to be receivable within an alignment indentation of a corresponding foot from an adjacently stacked chair. The foot is sized and shaped to carry an applied load from an adjacently stacked upper foot and to transfer the applied load to an adjacent load bearing surface. The foot is also sized and shaped to protect the wire frame chair from damage during stacking.

Abstract: A tamper resistant attachment apparatus for attaching a backrest to a chair frame. A flap is foldably coupled to an edge of a chair backrest. The flap is foldable over onto the backrest into a folded position. The flap has a channel that fits around a frame of a chair when the flap is in the folded position. At least one aperture that extends through the flap can receive a corresponding pin that is coupled to the backrest when the flap is in the folded position. The at least one pin is deformable to secure the flap and backrest around the chair frame when the flap is in the folded position.

Abstract: A decorative fence panel including opposite plastic walls that have opposite facing exterior surfaces. Each wall has a grid of traversing elongated channels formed by inward bending in the walls to define a decorative profile of a fence. A plurality of separate and discrete connections is disposed across the decorative fence panel. The connections are formed between the opposite walls by select intersections of the grids of traversing channels of the opposite walls. The connections form a plurality of continuous material nodes of thermal energy transfer paths between the opposite walls to transfer thermal energy between the opposite walls.

Abstract: A drop box for a rotational molding system includes a substantially rigid outer shell, a substantially rigid inner shell, configured to contain unmelted polymer material, and thermal insulating material, disposed between the inner and outer shells. Substantially rigid bridge material interconnects the inner and outer shells and forms part of the rigid structure thereof. The bridge material is configured to provide a thermal break between the inner and outer shells, to reduce heat transfer therebetween.

Abstract: A locking mechanism for a support leg hingedly attached to a support surface includes a base, attached to the support surface, with a plurality of angularly spaced, radial teeth, and a coupler, attached to the support leg, having a plurality of angularly spaced, radial teeth configured to mate with the teeth of the base. A selectively releasable engagement mechanism is configured to engage and disengage the teeth of the base with the teeth of the coupler, to allow selective rotation of the support leg between an extended position and a folded position, and to lock the leg in the extended or folded position.

Abstract: A molded article includes a rotationally-molded body of polymer material, formed in a mold, with an elongate reinforcing member, having an end, substantially encased within the body of polymer material during molding thereof. A slip zone, defining a void in the body of polymer material, is formed around the end of the reinforcing member, such that post-molding shrinkage of the polymer material imposes substantially no stress on the end of the reinforcing member.

Abstract: A molded article includes a rotationally-molded body of polymer material, and a reinforcing member substantially encased within and in direct contact with the polymer material. Both the polymer material and the reinforcing member have their own unique post-molding shrinkage characteristics. The reinforcing member has a surface that substantially eliminates adhesion with the polymer material, so as to enable displacement of the reinforcing member with respect to contacting polymer material, and thereby reduce post-molding deformation of the molded article.

Abstract: A plastic table structure includes a tabletop comprising a thin polymer shell layer surrounding an expanded foam core. The multiple layers of the finished tabletop are molded concurrently in a one pass biaxial or centrifugal rotational molding process, and cured in an oven. The rotational molding process advantageously allows the shell and foam core polymer materials to be distributed into all portions of the mold. In one embodiment, a structural frame is disposed in the mold, and the foam core encases and surrounds the frame. The structural frame may be made of steel, wood, composite materials, or other materials.

Abstract: A connector assembly with a connector body molded directly about a captive ball formed on a separate shaft, where the shaft and connector are attached to separate bodies which move relative to each other. This assembly retains an essentially zero clearance fit between the ball and the connector so as to prevent rattling between the parts from vibrations. This zero clearance fit is achieved at a much lower cost than comparable quality connectors due to higher diametric tolerances for the ball component. Higher diametric tolerances do not affect the final fit because the connector is molded directly about the ball.