Manufacturing process for manufacturing luggage case shell and recycling leftover materials

Abstract

The invention provides a manufacturing process for manufacturing a trunk shell and recycling leftover materials, which comprises the following steps of: a) providing a composite board with a base plate and a surface cloth, the surface cloth is connected with the base plate in a hot melting way, the base plate is made of polycarbonate, the surface cloth is made of polyethylene terephthalate, or the base plate and the surface cloth are both made of polypropylene; b) carrying out compression molding on the composite board to form a box shell semi-finished product; c) cutting the box shell semi-finished product to form a box shell finished product and leftover materials; and d) recycling leftover materials: when the base plate is made of polycarbonate and the surface cloth is made of polyethylene terephthalate, separating the base plate from the surface cloth by external force, crushing the base plate for recycling, and when both the base plate and the surface cloth are made of polypropylene, crushing the leftover materials for recycling. Therefore, leftover materials can be recycled to reduce pollution and reduce waste of raw materials.

Description

Technical Field

[0001] The invention relates to a method for manufacturing a luggage case shell, in particular to a process for manufacturing the luggage case shell and recycling leftover materials. Background Art

[0002] The inner surface of the suitcase shell is usually attached with a lining cloth to protect the items inside the suitcase, and the manufacturing method of combining the suitcase shell and the lining cloth into one body has been disclosed in the invention patent case CN 103895234 and the invention patent case TW 272121. However, the above two invention patents do not mention how to deal with the scraps left after cutting the suitcase shell, that is, the scraps are not properly recycled and reused. If the scraps are not recycled, it will cause environmental pollution and waste of raw materials. Therefore, the existing manufacturing method of the suitcase shell still has room for improvement. Summary of the invention

[0003] In view of the deficiencies in the prior art, the main purpose of the present invention is to provide a process for manufacturing a luggage case shell and recycling leftover materials, thereby overcoming the defects of environmental pollution and waste of raw materials caused by failure to recycle leftover materials.

[0004] To achieve the above-mentioned purpose, the process of the present invention includes the following steps: a) providing a composite board having a substrate and a surface cloth, the surface cloth being hot-melt bonded to the substrate, the substrate being made of polycarbonate and the surface cloth being made of polyethylene terephthalate, or the substrate and the surface cloth being made of polypropylene; b) molding the composite board into a semi-finished box shell; c) cutting the semi-finished box shell to form a finished box shell and scraps; and d) recycling the scraps, when the substrate is made of polycarbonate and the surface cloth is made of polyethylene terephthalate, separating the substrate from the surface cloth by external force, and crushing the separated substrate for recycling, and when the substrate and the surface cloth are both made of polypropylene, crushing the scraps for recycling.

[0005] Through the above technical features, the process of the present invention can further recycle the scraps remaining after cutting, and make the scraps into the finished box shell. In this way, the scraps can not only be recycled in the process of the present invention to reduce environmental pollution, but also reduce the waste of raw materials.

[0006] Preferably, in step b), the composite sheet is fed into a molding machine and molded into the box shell semi-finished product. The molding machine has a sheet heating zone and a box shell molding zone. The composite sheet is first fed into the sheet heating zone for heating and softening, and then fed into the box shell molding zone for molding.

[0007] Preferably, in step b), the box shell forming area includes a male mold and a female mold, and the compression molding places the composite board between the male and female molds to form the box shell semi-finished product from the composite board.

[0008] Preferably, in step a), a sheet forming machine is configured, the sheet forming machine comprising a heating extruder, an extrusion roller set, and a feeding roller; the heating extruder feeds the substrate raw material in a molten state to the extrusion roller set, so that the substrate raw material forms the substrate; the surface cloth is rolled up on the feeding roller and conveyed to the extrusion roller set by the feeding roller, so that the substrate and the surface cloth are thermally melted to form the composite sheet. In this way, the substrate and the surface cloth can be tightly combined without the need for adhesive to bond each other.

[0009] Preferably, in step a), the temperature of the heating extruder is maintained at 200° C. to 240° C., so that the substrate raw material is in a molten state to maintain appropriate fluidity.

[0010] Preferably, in step a), the temperature of the extrusion roller set is 30° C. to 100° C., the operating speed is 60 seconds to 90 seconds, and the pressure is 100 psi to 120 psi. Thus, the temperature, operating speed and pressure of the extrusion roller set are limited so that the extrusion roller set can smoothly convey the substrate material.

[0011] The detailed steps and features of the manufacturing process of the luggage shell and the scrap recycling process provided by the present invention will be described in the detailed description of the implementation method in the following. However, those with ordinary knowledge in the art should understand that the detailed description and the specific embodiments listed in the implementation of the present invention are only used to illustrate the present invention and are not used to limit the scope of the patent application of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a flowchart of the steps of the process of the present invention;

[0013] Figure 2 is a schematic diagram of the process of the present invention, showing that the surface cloth is wound around the feed roller and conveyed to the squeezing roller group;

[0014] Figure 3 is a schematic diagram of the manufacturing process of the present invention, showing the process of feeding the composite board into a molding machine for molding into a semi-finished box shell; and

[0015] Figure 4 is a schematic diagram of the manufacturing process of the present invention, showing the cutting of the semi-finished box shell into the finished box shell and the leftovers;

[0016] Among them, the reference numerals

[0017] 1-Process;

[0018] 10- Sheet forming machine;

[0019] 11- Heating the extruder;

[0020] 111-extrusion head;

[0021] 12-squeezing roller set;

[0022] 121-first squeezing roller;

[0023] 122-second squeezing roller;

[0024] 123-third squeezing roller;

[0025] 13-Feeding roller;

[0026] 14-calendering roller;

[0027] 20-substrate raw material;

[0028] 21-Substrate;

[0029] 30-surface cloth;

[0030] 40-composite sheet;

[0031] 41- box shell semi-finished product;

[0032] 411- finished box shell;

[0033] 412-scraps;

[0034] 50- Moulding machine;

[0035] 51-plate heating zone;

[0036] 511-upper heating element;

[0037] 512-lower heating element;

[0038] 52-box shell forming area;

[0039] 521-Male mold;

[0040] 522-mother mold;

[0041] L-box shell cutting line;

[0042] S1-S6B-steps. DETAILED DESCRIPTION

[0043] In order to explain the technical features of the present invention in detail, a preferred embodiment is now described with reference to the accompanying drawings. Figure 1 , the process 1 of the present invention comprises the following steps:

[0044] a) If Figure 1 As shown in step S1, a composite board 40 is provided, the composite board 40 has a substrate 21 and a surface fabric 30 hot-melt-bonded to the substrate 21, wherein the substrate 21 is made of polycarbonate and the surface fabric 30 is made of polyethylene terephthalate, or the substrate 21 is made of polypropylene and the surface fabric 30 is also made of polypropylene.

[0045] See also Figure 2 In this step, a sheet forming machine 10 is configured, and the sheet forming machine 10 includes a heating extruder 11, an extrusion roller set 12, a feeding roller 13 and two calendering rollers 14 arranged at intervals relative to each other, wherein the heating extruder 11 has an extrusion head 111; the extrusion roller set 12 includes a first extrusion roller 121, a second extrusion roller 122 and a third extrusion roller 123, all of which are located below the heating extruder 11 and are arranged in a side-by-side manner; the feeding roller 13 is located below the heating extruder 11 and is arranged on one side of the extrusion roller set 12, and the two calendering rollers 14 are arranged on the other side of the extrusion roller set 12 in an up-down manner.

[0046] Please continue reading Figure 2 In this step, the granular substrate raw material 20 is first placed in the heated extruder 11 to be heated and melted, so that the substrate raw material 20 is in a molten state, and the substrate raw material 20 is extruded between the first and second extrusion rollers 121 and 122 by the extrusion head 111 of the heated extruder 11. Since the first extrusion roller 121 and the third extrusion roller 123 rotate counterclockwise, and the second extrusion roller 122 rotates clockwise, the substrate raw material 20 will continue to pass between the first and second extrusion rollers 121 and 122 and the second and third extrusion rollers 122 and 123, so that the substrate raw material 20 forms a thin sheet of substrate 21. At the same time, the surface cloth 30 to be processed is wound on the surface of the feeding roller 13 and passes through the gaps between the first and second extrusion rollers 121, 122 and the second and third extrusion rollers 122, 123, and then fixed on a winding roller (not shown in the figure) adjacent to the third extrusion roller 123. Therefore, the surface cloth 30 will continue to pass between the first and second extrusion rollers 121, 122 and the second and third extrusion rollers 122, 123, so that the substrate 21 and the surface cloth 30 are bonded to each other by hot melt, and finally the two pass through the calendering rollers 14 together. In this way, the substrate 21 and the surface cloth 30 can be tightly combined to form a composite board 40 without the need for adhesive bonding.

[0047] It should be noted here that when the material of the substrate 21 is polycarbonate (PC) and the material of the surface fabric 30 is polyethylene terephthalate (PET), the appropriate thickness of the composite sheet 40 is 1.4 mm to 2.5 mm, and when the material of the substrate 21 is polypropylene (PP) and the material of the surface fabric 30 is also polypropylene (PP), the appropriate thickness of the composite sheet 40 is 1.6 mm to 2.7 mm.

[0048] In addition, in the present embodiment, it is preferred that the temperature of the heating extruder 11 be maintained between 200°C and 240°C. If the temperature is lower than 200°C, the fluidity of the substrate raw material 20 is too low, which is not in line with production efficiency and cost. If the temperature is higher than 240°C, although it helps to shorten the extrusion time of the substrate raw material 20, the fluidity of the substrate raw material 20 is too high, which in turn reduces the efficiency of the extrusion roller assembly 12 in conveying the substrate raw material 20. In addition, the temperature of the extrusion roller set 12 is maintained at 30°C to 100°C, the operating speed is maintained at 60 seconds to 90 seconds, and the pressure is maintained at 100psi to 120psi. If the temperature is lower than 30°C, the substrate raw material 20 is easily cooled and hardened. If the temperature is higher than 100°C, the substrate raw material 20 has too high fluidity and is difficult to transport. Secondly, if the operating speed is lower than 60 seconds, the substrate raw material 20 is difficult to adhere to the extrusion roller set 12 and is difficult to transport. If the operating speed is higher than 90 seconds, although the transport efficiency of the extrusion roller set 12 can be improved, it will cause the substrate raw material 20 to be easily covered by the extrusion roller set 12 and difficult to remove. Furthermore, if the pressure is lower than 100psi, the substrate raw material 20 is difficult to extend into a substrate 21 with an appropriate thickness. If the pressure is higher than 120psi, the substrate raw material 20 is easily over-extended, resulting in the possibility of fracture of the formed substrate 21.

[0049] b) If Figure 1 As shown in step S2, the composite board 40 is molded into a box shell semi-finished product 41.

[0050] In this step, the composite sheet 40 is mainly fed into a molding machine 50 and molded into a semi-finished box shell 41. Figure 3As shown, the molding machine 50 has a plate heating zone 51 and a box shell molding zone 52. The composite plate 40 is first sent to the plate heating zone 51 for heating and softening, and then sent to the box shell molding zone 52 for molding. In detail, the plate heating zone 51 includes an upper heating element 511 and a lower heating element 512. When the composite plate 40 is sent to the plate heating zone 51, the composite plate 40 is placed between the upper and lower heating elements 511 and 512 for heating. At this time, the temperature of the upper heating element 511 is maintained at 200°C to 270°C, and the temperature of the lower heating element 512 is maintained at 200°C to 240°C. This temperature range can heat and soften the composite plate 40 without making the fluidity of the composite plate 40 too high. In addition, the box shell molding area 52 includes a male mold 521 and a female mold 522. When the composite board 40 is sent into the box shell molding area 52, the composite board 40 is first placed between the male and female molds 521, 522 whose temperature is maintained at 70°C to 90°C, and then a downward force of 30 metric tons is applied to the male mold 521, so that the male mold 521 moves downward and extrude the composite board 40 sandwiched between the male and female molds 522 together. After the composite board 40 is molded to form the box shell semi-finished product 41, the male and female molds 521, 522 will separate from each other at a speed of 60 seconds to 90 seconds, and the box shell semi-finished product 41 can be taken out at this time.

[0051] c) If Figure 1 As shown in step S3, the box shell semi-finished product 41 is cut to form a required box shell finished product 411 and cut scraps 412.

[0052] In this step, see Figure 4 The box shell semi-finished product 41 is cut based on a box shell cutting line L to obtain a required box shell finished product 411 and the remaining scraps 412 after cutting, and the scraps 412 after cutting are approximately 25% to 50% of the box shell semi-finished product 41.

[0053] Step d) Figure 1 As shown in step S4, the scraps 412 are recycled.

[0054] In this step, firstly, step S5 is taken to determine whether the materials of the substrate 21 and the surface cloth 30 of the scrap 412 are the same. If the materials of the substrate 21 and the surface cloth 30 are the same, that is, the materials of the substrate 21 and the surface cloth 30 are both polypropylene (PP), then step S6A is taken to directly crush the scrap 412 to obtain the substrate raw material 20 mentioned in step a), and then repeat the aforementioned steps a) to c) to make it into the finished box shell 411; if the materials of the substrate 21 and the surface cloth 30 are different, that is, the material of the substrate 21 is polycarbonate (PC) and the material of the surface cloth 30 is polyethylene terephthalate (PET), then step S6B is taken to separate the substrate 21 and the surface cloth 30 by external force, and the separated surface cloth 30 cannot be recycled. In addition, the separated substrate 21 is crushed to obtain the substrate raw material 20 mentioned in step a), and then repeat the aforementioned steps a) to c) to make it into the finished box shell 411.

[0055] In summary, the process 1 of the present invention can recycle the scraps 412 remaining after cutting the box shell semi-finished product 41, and make the scraps 412 into the box shell finished product 411. In this way, the scraps 412 can not only be recycled in the process 1 of the present invention to reduce environmental pollution, but also reduce the waste of the substrate raw material 20.

[0056] The steps and components disclosed in the above embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of the present invention. Replacements or changes of other equivalent steps or components should also be covered by the scope of the patent application of the present invention.

Claims

1. A process for manufacturing a luggage case shell and recycling scraps, characterized in that: The following steps are involved: a) providing a composite board, the composite board having a base plate and a surface fabric hot-melt-bonded to the base plate, wherein the base plate is made of polycarbonate and the surface fabric is made of polyethylene terephthalate, or the base plate is made of polypropylene and the surface fabric is also made of polypropylene; b) molding the composite sheet into a semi-finished box shell; c) cutting the semi-finished box shell to form a desired finished box shell and cut scraps; and d) recycling the scraps, wherein when the substrate is made of polycarbonate and the surface cloth is made of polyethylene terephthalate, the substrate and the surface cloth of the scraps are separated by external force, and the separated substrate is crushed and then recycled; when the substrate is made of polypropylene and the surface cloth is also made of polypropylene, the scraps are crushed and then recycled.

2. The process for manufacturing a luggage case shell and recycling scraps according to claim 1, characterized in that: In step b), the composite sheet is fed into a molding machine and molded into the box shell semi-finished product. The molding machine has a sheet heating zone and a box shell molding zone. The composite sheet is first fed into the sheet heating zone for heating and softening, and then fed into the box shell molding zone for molding.

3. The process for manufacturing a luggage case shell and recycling scraps according to claim 2, characterized in that: In the step b), the box shell forming area includes a male mold and a female mold, and the compression molding places the composite board between the male and female molds to form the box shell semi-finished product.

4. The process for manufacturing a luggage case shell and recycling scraps according to claim 1, characterized in that: In the step a), a sheet forming machine is configured, and the sheet forming machine includes a heating extruder, an extrusion roller group, and a feeding roller; the heating extruder feeds the substrate raw material in a molten state to the extrusion roller group, so that the substrate raw material forms the substrate; the surface cloth is rolled up on the feeding roller and transported to the extrusion roller group by the feeding roller, so that the substrate and the surface cloth are hot-melt bonded to form the composite sheet.

5. The process for manufacturing a luggage case shell and recycling scraps according to claim 4, characterized in that: In the step a), the temperature of the heated extruder is maintained at 200°C to 240°C.

6. The process for manufacturing a luggage case shell and recycling scraps according to claim 4, characterized in that: In the step a), the temperature of the squeezing roller set is 30° C. to 100° C., the operating speed is 60 seconds to 90 seconds, and the pressure is 100 psi to 120 psi.

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