Injection molded integral inner rim for hard-sided luggage

Abstract

A luggage case (100, 500) includes at least one injection molded shell (118, 120, 520) having an interior region and including a sidewall (152, 154, 552, 554) at least partially defining a unitarily molded outer rim (202, 602) and a unitarily molded inner rim (212, 612) positioned interior of the outer rim (202, 602). The inner rim (212, 612) extends along at least a portion of a length of the outer rim (202, 602), and the inner rim (212, 612) extends away from the sidewall (152, 154, 552, 554) at an acute angle (240, 406, 412). A support feature (222, 622) extends between the outer rim (202, 602) and the inner rim (212, 612).

Description

Technical Field

[0001] The described embodiments generally relate to injection-molded suitcases and molding methods thereof. Background Technology

[0002] Travelers generally prefer hard-sided suitcases because they are more durable and offer better protection for belongings during travel. Hard-sided suitcases are also aesthetically appealing to travelers. Common forms of hard-sided suitcases include metal and plastic. However, metal suitcases are generally heavier or more expensive to manufacture. While plastic suitcases are lighter and less expensive to manufacture than metal suitcases, they typically require multi-part molding, such as using sliders, to achieve the desired shape, durability, or structural integrity. Because of the use of multi-part molding, the molding methods and techniques can become complex and more expensive, and may also result in externally visible structures, which reduces the aesthetic appeal of plastic suitcases.

[0003] Therefore, there is a need for durable molded suitcases with the required structural integrity. There is also a need for molded suitcases with the required structure and strength that require fewer mold parts during the molding process. Utility Model Content

[0004] Embodiments of this utility model relate to a suitcase. The suitcase includes at least one injection-molded outer shell, the outer shell including an internal storage space, and including a sidewall that at least partially defines an integrally molded outer edge and an integrally molded inner edge positioned inside the outer edge, wherein the inner edge extends along at least a portion of the length of the outer edge, the inner edge extending away from the sidewall at an acute angle, and a support feature extending between the outer edge and the inner edge.

[0005] In another example, the suitcase may include at least one injection-molded shell, which includes a main surface and at least one sidewall that together define an internal storage space. The sidewall at least partially defines an integrally molded outer edge and an integrally molded inner edge located inside the outer edge, wherein the inner edge extends along at least a portion of the length of the outer edge and extends away from the sidewall at an acute angle.

[0006] In addition, in some examples, the sidewall extends from at least a portion of the periphery of the main panel, the sidewall includes at least one corner region, the outer edge is defined to extend at least partially along the sidewall and at least one corner region, and the inner edge extends along at least a portion of the sidewall and along at least one corner region.

[0007] In some examples, the inner edge extends along at least a portion of each of at least two adjacent sidewalls and along at least one corner region.

[0008] In some cases, the inner edge is offset below the outer edge.

[0009] In some cases, the inner edge extends around approximately 50% to 90% of the length of the outer edge.

[0010] In some examples, the inner edge extends continuously for most of the length of the sidewall.

[0011] In some cases, the inner edge extends linearly along the sidewall.

[0012] In some cases, the inner edge extends the entire length of the outer edge.

[0013] In some cases, at least a portion of the inner edge is positioned further inward toward the interior space compared to the sidewall.

[0014] The inner edges formed on the sidewalls are continuous in some cases, and segmented in others. Continuous inner edges provide strong reinforcement to the outer edges. Segmented inner edges provide some reinforcement while using less material compared to continuous inner edges.

[0015] In some examples, the inner edge defines a ledge (which is also a flange or collar) extending from the at least one sidewall.

[0016] In some examples, the support feature extends between the outer and inner edges. Furthermore, the support feature can extend at a non-orthogonal angle between the outer and inner edges, providing sufficient strength and allowing for some deflection between the inner and outer edges.

[0017] In some cases, the support features are positioned along a direction orthogonal to the main panel (i.e., the release direction of the mold), making the release of the support features more convenient.

[0018] In some cases, the support features are elastic, allowing the inner edge to deflect relative to the outer edge.

[0019] In some examples, the outer edge is flush with the outer surface of at least one sidewall. In some examples, the edge band is flush with the site area. In some examples, the edge band has no raised structural features. In some examples, the outer edge has no external raised structural features. In some examples, the outer edge is flush with the outer surface of at least one sidewall. A flush surface, such as a surface without raised structural features, can provide a cleaner appearance.

[0020] In some examples, the sidewalls extend orthogonally from the main panel. In other examples, the sidewalls comprise a top panel and an opposing bottom panel; the bottom panel extends from the main panel at an angle of approximately 90 to 98 degrees. In some examples, the bottom panel extends from the main panel at an angle of approximately 98 degrees relative to the main panel. These angles allow other panels of the case (such as the top panel opposite the bottom panel) to be orthogonal to the main face while providing sufficient draft angle in the mold for proper release from the mold.

[0021] In some examples, the acute angle between the inner edge and the sidewall is approximately between 1 degree and 14 degrees (inclusive), or approximately between 4 degrees and 6 degrees (inclusive). In another example, it can be approximately 6 degrees.

[0022] In some cases, the acute angle between the inner edge and the sidewall is approximately between 80 and 94 degrees relative to the main panel (inclusive).

[0023] In some examples, the housing includes a first sidewall portion orthogonally oriented relative to the main panel, and a second sidewall portion oriented relative to the main panel at a greater outward angle than the first sidewall.

[0024] In some examples, the inner edge forms a sloped surface for sliding contact with the mold core during removal of the housing from the mold. In some examples, the inner edge deflects outward upon release from the mold core. In some examples, both the inner and outer edges deflect outward upon release from the mold core.

[0025] In some examples, the inner edge includes a first portion and a second portion extending along different portions of the outer edge and defining a gap between them. In some examples, the insert is coupled to a first end of the first portion and a second end of the second portion and extends through the gap. In some examples, the first and second portions of the inner edge are adjacent to a corner region, and the gap is defined at the corner region. In some examples, the outer edge has a first thickness and a thinner second thickness in the corner region. In some examples, the insert includes a shelf (e.g., a shoulder) extending along the corner region between adjacent sides to support the corner region, and an insert edge extending from the shelf and positioned adjacent to the outer edge. In some examples, the combined thickness of the insert edge and the outer edge at the corner region is similar to or the same as the first thickness. In some examples, the insert edge and the outer edge are joined by a suture. In some examples, the suture joins the closure assembly to the outer edge.

[0026] In some examples, the first and second portions of the inner edge, and the gap formed therebetween, are located on a sidewall of the housing. In some examples, the insert includes a handle extending outward relative to the outer surface of the housing. In some examples, the inner edge defines attachment features at opposing first and second ends. In some examples, the insert defines a receiving channel at each opposing end, and the attachment features are received in the respective receiving channels to engage the insert with the inner edge. In some examples, the inner edge is located in a corner region of the housing.

[0027] In some cases, the orientation of the second sidewall relative to the main panel is between 90 degrees and 98 degrees, including 90 degrees and 98 degrees.

[0028] In some examples, the sidewalls of the injection-molded housing include two or more sidewalls and a corner region located between at least two sidewalls, and the housing is formed in a mold including a core. In some examples, during separation of the injection-molded housing and the core, the inner edge elastically deflects outward when engaging the core.

[0029] In some cases, during the separation of the injection-molded shell and the core, when the core is engaged, two or more sidewalls elastically deflect outwards, and corner areas elastically deflect inwards.

[0030] In some examples, the housing also includes corner regions that elastically deflect inwards during separation of the housing and the core.

[0031] In some examples, the inner edge extends continuously through the corner region and defines a first width between the inner and outer edges. During separation of the housing and the core, the inner edge elastically deflects outward to define a second width between the inner and outer edges, which is smaller than the first width.

[0032] In some examples, the suitcase also includes at least one wheel mounted on a corner area of ​​the bottom panel of the suitcase shell, and a drag handle mounted on the rear main panel of the suitcase shell.

[0033] In another example, a method for injection molding a suitcase is disclosed. The method includes providing a core movably positioned within an outer mold defining a cavity, the core defining an inner cavity of a housing, and the outer mold defining an outer surface of the housing; a portion of the cavity defining at least one sidewall of the housing, and another portion of the cavity defining an inner edge located on the at least one sidewall, the inner edge being positioned further inward toward the inner cavity of the housing than the at least one sidewall. Furthermore, the core and the outer mold separate along a separation direction, and the portion of the cavity defining the main surface of the suitcase housing is non-orthogonal to the separation direction.

[0034] In some examples, the portions of the mold cavity define: a first sidewall of the injection-molded housing, a second sidewall of the injection-molded housing, and a corner region having a radius of curvature that defines the junction between the first and second sidewalls.

[0035] In some cases, during the separation of the mold core and the injection-molded shell, the first and second sidewalls expand outward, and the radius of curvature of the corner region increases.

[0036] In some examples, a portion of the mold cavity defines the top sidewall of the injection-molded housing, while another portion defines the bottom sidewall of the injection-molded housing.

[0037] In some examples, the first sidewall is the top sidewall, and the second sidewall is the bottom sidewall.

[0038] In some cases, the outer mold and the mold core separate along a separation direction that is not orthogonal to the portion of the mold cavity that defines the main panel.

[0039] In some cases, a portion of the cavity defines a top sidewall orthogonal to the main panel, while another portion defines a bottom sidewall at an angle relative to the main panel.

[0040] In some cases, the acute angle between the inner and outer edges decreases elastically during the separation of the mold core from the injection-molded shell.

[0041] In some examples, the inner edge is parallel to the separation direction of the core and the outer mold, or extends at an angle to intersect the separation direction.

[0042] In some examples of suitcases formed by this method, the injection-molded shell includes a panel defining the front or rear of the suitcase, and one or more sidewalls including an orthogonal sidewall extending from the panel and an opposing sidewall extending from the panel and opposite to the orthogonal sidewall, the opposing sidewall extending outward relative to the orthogonal sidewall.

[0043] In some examples, the orthogonal sidewalls are the top sidewalls, and the opposite sidewalls are the bottom sidewalls.

[0044] In some examples, the opposite sidewalls extend outward at an angle between 90 and 98 degrees relative to the panel.

[0045] In some examples, the inner edge extends along at least a portion of each of the orthogonal sidewalls and the opposing sidewalls.

[0046] In some examples, the acute angle between the inner edge and one or more sidewalls is approximately between 1 degree and 14 degrees.

[0047] In some examples, the acute angle between the inner edge and one or more sidewalls is approximately 6 degrees.

[0048] In some examples of suitcases formed by this method, the suitcase also includes at least one wheel mounted on a corner area of ​​the bottom panel of the suitcase shell, and a drag handle mounted on the rear main panel of the suitcase shell.

[0049] In another example, a suitcase is disclosed. The suitcase includes an integrally formed injection-molded shell, which includes an internal storage space, and includes a main face, a first sidewall extending approximately orthogonally from the main face, a second sidewall opposite to the first sidewall and extending from the main face at an outward angle relative to the first sidewall, an outer edge, and an integral inner edge positioned along a portion of the interior of the first or second sidewall. The inner edge extends along at least a portion of the length of the outer edge, and extends inward at an acute angle away from the sidewall.

[0050] In some examples, the angle of the second sidewall is approximately between 4 and 8 degrees. In some examples, the acute angle between the inner edge and the sidewall is approximately between 0 and 4 degrees. In some examples, the inner edge deflects upon release from the mold core. In some examples, the inner and outer edges deflect outwards upon release from the mold core. In some examples, the support feature extends at a non-orthogonal angle between the inner and outer edges. In some examples, the inner edge extends continuously along most of the periphery of the trunk shell. In some examples, an acute angle is defined between the inner edge and the first or second sidewall, which is approximately between 0 and 4 degrees.

[0051] In another example, a mold assembly for forming a suitcase shell is disclosed, the mold assembly including a core and an outer mold. The core and outer mold define a mold cavity to define an integrally molded shell, the core and outer mold separating along a separation direction, and portions defining the main surface within the mold cavity being non-orthogonal to the separation direction.

[0052] In some examples, the angle between the portion defining the sidewalls in the mold cavity and the portion defining the main face in the mold cavity is approximately between 86 and 94 degrees. In other examples, the mold assembly includes an acute angle between the portion defining the inner edge of the mold cavity and the portion defining the sidewalls in the mold cavity, which is approximately between 1 and 14 degrees.

[0053] In another example, the injection mold assembly for injection molding a suitcase shell includes a core and an outer mold, wherein the core and outer mold define a mold cavity, the core and outer mold are separated along a separation direction, and a portion of the mold cavity defining the main surface of the suitcase shell is oriented non-orthogonally to the separation direction. Furthermore, the angle between the portion of the mold cavity defining the sidewall of the suitcase shell and the portion defining the main surface of the mold cavity is approximately between 86 degrees and 94 degrees.

[0054] Additionally or optionally, the acute angle between the portion of the mold cavity defining the inner edge of the luggage shell and the portion of the mold cavity defining the sidewall is approximately between 1 degree and 14 degrees.

[0055] According to this disclosure, numerous feature modifications and additional features can be applied and envisioned. These feature modifications and additional features can be used individually or in any combination. Therefore, each feature discussed below can be used in combination with any other feature of the first aspect, but is not required to be used.

[0056] In addition to the exemplary aspects and embodiments described above, other aspects and embodiments will also be apparent from reference to the accompanying drawings and by studying the following description. Attached Figure Description

[0057] The present disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals denote like structural elements, and wherein:

[0058] Figure 1 A right front perspective view of an exemplary suitcase is depicted;

[0059] Figure 2 A right front perspective view of an exemplary suitcase in its open configuration is depicted;

[0060] Figure 3A A perspective view depicting an edge portion of an exemplary suitcase shell and a plug attached to that edge portion;

[0061] Figure 3B Depicting Figure 3A The edge portion and the exploded view of the plugin;

[0062] Figure 4A A plan view depicting the edge portion and corner area of ​​an exemplary suitcase shell;

[0063] Figure 4B Describing as Figure 4A A cross-sectional view of the edge portion indicated by lines 4B-4B in the diagram;

[0064] Figure 5A A perspective view of an exemplary corner plug-in is depicted;

[0065] Figure 5B Depicting the connection to the exemplary edge portion Figure 5A A perspective view of an exemplary corner plugin;

[0066] Figure 5C Describing as Figure 5B A cross-sectional view of the exemplary corner insert and edge portion indicated by lines 5C-5C in the diagram;

[0067] Figure 5D Depicting the connection to the exemplary edge portion Figure 5B A floor plan of an exemplary corner plug-in;

[0068] Figure 6 A perspective view depicting the corner area of ​​an exemplary suitcase, including a corner insert and a closure assembly;

[0069] Figure 7 Describing as Figure 3A A cross-sectional view of an exemplary handle insert indicated by lines 7A-7A in the figure;

[0070] Figure 8A A cross-sectional view of an exemplary suitcase shell including its edge portions and an exemplary male mold is depicted;

[0071] Figure 8B Depicting the process of removing the male mold Figure 8A A cross-sectional view of an exemplary suitcase;

[0072] Figure 8C Depicting Figure 8A A plan view of an exemplary suitcase shell and a male mold;

[0073] Figure 8D Depicting the process during the removal of the positive mold, as Figure 8B Cross-sectional plan view of the exemplary suitcase shell and male mold indicated by lines 8D-8D in the figure;

[0074] Figure 9A Depicting from Figure 2 A cross-sectional view of an exemplary suitcase shell taken by lines 9A-9A;

[0075] Figure 9B An exploded cross-sectional view of an exemplary suitcase shell and mold assembly is depicted;

[0076] Figure 9C The corresponding angles between the top wall and the main surface, the bottom wall and the main surface, and the side wall and the main surface are displayed.

[0077] Figure 10 A perspective view depicting an exemplary suitcase shell and edge portion is provided;

[0078] Figure 11A A plan view depicting an exemplary male mold and an exemplary suitcase shell is provided;

[0079] Figure 11B Depicting the process during the removal of an exemplary positive mold Figure 11A A plan view of an exemplary suitcase shell. Detailed Implementation

[0080] The following description includes example products, systems, methods, and / or apparatuses embodying various elements of this disclosure. However, it should be understood that the disclosure may be implemented in many other forms besides those described herein.

[0081] The following disclosure generally relates to a suitcase comprising at least one molded suitcase shell having an integrally formed inner edge. The suitcase may include two or more shells selectively connected by a closure mechanism. The shell may include edge portions. Edge portions may include a periphery or an outer edge. Edge portions may include an integrally formed inner edge positioned inside the shell relative to the periphery or outer edge. The inner edge may extend along a portion of the interior length of the shell. In some examples, the inner edge may extend discontinuously along the periphery. In some examples, the inner edge may extend continuously along the periphery of the shell. For example, the inner edge may extend around or along the entire length or a portion of the sidewall of the shell, and / or along a corner of the shell. The inner edge extends inward relative to the outer edge or toward the interior of the shell. Structural supports may extend between the outer edge and the inner edge. The inner edge may provide structural support for the shell. Optionally, the exterior of the shell near the edge portions may be featureless or smooth for an aesthetically pleasing appearance. For example, the exterior of the shell adjacent to the outer edge may or may not include raised ridges or shoulders. In some cases, the edge portion may include raised ridges or shoulders to conceal or reduce traces caused by the molding process, such as shrinkage marks.

[0082] In examples where the inner edge is discontinuous, the suitcase may optionally include inserts positioned in all or part of the gaps within the inner edge. The inserts may be attached to the inner edge. For example, the inner edge may include two or more portions defining the gap, and the inserts may be positioned to extend between said two portions. The inserts may provide structural support for the outer shell. In one example, the gap may be located in a corner region of the outer edge, and the insert may be a corner insert extending to support the corner region of the outer shell. The inserts may reinforce the corners of the outer shell. In another example, the gap may be positioned along one side of the outer edge. The inserts may form at least a portion of the structure to which the carrying handle is attached to the exterior of the outer shell. The handle insert may reinforce the edge region of the outer shell and support concentrated loads (e.g., "point" loads) generated when the suitcase is supported by the carrying handle.

[0083] The luggage shell can be formed by molding. For example, molding can be injection molding. The injection mold assembly may include an outer mold defining the exterior of the shell. The injection mold assembly may include a core defining the interior of the shell. When the core and outer mold are positioned together, a cavity can be defined between the components. Heated material can be injected into the cavity to form the luggage shell or case. The core and outer mold are separable so that the molded product can be removed along the separation direction. In order to separate without damaging the molded luggage shell, features of the core and outer mold can be positioned or defined relative to the separation direction at a draft angle to limit contact between the molded luggage shell and the core or outer mold.

[0084] The suitcase disclosed herein can be constructed such that a portion of the outer shell deflects, stretches, or bends during separation of the outer shell and the mold core. For example, during separation of the outer shell and the mold core, the inner edge can deflect in response to contact with the mold core. In some examples, the sidewalls of the outer shell can deflect outwards. Corner areas of the outer shell can stretch or bend inwards to allow deflection of the inner edge or sidewalls. By deflecting a portion of the suitcase outwards, such as an inwardly extending inner edge, the suitcase or edge portion can be formed without the use of conventional mold sliders (e.g., internal mold components movable laterally in the separation direction).

[0085] In some examples, the inner edge is discontinuous and forms a gap along one or more corner regions of the housing. During separation, the corner regions can deflect inward. As the corner regions deflect inward, other regions (such as the inner and / or outer edges, or both) can be allowed to extend or deflect outward, or deflect outward to a greater extent. Draft angles can be selected to limit or prevent plastic deformation of the corner regions. In another example, the inner edge can contact the mold core to deflect outward toward the outer edge.

[0086] In some examples, the inner edge extends along at least a portion of the edge of the housing, including extending along one or more corner regions of the housing. During the separation of the molded product and the mold core, the inner edge may elastically bend, flex, or deflect outward in certain areas to allow the molded parts to separate and the housing to be removed. The corner regions may or may not extend outward. The inner edge may deflect outward toward the outer edge. The outer edge may deflect outward together with the inner edge. Draft angles may be selected to limit or prevent plastic or permanent deformation of the corner regions.

[0087] In some examples, the core and outer mold can define a cavity or mold volume oriented at an offset angle relative to the separation direction. For example, a portion of the cavity defining the main face can be offset at an angle relative to the separation direction. In some examples, one of the sidewalls can be positioned orthogonally to the separation direction. The opposing sidewall can extend outward at an angle relative to the main face. During separation of the core and outer mold, the opposing sidewall angle and the offset angle can provide draft angles for both the orthogonal sidewall and the opposing sidewall. By positioning the core and outer mold at an angle, the draft angle of the core can be determined by reducing the outward angle of the opposing sidewall, thus determining the draft angle of the orthogonal sidewall.

[0088] Referring now to the accompanying drawings, which help to illustrate the various features of this disclosure. The following description is for illustrative and descriptive purposes only. Furthermore, this description is not intended to limit the various aspects of the present invention to the forms disclosed herein. Therefore, variations and modifications adapted to the following teachings and the skills and knowledge in related fields fall within the scope of the various aspects of the present invention.

[0089] Figure 1 An exemplary suitcase 100 in a closed configuration is shown. Suitcase 100 may alternatively be referred to as luggage, carry-on, bag, trolley, etc. In one example, suitcase 100 may be an upright hard-sided suitcase, such as a wheeled suitcase. In other examples, luggage 100 may be various types of suitcases, including soft-sided wheeled suitcases with molded inner shells or panels, hybrid wheeled suitcases, containers, or the like. Suitcase 100 may include at least two outer shells, such as a first outer shell or top shell 118, and a second outer shell or bottom shell 120. Shells 118 and 120 may define an internal storage space 130 for carrying or storing a traveler's belongings.

[0090] The suitcase 100 may include multiple panels or sides. For example, the suitcase may include a front panel 104 and an opposite rear panel 106, a top panel 112 and an opposite bottom side or bottom panel 114, and opposite left panels 108 and right panels 110. Each of the panels may have an outer surface 138 and an inner surface 136, the inner surface 136 defining an internal storage space 130.

[0091] The suitcase 100 or outer shell 118, 120 may include at least one sidewall extending around the periphery of a main panel. In one example, the at least one sidewall includes two or more sidewalls. The at least one sidewall may at least partially define the panel. For example, the outer shell 118, 120 may each include a short sidewall 152 and a long sidewall 154. The short sidewall 152 and the long sidewall 154 may extend from or intersect at a corner region 160 of the outer shell 118, 120. In some examples, each suitcase outer shell 118, 120 includes at least two short sidewalls 152 and two long sidewalls 154. In some examples, the suitcase 100 or outer shell 118, 120 may have various shapes or orientations. Therefore, the description of the short sidewall 152 or the long sidewall 154 can be used for identification purposes. In one example, the suitcase 100 may be a carry-on suitcase. In such an example, the long sidewall 154 may be approximately 490 mm. The short sidewall 152 can be 390 mm. The corner region 160 can have an initial radius or a final radius of approximately 40 mm.

[0092] Side walls 152, 154 may be positioned around or adjacent to the main surface or panel 156 of the suitcase 100 or outer shell 118, 120. In some examples, the main panel 156 may be the front panel 104 or rear panel 106 of the suitcase 100, or define the front panel 104 or rear panel 106 of the suitcase 100. As described herein, see, for example, reference to Figure 9ASidewalls 152 and 154 can be oriented at an angle relative to the main surface 156. Sidewalls 152 and 154 can be oriented at the same angle or different angles. In some examples, opposing sidewalls relative to the main surface can be formed at the same angle or different angles. In one example, the top panel 112 can be oriented orthogonally to the main surface 156. The bottom panel 114 can extend outward relative to the main surface 156. For example, the angle of the bottom panel 114 relative to the main surface 156 can be approximately between 90 and 98 degrees. The outward angle of the bottom panel 114 can provide sufficient draft angle for both the top panel 112 and the bottom panel 114 during molding.

[0093] The suitcase 100 is movable between a closed configuration and an open configuration. In the closed configuration, the edge portions 200 of two or more outer shells 118, 120 are positioned adjacent to each other, while in the open configuration, access to the internal storage space 130 is provided. Figure 2 As shown. The suitcase 100 can be selectively opened or closed via a closure assembly 144. The closure assembly 144 may be a latch or zipper extending along a connecting line 146 between two or more housings 118, 120. Reference may be made to the first housing 118 or the second housing 120, but it should be understood that either housing 118, 120 may include the same or similar feature structures.

[0094] Each of the outer shells 118 and 120 can be integrally formed from material. For example, outer shells 118 and 120 can be formed wholly or partially from a molding polymer. In some examples, outer shells 118 and 120 can be formed from polypropylene or polypropylene blends, polycarbonate, ABS polymers, glass-filled or glass blends, or various combinations thereof. Any one or both of outer shells 118 and 120 can be formed as a single unit, and at least some features of outer shells 118 and 120 are integrally molded with outer shells 118 and 120. For example, edge portion 200 can be integrally molded with outer shells 118 and 120. In some examples, a part of the suitcase 100 is formed by injection molding all or part of each outer shell 118 and 120 and attaching additional or external portions to the exterior of the outer shell.

[0095] In some examples, luggage item 100 may include one or more carrying handles 128 and / or retractable tow handles 126. Tow handles 126 may be attached to or extend from the rear panel 106 of luggage item 100, for example, in a border or recess. Carrying handles 128 may be defined by or attached to luggage item 100. Luggage item 100 includes one or more support elements 140. Support elements 140 may be wheels, casters, swivel wheel assemblies, struts, or combinations thereof to support luggage item 100 on a support surface or to enable luggage item 100 to move on a support surface (such as a floor, street, sidewalk, or ground). In one example, wheels 140 may be coupled to housings 118, 120 along the bottom side or bottom panel 114. In some examples, wheels 140 may be coupled to corner areas 160 of housings 118, 120.

[0096] Reference Figures 2 to 4B The suitcase 100 includes an edge portion 200. The edge portion 200 is defined along the periphery or outer edge of any one or both of the outer shells 118 and 120. The edge portion 200 may be continuous or discontinuous along the outer shells 118 and 120. The edge portion 200 includes an outer edge or peripheral edge 202 and an inner edge or secondary edge 212.

[0097] The inner edge 212 extends inwardly from the inner surface 136 of the luggage outer shell 118, 120. The inner edge 212 may extend along the short sidewall 152, long sidewall 154, corner 160, etc. Accordingly, the inner edge 212 may be spaced inwardly from or positioned inside the outer edge 202. The inner edge 212 may be defined by a flange 230 having opposing inner edges 234 and outer edges 236. The inner edges 234 engage with the sidewalls 152, 154 (where the inner edge 212 is located). (At least refer to...) Figure 4B The outer edge 236 forms a free edge away from the inner edge 234, and is positioned away from the sidewalls 152, 154 when the flange 230 is tilted away from the sidewalls 152, 154. At least a portion of the inner edge 212 may be positioned further inward into the storage space 130 than the sidewalls 152, 154. In one example, the free edge 236 is positioned further inward into the storage space 130 than the sidewalls 152, 154. In some examples, the free edge 236 may deflect upon removal from the mold, as further described below. The inner edge 212 may extend along all or a portion of the outer edge 202. As described herein, the inner edge 212 may be integrally molded onto or integrally formed with the housings 118, 120.

[0098] In some examples, the outer surface 138 of the edge portion 200 may optionally define a featureless, straight edge band 210. For example, the outer edge 202 may be flush with the sidewalls 152, 154. The edge band 210 may be defined on the outer surface of at least one sidewall 152, 154 and adjacent to the outer edge 202. In one example, the edge band 210 does not protrude relative to the outer surface 138. In another example, the edge band 210 is flush with the site area.

[0099] Optionally, the outer surface 138 of the edge portion 200 defines or includes a raised ridge or shoulder. The shoulder may be disposed adjacent to the inner edge 212. In some examples, the shoulder may provide a spacing between the outer edge 202 and the inner edge 212, for example, 1 to 5 mm from the inner edge 212 at the intersection of the inner and outer edges 202. In some examples, indentation or step features may help to conceal or reduce the perceptibility of some marks, such as those produced during molding due to the forming edge portion 200.

[0100] refer to Figure 2 and Figure 3A The inner edge 212 is discontinuous, and the insert 250 may be selectively attached to the inner edge 212 to support the housing 120, for example, along the gap 235. The insert 250 may be at least partially attached to the inner edge 212 or the luggage housing 118, 120, and support the edge portion 200 along the gap 235. The insert 250 may be an edge insert 252 to support a portion of the edge portion 200, for example, in the corner area 160 or along the side panels 152, 154. The insert 250 may be a handle insert 270 to allow attachment to or define a carrying handle 274 on the exterior 138 of the luggage housing 120.

[0101] Figure 3A Showing Figure 2 A close-up view of the 120mm suitcase shell. Figure 3B Showing Figure 3A The exploded assembly diagram of the luggage shell 120 depicted is shown below. Please refer to the following for further details. Figure 3A and Figure 3B and refer to Figure 4A and Figure 4B The luggage shell 120 includes an edge portion 200, which includes an outer edge 202 and an inner edge 212.

[0102] As described herein, the edge portion 200 may be defined at the periphery of the housings 118, 120 or along the periphery of the housings 118, 122. Both the outer edge 202 and the inner edge 212 may be integrally formed or integrally molded with the housings 118, 120.

[0103] The outer edge 202 may define the perimeter or boundary of the luggage shell 118 or 120. The outer edge 202 may be partially defined by sidewalls 152, 154. The outer edge 202 may include an outer perimeter 204. The outer perimeter 204 may represent the boundary or junction between the inner surface 136 and the outer surface 138 of the shell 120. The outer edge 202 may extend in the same or similar direction as the sidewalls. In some examples, the outer edge 202 or the sidewalls 152, 154 may be positioned orthogonally (e.g., substantially perpendicular) to the main panel 156, or at an angle (e.g., a draft angle) to aid in removal from the mold. For example, the outer edge 202 or the sidewalls 152, 154 may be positioned at an angle between approximately 0 and 8 degrees relative to a direction orthogonal to the main surface 156. In some examples, the outer edge 202 may extend approximately 2 to 6 cm from its intersection with the inner edge 212 to the outer perimeter 204. In one example, the outer edge extends approximately 4 cm.

[0104] The outer edge 202 may have an edge thickness dimension 206 along a portion of the short sidewall 152 or the long sidewall 154. The edge thickness 206 may be the same at the outer perimeter 204 when along the sidewalls 152, 154, or panels of the housing 120. In some examples, the outer edge 202 may have a second corner thickness 208 at or along the corner region 160. The corner thickness 208 may be less than the edge thickness 206. The reduced corner thickness 208 may be adjacent only to the outer perimeter 204 or located between the outer perimeter 204 and the main surface 156. The reduced corner thickness 208 may be a recess in the inner surface 136 of the corner region 160. As described herein, the reduced corner thickness 208 may allow the corner region 160 of the housing 120 to deflect or bend during molding to release the molded component from the housing 120 after molding.

[0105] The inner edge 212 may be a ledge or collar extending from the sidewalls 152, 154. For example, the inner edge 212 may be a solid feature extending inward from the sidewalls 152, 154. In some examples, the inner edge 212 may extend linearly from the sidewalls 152, 154. The inner edge 212 may extend to the inner perimeter 220. The inner edge 212 may extend inward from the sidewalls 152, 154 or one or more corner regions 160, or extend inward relative to the sidewalls 152, 154 or one or more corner regions 160. The inner perimeter 220 may be located below the outer perimeter 204 to prevent interference between the inner edges 212 of the two outer shells 118, 120 in a closed configuration. A gap or channel 214 may be defined between the outer edge 202 and the inner edge 212.

[0106] The inner edge 212 may extend with an edge angle 240 relative to the sidewalls 152, 154, or corner area 160 to which it extends. The edge angle 240 may be an acute or non-orthogonal angle relative to the sidewalls 152, 154, for example, referring to the sidewalls 152, 154, or the outer edge 202. The edge angle 240 relative to the sidewalls 152, 154, or the outer edge 202 may be between 1 degree and 14 degrees. In one example, the edge angle 240 may be approximately in the range of 4 to 6 degrees, including 4 and 6 degrees. In another example, the edge angle 240 may be approximately 6 degrees. The extension length of the inner edge 212 from the sidewall to the inner perimeter 220 may be between 0.5 cm and 4 cm. In one example, the inner edge 212 may extend inwards by approximately 2.5 cm relative to the sidewalls 152, 154. In some examples, the edge angle 240 may be an angle relative to the main surface 156 of the suitcase 100. For example, the inner edge 212 can extend inward by approximately 1 to 14 degrees relative to the direction orthogonal to the main surface 156. Due to the draft angle of the sidewalls 152 or 154, the angle of the inner edge 212 relative to the main surface 156 can be approximately between 80 and 94 degrees. Because the edge angle 240 is inward relative to the sidewalls 152 and 154, the edge angle 240 can be referred to as the negative draft angle 240.

[0107] Edge portion 200 may include one or more support features or trusses 222 extending between outer edge 202 or inner surface 136 and inner edge 212. Trusses 222 may be positioned within channel 214. Support features 222 extend non-orthogonally between outer edge 202 and inner edge 212. For example, support features 222 may extend at an acute or obtuse angle between inner surface 136 and inner edge 212. In some examples, support features 222 may have a triangular, honeycomb, or zigzag pattern. Support features 222 may be integrally formed with housing 118, 120 or edge portion 200. In alternative examples, support features 222 may be coupled to edge portion 200. Support features 222 may be oriented perpendicular to the main surface. Support features 222 may provide structural support or rigidity to edge portion 200 to improve or enhance the durability of housing 118, 120.

[0108] The inner edge 212 may extend continuously along a portion of the interior 136 of the housing 120. In some examples, the inner edge 212 may extend discontinuously, such as in segments. In examples where the inner edge 212 is discontinuous, the inner edge 212 may include a first portion 216 spaced apart from the second portion 218. For example, in the case where the inner edge 212 extends discontinuously along the outer edge 202, a portion of the inner edge 212 may include or terminate at one or more side ends 224. The first portion 216 and the second portion 218 may define a gap 235. Each side end 224 may define an attachment portion 226 for engagement or connection with a portion of an insert 250 that spans the gap 235 between the side ends 224. The attachment portion 226 may include a T-shaped flange 228.

[0109] In one example, the first portion 216 extends along a portion of the long sidewall 154, and the second portion 218 extends along a portion of the short sidewall 152. The gap 235 may be defined at the corner region 160. Therefore, the inner edge 212 may be positioned adjacent to the corner region 160, rather than extending through the corner region 160.

[0110] In some examples, the inner edge 212 includes a third portion 232. The second portion 218 and the third portion 232 may be positioned along a portion of the same sidewall (e.g., the short sidewall 152) and define another gap 235 between them. The ends of each of the second portion 218 and the third portion 232 may define an attachment portion 226, respectively.

[0111] Continue to refer to Figure 3A and Figure 3B And refer to other sources. Figures 5A to 7 The luggage compartment housing 120 may include one or more inserts 250 positioned within a gap 235 in the inner edge 212. The inserts 250 may be selectively coupled to the interior of the luggage compartment housings 118, 120. For example, the insert 250 may be at least partially coupled to the inner edge 212. In some examples, the insert 250 may be bent or angled to form a corner insert 252, thereby engaging with a gap 235 formed in a corner region 160 (e.g., Figures 5A to 6 In addition to what is described, there is Figure 3A and Figure 3B ). Plug-in 250 may include specific attachment features to function as a carrying handle plug-in 270, such as Figure 7 In addition to what is described, there is Figure 3A and Figure 3B .

[0112] Insert 250 may include rigid, semi-rigid, or flexible materials. Corner insert 252 may be used when the material of the luggage shell 118, 120 is polycarbonate, ABS polymer, or glass-filled or glass-mixed materials. Carrying handle 270 or insert 250 can typically be selectively attached to or removed from luggage 100 to add or remove features of luggage 100 or select the color of features of luggage 100.

[0113] The corner insert 252 may include an insert edge 257 that defines a thinner upper portion of the corner insert 252. The insert edge 257 may be a fin or a flange. The insert edge 257 may have an insert thickness 259. The corner insert 252 may include a shelf portion 262 (e.g., a shoulder). The shelf portion 262 may be the body of the corner insert 252. The shelf portion 262 may define a receiving channel 264 opposite to the insert edge 257 at its bottom or bottom side. The receiving channel 264 may be defined at an insertion end 266 of the shelf portion 262. The shelf portion 262 may include two spaced-apart insertion ends 266.

[0114] Figure 5B and Figure 3A An exemplary corner insert 252 is depicted attached to housing 120. In one example, corner insert 252 is attached to a first portion 216 and a second portion 218 of inner edge 212 and is positioned in a gap 235 formed in corner region 160. For example, it extends from side end 224 of first portion 216 to side end 224 of second portion 218.

[0115] The corner plug 252 is attached to a portion of the inner edge 212 via the attachment portion 226 received in the receiving channel 264. For example... Figure 5C As shown, when the T-shaped attachment portion 226 is received in the corresponding T-shaped receiving channel, the flange 228 can be held by the receiving channel 264. Accordingly, the attachment portion 226 connects the corner plug 252 to the inner edge 212.

[0116] When the corner insert 252 is attached to the inner edge 212, the corner insert 252 can contact the inner surface 136 of the corner region 160. The shelf portion 262 can provide structural support or rigidity to the housing 120, for example, in the corner region 160. The insert edge 257 can extend along the inner surface 136 of the corner region 160, reaching or near the outer perimeter 204. Figure 5DAs shown, the combined thickness 268 of the plug-in thickness 259 at the plug-in edge 257 and the corner thickness 208 at the corner region 160 can be similar to or equal to the outer edge thickness 206 of the adjacent corner region 160. The combined thickness 268 of the plug-in thickness 257 and the outer perimeter 204 at the corner region 160 can make the corner region 160 of the housing 120 more robust or more durable.

[0117] Reference Figure 6 The insert 250 can be secured to the housing 120 via stitches 148. In one example, a portion of the closure assembly 144 (such as a zipper tape) can be stitched to the housing 120 together with the corner insert 252. The closure assembly 144 can be stitched to the inside 136 or the outside 138 of the housing 120. The thin structure of the insert edge 257 allows the stitching device to pierce the corner insert 252 while also providing support for the edge portion 160.

[0118] Reference Figure 3A , Figure 3B and Figure 7 The insert 250 may be a carrying handle insert 270. The carrying handle insert 270 may include a handle feature that is positioned externally to the luggage compartment housing 120. The carrying handle insert 270 may include an anchoring portion 278 for attaching the handle portion 274 via the luggage compartment side walls 152, 154. The anchoring portion 278 or the carrying handle insert 270 may be attached to the housing 120, for example, at the inner edge 212.

[0119] The handle portion 274 may be a handle, a hook, or other feature for the traveler to grip. The handle portion 274 may define one or more openings 280a. The openings 280a are positioned and shaped to receive fasteners, such as countersunk holes or threads. In one example, at least two openings 280a are defined at opposite ends of the handle portion 274 to receive fasteners attached to the handle portion 274.

[0120] Anchoring portion 278 may be a feature that joins or connects to the housing 120 and handle portion 274. Anchoring portion 278 may be a support feature for reinforcing edge 202 in the absence of inner edge 212. For example, anchoring portion 278 may reinforce edge portion 200 and support point loads generated when carrying the suitcase using carrying handle 274. The shape of anchoring portion 278 may match the contours of the interior of suitcase housing 120 or suitcase 100.

[0121] Anchoring portion 278 may define receiving channel 282 at opposite ends. Receiving channel 282 may be the same as or similar to T-shaped receiving channel 264. Thus, receiving channel 282 may be an aperture having a shape corresponding to attachment portion 226 or flange 228, such as T-shape.

[0122] In examples where the housing 120 includes a carrying handle insert 270, the inner edge 212 may be discontinuous or largely continuous and defines a portion for receiving the carrying handle insert 270. For example, the inner edge 212 may define a gap 235 between two portions, such as a second portion 218 and a third portion 232. An anchoring portion 278 may be engaged with the handle portion 274. In some examples, the housing 120 defines one or more housing apertures 272, which are correspondingly spaced from apertures 280a. Fasteners may be used to attach the insert 270 to the housing 120, or the anchoring portion 278 may be engaged with the inner edge 212.

[0123] Go to Figure 8A and Figure 8B They depict example diagrams of forming an integral molded housing 120.

[0124] To allow the portions of the outer casing 120 to bend, deflect, or stretch during separation of the mold core 303, the outer casing 120 may be formed of polypropylene or a polypropylene blend. The polypropylene material may have favorable melt flow characteristics that facilitate the formation of the casing by injection molding. After the luggage compartment 100 is formed, the polypropylene material may be elastic at lower or colder temperatures. The polypropylene material also resists visible or permanent deformation, such as whitening, during bending, deflection, or stretching. One or more materials may also include or be ABS, polycarbonate, or glass-filled or glass-blended materials.

[0125] like Figure 9A As shown, the mold core 303 and the outer mold 315 can be part of the mold assembly 300. When the mold core 303 and the outer mold 315 are closed together, they define the mold cavity 301 (see reference). Figure 9A and Figure 9B(As described above), material is injected into mold cavity 301 to form outer shell 120 by injection molding. To insert or remove mold core 303 from outer mold 315, mold core and / or outer mold 315 typically move relative to each other along a single axis or direction. For example, mold core 303 may move only along direction 330. Mold core 303 may define internal features of luggage outer shell 120. For example, mold core 303 may have a surface corresponding to the shape of interior 136 of outer shell 120. Outer mold 315 may define external features of luggage outer shell 120. In some examples, edge portion 200 is at least partially defined by mold core 303 and outer mold 315. In some examples, outer mold 315 may be separated from luggage outer shell 120 before separating mold core 303 from luggage outer shell 120.

[0126] Typically, to remove the molded part from the mold core, the mold core and molded part are shaped to limit or reduce contact to prevent damage to the molded part by the mold core. To achieve this, the molded part and mold core are often defined with draft angles or tapered shapes, such that a space is created between the molded part and mold core as the mold core 303 moves along the separation direction 330 (which is also the direction of separation), and this space increases with the removal of the mold core. Furthermore, inwardly oriented features often require separate mold components, such as sliders, that move laterally to the separation direction 330. However, these laterally moving components increase complexity and cost and may produce surface features or other visible defects, giving travelers an unsightly experience.

[0127] refer to Figures 8A to 8DTo form an inner edge 212 extending inward from the interior 136 of the housing 120, one or more portions of the housing 120 are designed to deflect or bend during separation from the core 303, thus eliminating the need for lateral movement components such as sliders. As the core 303 moves along the separation direction 330, it may contact the inclined surface of the inner edge 212, which may elastically deflect outward, for example, along direction 344. In some examples, regions of the housing 120 (such as sidewalls 152, 154) deflect outward to accommodate the removal of the core 303 to a deflection position 342, which may deflect together with the inner edge 212. In some examples, the inner edge 212 deflects outward (e.g., moves toward the outer edge 202), while the deflection of the sidewalls 152, 154 is smaller. In some examples, the edge angle 240 between the inner edge 212 and the outer edge 202 may be reduced during separation of the core 303 from the housing 120. Because the inner edge 212 can be formed at an inward angle (e.g., a negative draft angle), and this can result in elastic deflection of the sidewalls 152, 154 and / or the inner edge 212, a mold without a slider can be used. Alternatively or additionally, the formation of structural features (e.g., shoulders) near the edge portion 200 on the exterior of the luggage housing 120 is reduced or eliminated. As an alternative or supplement, aesthetic defects in the molded luggage housing 120 are also reduced.

[0128] Go to Figure 8C and Figure 8D A cross-sectional view of an exemplary mold core 303 separated from the housing 120 is depicted. Figure 8C and Figure 8D The deflection or flexure of the corner region 160 for separating the mold core 303 and the luggage shell 120 is depicted. In some examples, deflection can be achieved by defining a corner region 160 without an inner edge 212 and / or with a thinner corner thickness 208. For example, the corner region 160 can be moved inward and the sidewalls 152, 154 can be bent outward, which allows the mold core 303 to pass through the inner edge 212 and separate from the shell 120.

[0129] Figure 8C A top view of the mold core 303 in the molded luggage shell 120 is shown. Figure 8A The cross section represented by the centerline 8C-8C is taken at the depth where it intersects with the edge portion 200 (including the outer edge 202 and the inner edge 212). The portion 307 of the mold core 303 below the section line 8C-8C is represented by a dashed line. The lower portion 307 shows the draft angle or taper of the mold core 303 (e.g., different widths at different heights). The lower portion 307 can be the bottom, middle, or other area of ​​the mold core 303.

[0130] At the corner region 160, the outer edge 202 can be defined at the initial position 340 as a first radius of curvature 346. The first radius of curvature 346 may correspond to the radius of the corner 160 after or before separation from the mold core 303 (e.g., after forming the luggage case shell 120).

[0131] Figure 8D Depicting the process of removal (e.g., along) Figure 8B The cross-section of the core 303 and the housing 120 is shown in direction 330. During removal, as described herein, the core 303 may contact the inner edge 212 and deflect the sidewalls 152, 154 outward, for example, along direction 344. In some examples, to cause the sidewalls 152, 154 to bend outward, the corner region 160 of the housing 120 may be elastically deflected or bent inward, for example, along direction 349. For example, as the outer periphery 204 moves inward in the corner region 160, the radius of the corner 160 increases from a first radius of curvature 346 to a second radius of curvature 348. To increase the radius of curvature, the lower portion 307 may contact the inner edge 212, and the corner region 160 may be forced inward to contact the lower portion 307. By bending or deflecting the corner region 160, an inwardly extending inner edge 212 can be formed to reinforce the edge 200 without the use of transverse mold components (e.g., sliders).

[0132] In some examples, during separation of the housing 120 and the core 303, the material of the housing 120 may allow deflection while resisting stretching or deformation (e.g., permanent or substantial changes in dimensions such as the width, thickness, or length of a portion of the housing 120). For example, corner region 160 may deflect inward without stretching. In examples where only deflection occurs in corner region 160, the material of the housing 120 may be a relatively rigid or durable material. In some examples, support 222 may help prevent stretching of the portion of the housing 120 containing the inner edge 212.

[0133] In some examples, when the inner edge 212 deflects toward the outer edge 202, the support or truss 222 also elastically deflects or deforms. As a result, the width of the channel 214 can be reduced to help separate the housing 120 from the core 303. By positioning the support or truss 222 in a non-orthogonal position relative to the inner edge 212 and the outer edge 202, the support feature 222 can support the inner edge 212 while also accommodating elastic deflection.

[0134] Go to Figure 9A and Figure 9B An exemplary mold assembly 300 for forming exemplary suitcase shells 118, 120 is depicted.

[0135] Reference Figure 9A The suitcase 100 includes side panels 152 and 154 (see Figure 2 It may extend from the main face 156 defined by the mold cavity 301. Side walls 152 or 154 may be a top side wall 112 or a bottom side wall 114. In some examples, the angles of side walls 112 and 114 relative to the main face 156 may be approximately orthogonal or outwardly oriented. In one example, the angles relative to the main face 156 are approximately between 90 and 98 degrees.

[0136] In one example, for example, Figure 9A and Figure 9B As shown, the trunk shells 118 and 120 are designed with one side (such as the top panel 112) extending or orthogonally to the main wall 156 at an angle 320 of approximately 90 degrees. The opposite side (such as the bottom panel 114) can extend outward at an angle 247 from a line perpendicular or orthogonal to the main wall 156. The angle 247 can be approximately 8 degrees. The angle 322 between the main wall 156 and the bottom panel 114 includes a right angle and angle 247, approximately 98 degrees. For example, the bottom panel 114 can extend outward at an angle 322 of approximately 98 degrees relative to the main wall 156.

[0137] Reference Figure 9B Typically, the mold cavity is vertically oriented and "perpendicular" to the mold separation direction 330. The mold separation direction 330 refers to the direction of relative movement between the core 303 and the outer mold 315 as they separate to remove the molded part. In the examples herein, the offset angle 305 of the mold cavity 301 is relative to the mold separation direction 330. Generally, the draft angle can be determined relative to the separation direction 330 to reduce, minimize, or prevent interference between mold components or molded parts. The draft angle can be between 1 degree and 5 degrees, but can also be greater or less than this range. For illustrative purposes, in one example, the draft angle could be 4 degrees. Because molds may require draft angles, features that are parallel or inwardly inclined relative to the mold movement direction 330 (e.g., with a negative draft angle) are often difficult to remove from the mold without damage. For example, during the separation of mold components and demolding of the molded part, the core or outer mold may come into contact with features of the molded part and cause damage.

[0138] The mold assembly 300 includes a mold core 303 or male mold, and a female mold or outer mold 315. The mold core 303 and the outer mold 315 may define a mold cavity 301 therebetween, into which luggage shell material is injected to form luggage shells 118, 120. The mold cavity 301 may correspond to the shape and features of the luggage shells 118, 120. For example, when injection molding material, the mold cavity 301 may define the sidewalls and edge portions 200 of the shells 118, 120.

[0139] In the assembly configuration, the walls 309a, 309b and bottom wall 319 of the mold core 303, and the walls 310a, 310b and bottom wall 318 of the outer mold 315, can be aligned and spaced apart (e.g., not in contact or interfering) to define at least a portion of the mold cavity 301. The walls 309a of the mold core 303 and 310a of the outer mold 315 can define the orientation of the top wall 112 relative to the main surface 156 by an angle 320. The angle 320 can be approximately orthogonal or right-angled. The walls 309b of the mold core 303 and 310b of the outer mold 315 can define the orientation of the bottom wall 114 relative to the main surface 156 by an angle 322. The angle 322 can be greater than the orthogonal angle. For example, it can be 0 to 8 degrees larger than the orthogonal angle. Therefore, the angle 322 can be approximately between 90 and 98 degrees.

[0140] In a typical mold assembly with vertically arranged cavities, an angle 320 of 90 degrees between the top panel 112 and the main wall 156 is impractical because there is insufficient draft angle to allow the molded part to be demolded from the mold assembly. Furthermore, a negative draft angle may occur because the inner edge 212 is inclined relative to the sidewalls toward the internal storage space 130 of the trunk housing 120. This results in the inner edge 212 engaging with the core 303 upon release of the housings 118, 120 from the outer mold 315. In some examples, the inner edge 212 may be angled to the parallel direction or extend laterally relative to the separation direction 330, but extend inward relative to the orientation of the sidewalls 112, 114 or the outer edge 202. For example, the inner edge 212 may extend at an angle toward or intersect with the separation direction 330 of the core 303 and the outer mold 315.

[0141] Walls 309a and 309b may include cavity features 328 to define an inner edge 212. Walls 309a and 309b may be continuous around the entire outer mold 315 and mold core 303 to define short sidewalls 152 and long sidewalls 154 of the housings 118 and 120. Cavity features 328 are located on the mold core where the inner edge 212 is desired to extend along the luggage housings 118 and 120, as described herein. Cavity features 328 are configured to form the inner edge 212. In some examples, the inner edge 212 may be defined on the short sidewalls 152 and long sidewalls 154.

[0142] The cavity 301 can be oriented at an offset angle 305 relative to the separation direction 330 within the mold assembly 300. The offset angle 305 facilitates the separation of the outer shells 118, 120 from the core 303 by deflecting the inner edges 212 and outer edges 202 outward during separation. The offset angle 305 of the cavity 301 can be approximately 4 degrees below the horizontal plane and approximately 94 degrees relative to the mold removal or separation direction 330. The main surface 156 forms an angle 400 of 4 degrees relative to the horizontal direction and an angle of approximately 94 degrees relative to the mold separation direction 330.

[0143] An offset angle of 305 results in a draft angle 402 of approximately 4 degrees for the top panel 112. The draft angle 402 is determined by the superposition of angle 320 and offset angle 305. The draft angle is measured relative to the mold separation direction 330. The draft angle 406 of the inner edge 212a (on the top panel 112) is negative, approximately -4 degrees. The bottom panel 114 portion of the mold cavity 301 has a draft angle 410 of approximately 4 degrees. The draft angle 410 of the bottom panel 114 is derived from the difference between offset angle 305 and mold cavity angle 322. Accordingly, the draft angle 402 of the top wall 112 is determined by angle 322, where angle 322 is greater than the draft angle 410 by offsetting the mold cavity along angle 305. In one example, for reference purposes, the draft angle 414 of the inner edge 212b is negative, and can be approximately -4 degrees relative to the perpendicular direction of the main surface 156. Figure 9B The offset angles and draft angles shown in the examples can vary, for example, depending on the size of the suitcase, the material used, or the intended aesthetics of the suitcase. For example, offset angle 305 can be approximately half of the symmetrical draft angle 322 of opposite sides or opposite walls. In some examples, offset angle 305 is equal to the intended draft angle 402 of the orthogonally oriented wall after molding.

[0144] like Figure 9B As shown, the problem of negative draft angle is mitigated by setting the mold cavity 301 in the mold assembly 300 with an offset angle. The top panel 112 is oriented with sufficient draft angle relative to the mold separation direction 330 to allow separation of the trunk shells 118, 120 from the mold core 303. The draft angle 402 of the top panel 112 is derived from an increased or greater draft angle of the bottom panel 114 defined by angle 322. The draft angle 402 of the top panel 112 helps to separate or reduce contact between the top wall 112 and the mold core 303 during separation.

[0145] Additionally or alternatively, the negative draft angle 240 of the inner edge 212 is sufficiently reduced to allow release of the mold core 303 from the housings 118, 120 by deflecting the inner edge 212 and / or the outer edge 202 outward. The undercut feature formed by the inner edge 212 is sufficiently gentle so that the mold core 303 slides over the inner edge 212 without getting stuck. For example, the inner edge 212 may be formed with an inclined cam surface in the relative movement direction 330 to allow the inner edge 212 and / or the outer edge 202 to gradually deflect outward in response to sliding contact with the mold core 303. In some examples, the offset angle 305 may orient the inner edge 212 closer to or parallel to the mold movement direction 325, thus reducing the negative draft angle that needs to be overcome when demolding from the mold assembly.

[0146] Therefore, the features of the housings 118 and 120 are configured to be spaced apart or deflected upon contact with the mold assembly 300 upon release, avoiding undesirable damage caused by contact with the mold core 303. This, in turn, allows for more efficient injection molding of the luggage housings 118 and 120 in the mold assembly 300 at a lower cost, because the mold assembly may not require complex moving parts (such as sliders) that increase the cost, maintenance costs, and complexity of the injection molding operation.

[0147] Reference Figure 9C This shows an example of the rear cover of the trunk 120, with Figure 2 The same or similar depictions are shown, with wheels, carrying handles, and traction handles omitted for clarity. The storage space 130 of the trunk shell 120 is depicted having a top wall 112, opposing side walls 108, 110, and a bottom wall 114, which are attached to and extend away from the main panel 156. As described herein, for example, the angle 320 between the top wall 112 and the main panel 156 can be approximately 90 degrees. In one example, the draft angle of the top wall in the mold can be approximately 4 degrees. The angle 322 between the bottom wall 114 and the main panel 156 can be approximately 98 degrees. In one example, the draft angle of the bottom wall in the mold can be approximately 8 degrees. This draft angle is approximately twice the typical draft angle (i.e., 4 degrees) of a similar side wall structure in a trunk. The angles 324 between the opposing side walls 108, 110, and the main panel 156 can each be approximately 94 degrees. In one example, the draft angle of each of these walls can be approximately 4 degrees.

[0148] Still referencing Figure 9C In this example, the inner edge 212 of the suitcase 100 continuously passes through at least one corner area and extends through all four corner areas of the outer shell as shown. In some examples, such as the one shown, the inner edge 212 extends around a large portion of the periphery 202 of the outer shell 120 and may extend around the entire length of the periphery 202 of the outer shell 120.

[0149] Go to Figure 10 , Figure 11A and Figure 11B An exemplary suitcase 500 is depicted, showing an inner edge 612 that extends continuously through at least one or more corner areas 560. This suitcase 500 may be similar to those previously referenced. Figures 1 to 9B The described suitcase 100 is distinguished primarily by its inner edge 612 extending through at least one corner region 560. For example, the suitcase 500 may include two or more outer shells 520. The outer shell 520 may include sidewalls, such as a short sidewall 552 and a long sidewall 554. Sidewalls 552 and 554 may intersect or transition at the corner region 560. The suitcase outer shell 520 may have an inner surface 536 and an outer surface 538.

[0150] The suitcase 500 includes an edge portion 600. The edge portion 600 may be similar to edge portion 200 and includes an outer edge 602 and an inner edge 612. The outer edge 602 may define an outer perimeter 604. The inner edge 612 may extend inwardly from the inner surface 536 of the sidewalls 652, 654 to an inner perimeter 620. Therefore, the inner edge 612 may be spaced apart from the outer edge 602. For example, a passage 614 may be defined between the inner edge 612 and the outer edge 602. The edge portion 600 may include a support feature or truss 622. The support feature or truss 622 may extend between the inner edge 612 and the outer edge 602, for example, extending in the passage 614. The support feature 622 may be oriented at a non-orthogonal angle between the inner edge 612 and the outer edge 602. The inner edge 612 and the truss 622 may support the outer casing 520 or increase the rigidity of the outer casing 520 along the edge portion 600.

[0151] The inner edge 612 of the suitcase 500 may be continuous or discontinuous. The inner edge 612 of the suitcase 500 continuously extends through at least one corner region 560 of the outer casing 520. In some examples, the inner edge 612 may extend continuously along a large portion of the outer periphery of the suitcase 500. The inner edge 612 may continuously extend 50% to 90% of the outer periphery of the suitcase 500. For example, the inner edge 612 extends along the outer edge 602, passing through the corner region 560 of the outer casing 520. In some examples, the inner edge 612 may extend continuously along the outer periphery of the outer casing 500, or continuously around the outer periphery of the outer casing 500, except for a portion or gap for receiving or attaching a suitcase insert 650 (such as a handle). Where the inner edge 612 optionally includes a gap for a handle feature or insert 650, the inner edge 612 may define two or more side ends 624. The side ends 624 may define attachment features 626 to receive or attach to one or more inserts 650, as shown above. Figures 1 to 9B The aforementioned carrying handle.

[0152] Go to Figure 11A and Figure 11B The diagram depicts a top cross-sectional view of the luggage housing 520 and the mold core 703. As described herein, the luggage housing 500 can be formed by molding (e.g., injection molding) of a mold assembly including the mold core 703. Separation of the luggage housing 520 from the mold core 703 can be similar to the separation of the luggage housing 120 from the mold core 303 discussed herein. To separate the luggage housing 520, which includes an inner edge 612 that continuously passes through a corner region 560, the inner edge 612 is deflected toward the outer edge 602 or sidewalls 552, 554. The outer edge 602 or sidewalls 552, 554 may also be resiliently deflected outward to allow the inner edge 612 to pass over the mold core 703 during removal. For example, the corner region 560 may be stretched or bent to provide increased space for separation of the mold core 703.

[0153] The material of housing 520 may be similar to or different from that of housing 120. For example, housing 520 may be polypropylene, ABS, polycarbonate, glass-filled or glass-blended materials, or mixtures and compositions thereof. In some examples, the continuous inner edge 612 may allow a portion of housing 520 to be stretched or elastically deformed to separate from the core 703. To allow stretching, the material may be softer or thinner to reduce resistance to stretching. Housing 520 may use polypropylene or other materials that resist visual indications of stretching (e.g., whitening).

[0154] Reference Figure 11A Before separating from the mold core 703, the inner edge 612 can be separated from the outer edge 602 by a distance 640, which can also be the channel width 640. The channel width 640 can be determined between the inner perimeter 620 and the outer perimeter 604. This configuration can also correspond to the final position of the inner edge 612.

[0155] Reference Figure 11B The mold core 703 can be removed along the separation direction. The separation direction can be parallel to the viewing angle (e.g., entering or leaving the page). Figure 8B and Figure 8D Similar to the depiction, the inward orientation of the inner edge 612 can cause a portion of the mold core 703 to contact the inner edge 612. When the mold core 703 separates from the luggage housing 520, the inner edge 612 can deflect toward the outer edge 602 or the sidewalls 552, 554. For example, a reduced channel width 642 can be defined between the inner edge 612 and the outer edge 602. By deflecting outward or reducing the channel width 642, the resilient deflection of the inwardly extending inner edge 612 allows the mold core 703 and the luggage housing 620 to separate without damaging the housing 520. In some examples, the sidewalls 552, 554 can also deflect outward. In such examples, the inner edge 612 can resiliently deflect a greater distance than the outer edge 602, resulting in a reduced channel width 642.

[0156] The elastic deflection or bending of the support 622 and the inner edge 612 can facilitate the deflection of the inner edge 612. For example, a non-orthogonal orientation of the support 622 can achieve bending of the inner edge 612 by distributing the load across the inner edge 612 when bending occurs between the outer edge 602 and the inner edge 612. In contrast, while an orthogonal orientation support could be used, it may be more rigid and exhibit less deflection or deformation.

[0157] In some examples, the corner region 560 can be stretched to provide increased space for the separation of the housing 520 and the core 703. In some examples, both the corner region 560 and the inner edge 612 can be stretched or bent, for example, joined together. Stretching of the corner region 560 can occur along the inner edge 612. Stretching of the housing 520 can occur along a portion of the corner region 560 spaced apart from or adjacent to the inner edge 612. For example, the inner edge 612 can resist stretching or deformation. In such examples, a continuous inner edge 612 can help maintain the peripheral dimensions of the housing 520, for example, a predetermined length for a closure mechanism such as a zipper tape.

[0158] Other examples and implementations fall within the scope and spirit of this disclosure and the appended claims. For example, features that implement the functions may also be physically located in different places, including portions distributed such that the functions are implemented in different physical locations. Furthermore, as used herein (including the claims), the word "or" in a list of items prefixed with "at least one" indicates a disjunctive list, for example, a list of "at least one of A, B, or C" means A or B or C or AB or AC or BC or ABC (i.e., A and B and C). Moreover, the word "exemplary" does not imply that the described examples are preferred or superior to other examples.

[0159] For ease of explanation, specific terminology has been used in the above description to provide a comprehensive understanding of the described embodiments. However, it will be apparent to those skilled in the art that these specific details are not necessary to implement the described embodiments. Therefore, the above description of specific embodiments is provided for illustrative and descriptive purposes only. It is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to those skilled in the art that various modifications and variations can be made based on the above teachings.

Claims

1. A suitcase, comprising: At least one injection-molded housing, including a main panel and at least one sidewall that together define an internal storage space, the sidewall at least partially defining an integrally molded outer edge and an integrally molded inner edge positioned inside the outer edge; and The inner edge extends along at least a portion of the length of the outer edge, and the inner edge extends away from the sidewall at an acute angle.

2. The suitcase according to claim 1, wherein, The sidewall extends from at least a portion of the periphery of the main panel, the sidewall including at least one corner region, and the outer edge is defined to extend at least partially along the sidewall and the at least one corner region; and The inner edge extends along at least a portion of the sidewall and along the at least one corner region.

3. The suitcase according to claim 1 or 2, wherein, The inner edge extends around approximately 50-90% of the length of the outer edge.

4. The suitcase according to claim 1 or 2, wherein, The inner edge extends continuously along most of the length of the sidewall.

5. The suitcase according to claim 1 or 2, wherein, The inner edge extends around the entire length of the outer edge.

6. The suitcase according to claim 1 or 2, wherein, The supporting feature extends between the outer and inner edges.

7. The suitcase according to claim 1 or 2, wherein, The outer edge is flush with the outer surface of at least one sidewall.

8. The suitcase according to claim 1 or 2, wherein, At least a portion of the sidewall extends substantially orthogonally from the main panel.

9. The suitcase according to claim 2, wherein, The sidewall includes a top panel and an opposing bottom panel; and The bottom panel extends from the main panel at an angle that is approximately between 90 and 98 degrees, and includes both 90 and 98 degrees.

10. The suitcase according to claim 1 or 2, wherein, The acute angle between the inner edge and the sidewall is approximately between 1 degree and 14 degrees, and includes 1 degree and 14 degrees, or approximately between 4 degrees and 6 degrees, and includes 4 degrees and 6 degrees.

11. The suitcase according to claim 1 or 2, wherein, The angle of the inner edge relative to the main panel is approximately between 80 degrees and 94 degrees, and includes both 80 degrees and 94 degrees.

12. The suitcase according to claim 1, wherein, The at least one housing includes: A first portion and a second portion of the sidewall, wherein the first portion is orthogonally oriented relative to the main panel, and the second portion is oriented relative to the main panel at a greater outward angle than the first portion.

13. The suitcase according to claim 1 or 2, wherein, The inner edge forms an inclined surface for sliding contact with the mold core during removal of the outer shell from the mold.

14. The suitcase according to claim 1 or 2, wherein, The inner edge deflects outward when released from the mold core, or the inner and outer edges deflect outward when released from the mold core.

15. The suitcase according to claim 1, further comprising: At least one wheel is mounted on the corner area of ​​the bottom panel of the housing; as well as The towing handle is mounted on the rear main panel of the housing.

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