Part of a luggage system including natural fiber materials and methods for making and repairing same - Patents.com

Abstract

The present invention relates to a part for a luggage system, in particular a hard shell case or trolley shell, comprising a natural fibre material. The invention further relates to a method for the manufacture and for the repair of such a part. A part for a luggage system is provided which comprises a fibre reinforced material comprising a natural fibre material and a matrix material. The natural fibre material comprises at least one set of unidirectional fibres embedded in and / or impregnated with the matrix material.

Description

[Technical field]

[0001] 1.Technical Field The present invention relates to luggage systems or parts of luggage systems comprising natural fibre material, in particular hard shell cases or trolley shells or parts of such shells. The present invention further relates to methods for the manufacture and repair of such luggage systems or parts of luggage systems. [Background technology]

[0002] 2. Conventional Technology Fiber materials made of synthetics, carbon or e-glass have been utilized in the carry bag industry for decades, both in woven and non-woven patterns suspended in a suitable matrix material, to add strength in many areas, such as tensile, tear and torsional stability of luggage. Although these composite materials can provide high levels of mechanical performance, they are prone to weakening and breakage due to poor processing and environmental conditions.

[0003] Regardless of the cause, once a defect occurs in such a composite shell, there is little possibility of repairing the shell, only replacement is considered. In order to be recycled, the individual materials comprising the composite within the broken shell must be individually separated via thermal, mechanical or chemical processes in state-of-the-art recycling facilities. Globally, composites are rarely recycled due to the difficulty of separating the contained materials, the high amount of energy required to perform the separation, and the lack of economic incentives to do so.

[0004] Considering that the materials contained in known composites are inorganic and that their extraction and processing can or are already known to be highly damaging to the environment, most often ending up in landfills, the life cycle analysis of the strongest composites worldwide in the luggage industry is surprisingly short, with negative impacts on the environment both at the beginning and end of their life.

[0005] However, for many consumers, ecological sustainability has become an important attribute that they would like to see developed in many products. It is often said that sustainability and durability are opposing ideas at a reasonable cost, and that one must be sacrificed for the other, thereby forcing constant compromise on the consumer.

[0006] The use of natural fibers is considered in document US 3,383,272 A, which describes a modeled rigid product having curved and non-curved portions, obtained from a resin-containing fiber mass containing a plurality of fibers, in particular jute fibers, formed into a porous intertwined mass by suitable needling or gigging means.

[0007] More recently, luggage made from flax fibre and bioplastics has been offered by PROJECTKIN (website: https: / / projectkin.com / ) of Denmark. Summary of the Invention [Problem to be solved by the invention]

[0008] However, a need remains for luggage that improves upon the environmental impact of conventional luggage systems while maintaining the stability and strength of known constructions and composite materials. [Means for solving the problem]

[0009] This problem is addressed and at least partially solved by different aspects of the present invention.

[0010] 3. Overview of the Invention A first aspect of the invention relates to part of a luggage system, in particular a shell or part of a shell of a hard shell case or trolley.

[0011] In one embodiment, a portion of a luggage system includes a fiber reinforced material, the fiber reinforced material including a natural fiber material and a matrix material, the natural fiber material including at least one set of unidirectional fibers embedded in and / or impregnated with the matrix material.

[0012] Throughout much of this document, for simplicity and brevity, reference will be made simply to "parts of a luggage system" (or even shorter, "luggage parts"), but unless otherwise stated, the option of the entire luggage system, such as a complete hard shell case or a complete trolley, is always implied.

[0013] Also, in addition to the shells or shell parts of hard shell cases or trolleys already mentioned, the disclosed fiber reinforced material may also be applied to other types of luggage where the fiber reinforced material can be beneficially used as reinforcement in certain areas of a bag or travel case made from a different material, for example at the edges or corners of the bag or case or in areas where wheels are attached.

[0014] In the context of this document, natural fiber materials, sometimes also called organic fiber materials, are fiber materials derived from plants or other natural sources, as opposed to the synthetic or chemical-based materials conventionally used in the art as mentioned at the outset. Specific examples of such materials are given below.

[0015] A set of unidirectional fibers is a set of fibers that are arranged along a preferred direction (e.g., by intentional arrangement during manufacturing) as opposed to randomly or disorderly arranged fibers, either naturally or after being processed into such an arrangement, for example, by needling or gigging. Of course, in an actual product, such unidirectional fibers are generally not arranged perfectly parallel to the above-mentioned preferred direction, if the term "parallel" is interpreted in the strict mathematical sense. A discernible "direction" is imparted to the fiber arrangement, although some unavoidable deviations due to, for example, the manufacturing process and / or inherent irregularities in the shape of the fibers are allowed. Thus, when the term "unidirectional" is used in the context of this document, the understanding of the term may be consistent with the natural understanding of the term by a person skilled in the relevant art.

[0016] In addition to one or more sets of unidirectional natural fibers, the natural fiber material may contain additional natural fibers in any type of arrangement, but in a preferred option, the natural fiber material is composed entirely of one or more sets of unidirectional natural fibers.

[0017] The unidirectional fibres may be partially or completely embedded in the matrix material (suitable matrix materials and their properties are described below) and / or partially or completely saturated with the matrix material. Embedded in the matrix material may be understood in the sense that the fibres are suspended or "floating" in a bed of matrix material, i.e. that the fibres may be interspersed in the spaces between the individual fibres by the matrix material. Saturated with the matrix material may be understood in the sense that the matrix material is "wicked" into the fibres, e.g. such that the fibres become "sticky" or stick to each other, without any appreciable amount of matrix material being present between the individual fibres. Of course, a gradation between the two options is also conceivable; i.e. the fibres may be (partially) embedded in the material matrix and (partially) saturated with the matrix material.

[0018] In addition to the natural fiber material comprising at least one set of unidirectional fibers embedded in and / or impregnated with a matrix material, the fiber-reinforced material may also comprise additional materials or components, such as (non-organic) woven fabrics for additional reinforcement, especially in areas subject to high loads and forces. However, in a preferred scenario, the fiber-reinforced material does not comprise any fiber material in addition to one or more natural fiber materials.

[0019] A portion of the luggage system may be made only from the fiber reinforced material. However, the portion may include additional components made from or including one or more different materials. For example, the portion of the luggage system may be a (front and / or back) shell of a hard shell case or a travel or cabin trolley, generally consisting of a front shell and a back shell. The shell body may be made from the disclosed fiber reinforced material. In addition, the shell may include, for example, a hinge system, a zipper or closure system, a handlebar or grip structure, one or more wheels, etc., with or without the disclosed fiber reinforced material or consisting of the disclosed fiber reinforced material.

[0020] Natural or organic fiber materials that may be used in the context of the present invention (some examples of which are described in more detail below) may require few herbicides and pesticides, little water to grow, little energy to harvest and process, and may contain few or no harmful chemicals. Also, especially when combined with a matrix material consisting of or including biodegradable compounds of biological origin, it may be possible to extract the fibers from the matrix material at the end of the life of the luggage system through common composting methods that rely on water, ambient temperature, pressure, and UV light to degrade and be recycled or act as additional soil fertilizer.

[0021] Furthermore, in non-directional composite materials (e.g. fiber reinforced materials with randomly arranged fibers), the reinforcing fibers do not have a specific orientation, so that the energy during an impact is not distributed evenly in the material, and therefore, in case of a defect, the failure of the material can propagate in any of several directions. This is especially dangerous in luggage systems such as trolleys, where there are generally no designated impact absorbing zones (in other words, an impact can occur from any direction in any part of the luggage), and there is a high risk of damage beyond the possible repair point of the trolley or even the risk of destruction if such non-directional composite materials are used. Also, in such non-directional materials, adding mass in certain areas (i.e. additional layers in the corners of the trolley) is almost the only method used to increase the strength of the material, which goes against the principles of sustainability and the ever-increasing regulations on the weight limits of luggage.

[0022] In contrast, the set of unidirectional fibers used in the present invention transfers the impact energy in a more predictable and controllable manner, since each fiber transmits the energy in a specific direction and along the path of least resistance. In addition to the option of orienting the fibers so that the energy is more efficiently dispersed away from areas at least considered more likely to cause an impact (e.g. at an edge or corner), the unidirectional fibers can limit the amount of damage, if a break does eventually occur, for example by directing the break in a direction that is less critical with respect to the stability of the entire suitcase / trolley. Thus, compared to using randomly arranged fibers, the unidirectional fibers used in the disclosed material can provide the material with a "stable frame" that increases its overall stability and lifespan.

[0023] Another advantage of using natural fibers in a unidirectional arrangement is that natural fibers are often very strong in the machine direction, but can fray, split, or break apart when pulled or stacked in the cross direction (as opposed to synthetic fibers, where this problem does not exist or is minimal.) Also, in this regard, using properly selected natural fibers in a unidirectional arrangement (e.g., such that the fibers are stacked primarily machine direction) can help extend the life of a product compared to using completely randomly arranged natural fibers, which are more susceptible to fraying and splitting of individual fibers.

[0024] In this regard, it is mentioned that a part of a luggage system may comprise two or more regions in which a fibre reinforced material is used comprising one or more sets of unidirectional natural fibres oriented in different directions, taking into account, for example, the particular geometry of these regions and / or the type of impacts that these regions are prone to. The material composition of the natural fibres and / or the matrix material, or their physical and mechanical properties, may vary between such regions.

[0025] In summary, the use of fiber reinforced materials comprising natural fiber materials having at least one set of unidirectional fibers embedded in and / or impregnated with a matrix material combines the advantageous mechanical properties of such oriented materials with the environmental compatibility of naturally derived materials, particularly with respect to the construction of luggage systems such as hard shell cases or trolleys.

[0026] Further options and refinements relating to the first aspect of the invention are now shown and described, and these further options and refinements may be combined with one another to obtain the desired material and performance characteristics of that portion of the luggage system, even if not each possible permutation among the disclosed options is explicitly stated below. Individual features of the subfeatures may be omitted if they are not considered necessary to achieve the desired goal.

[0027] For example, a natural fiber material may include n sets of unidirectional (natural) fibers embedded in and / or impregnated with a matrix material, where n is an integer greater than 1, and the n sets of unidirectional fibers are non-parallel to one another.

[0028] In other words, natural fibers may provide a multiaxial material, where n is the number of axes. Increasing the number of axes n may increase the isotropy of the material properties, possibly at the expense of more manufacturing cost and complexity, so that there is generally a compromise between stability and isotropy on the one hand and manufacturing cost and complexity, as well as weight of the product, on the other hand.

[0029] Also, in the context of two or more sets of unidirectional fibers, a part of a luggage system can include several regions (i.e., two or more regions) in which different embodiments of the disclosed materials are used. To give a specific example, a shell of a hard shell case or a trolley can include, on its main surface, a fiber reinforced material comprising a natural fiber material having two sets (i.e., n=2) of unidirectional (natural) fibers embedded and / or impregnated with a matrix material. At the edges and / or corners and / or where the wheels are attached, the shell can include a fiber reinforced material comprising a natural fiber material having three or more sets (i.e., n≧3) of unidirectional (natural) fibers embedded and / or impregnated with a matrix material to provide a high degree of stability in these particular regions. The material composition and / or mechanical properties of the natural fibers and / or matrix material can be varied between different regions to further control the properties of the luggage part.

[0030] In particular, each set of unidirectional fibers may include multiple fiber bundles and / or fiber threads arranged along a respective axis.

[0031] In other words, the fibers may be pre-arranged or spun into bundles or threads that are oriented and incorporated into the fiber reinforced material to form part of the luggage. This may facilitate and simplify manufacturing, but may also increase the "directionality" of the fiber reinforced material, imparting specific strength in a direction defined by one or more material axes.

[0032] As stated, two sets of unidirectional (natural) fibres may be used, i.e. n = 2. This means that the natural fibre material is provided as a biaxial fabric or material.

[0033] Biaxial materials are the simplest case of multiaxial materials compared to the case of having only one set of unidirectional fibers oriented along a single axis. They can therefore be relatively easily manufactured, yet still provide better isotropy and overall stability than uniaxial materials. Especially considering that natural fibers can be more stable in the longitudinal direction (i.e. along the extension of the fibers) than in the transverse / lateral direction, adding one or more additional axes to the material can significantly increase the stability and lifespan of parts of a luggage system. Thus, biaxial materials provide a lightweight, sufficiently stable and easily manufactured fiber reinforced material for luggage manufacturing based on natural or organic fibers.

[0034] The two axes of a biaxial fabric may intersect at an oblique angle (ie, an angle not equal to 90°).

[0035] Of course, in general, crossing angles of the two axes equal to 90° are also conceivable. However, oblique crossing angles (i.e. ≠ 90°) may further provide an opportunity to combine the overall high stability of the luggage part with a higher degree of "directionality" or anisotropy by using more than one axis. By not crossing the two axes at 90°, an acute angle (i.e. angle < 90°) as well as an obtuse complementary angle (i.e. angle > 90°) are formed between them. For example, the direction defined by the acute angle resolution is "closer" to the two axes than the obtuse angle resolution, so that along the acute angle resolution, a greater stiffness / stability can be obtained compared to the perpendicular direction, i.e. the direction of the obtuse angle resolution. Those skilled in the art will recognize how this concept can be used to affect the physical and mechanical properties of the luggage part, not only along the two material axes, but also in the angle segment between them.

[0036] Another option is three sets of unidirectional (natural) fibres, i.e. n=3, meaning that the natural fibre material is provided as a triaxial fabric or material.

[0037] One advantage of using triaxiality (or even a larger even number of axes, e.g., n=4,5,6,..., although further increasing the number of axes beyond n=3 would be prohibitively expensive from a construction and manufacturing standpoint) is that the impact energy that would cause an initial failure of the luggage part at a certain location is immediately met with a barrier against that energy at one or more of the nearest intersections of fibers of different sets, and thus redirected in three directions. This redirection of energy continues until the energy is either in the system or dissipated within the material, and splits again. In this way, major breaks can be avoided, which facilitates repair instead of scrapping. In addition, the stability and isotropy of the overall material is increased compared to using only uniaxial or biaxiality.

[0038] Also in this case, at least two of the axes of the triaxial fabric may intersect at an angle different from 60°.

[0039] In other words, for more than two axes, the axes (or at least some of them) may intersect at "irregular" angles. The "regular" angle at which n axes intersect is considered to be 360° divided by n (the intersection angle is considered to be the acute angle formed by two intersecting oblique axes, and not the complement of an obtuse angle).

[0040] The fibers contained in the natural fiber material may be continuous.

[0041] Continuous fibers, i.e., fibers that have not been torn, cut, or shortened during or after extraction from natural sources, maintain a very high level of (tear) strength in their longitudinal direction (along the extension of the fiber). This equates to a correspondingly high stability of the luggage part in which they are used. The use of continuous fibers also facilitates or even makes the manufacturing process feasible, especially when natural fibers are processed to form woven fabrics. However, laminated textiles can also benefit from the use of continuous fibers, increasing the overall tear strength of the finished product along one or more fiber directions. Regardless of the structure of the natural fiber material (woven or laminated), the use of continuous fibers can increase the resistance of the luggage part to uncontrolled damage propagation due to impact forces traveling along the extension of the fibers.

[0042] Of course, it is generally possible to add discontinuous and / or particulate (natural and / or synthetic) fibers to the fiber-reinforced material, but the predominantly or exclusively use of continuous natural fibers is advantageous in the sense that it increases the "directionality" of the fiber-reinforced material, limiting the previously mentioned uncontrolled damage propagation in the above-mentioned times, as well as from the standpoint of sustainability.

[0043] The natural fiber material may be provided as a laminated fabric.

[0044] Providing natural fiber materials as laminate structures may reduce manufacturing efforts, for example, compared to utilizing woven structures, potentially with less material stability and cost, as described below. For example, manufacturing can be accomplished via wet lay-up by laminating one or more sheets or layers of oriented fiber material in a bed of liquid resin, which after curing forms a matrix material, and then press-molding this preform into the desired shape, for example under the influence of pressure, and curing the resin by heat, ultraviolet light, or a sudden change in humidity during the required resin curing method. Alternatively, manufacturing can proceed via impregnated sheets or layers of fiber material suspended in or on epoxy resin, thermoplastic resin, or the like, and then thermoformed into the desired shape.

[0045] Each layer may further include several plies of parallel oriented unidirectional fibers, or only a portion of the layer may include several plies of parallel oriented unidirectional fibers, and the number of plies per layer may further vary between individual layers.

[0046] Stacking layers with several plies of parallel oriented unidirectional fibers, on the one hand, simplifies production and, on the other hand, allows fine-tuned control over the thickness, density, tear strength, etc. of each layer, especially when the number of plies is controlled individually for each layer.

[0047] It is also possible for the natural fibre material to be provided as a woven fabric, in particular a fabric woven from the abovementioned fibre bundles and / or fibre threads.

[0048] Providing natural fiber materials as woven fabrics generally requires at least two sets of unidirectional fibers that are non-parallel to each other, i.e. at least a biaxial weave, as opposed to laminates which can be used with only one set of unidirectional natural fibers. Thus, although weaving can be more expensive from a manufacturing standpoint compared to laminations, it can improve the stability and longevity of the luggage part by interlacing the sets of unidirectional fibers, thereby locking them together due to the spatial arrangement created during the weaving process, thereby preventing the different sets of fibers from easily separating / peeling apart.

[0049] The natural fiber materials of the present invention include fibers made from one or more of the following materials or plant parts: leaf fibers, bast fibers, or stem fibers.

[0050] To give numerous examples of these different categories, leaf fibers that may be used with the present invention include abaca, pineapple, and / or palm fibers, bast fibers that may be used include hemp, flax, ramie, kenaf, and / or jute fibers, and stem fibers that may be used include bamboo and / or straw fibers.

[0051] Even more specifically, examples of natural fiber materials that may be used in the present invention include triaxial natural fiber materials using flax and / or bamboo fibers or biaxial natural fiber materials using basalt and / or bamboo fibers, which are advantageously used with the present invention since they offer a good combination of commercial availability, structural and mechanical stability, and a small environmental footprint.

[0052] The material composition of the natural fiber material may further vary within a set of unidirectional fibers and / or between at least two sets of unidirectional fibers. Alternatively or additionally, one or more physical properties, in particular fiber gauge and / or fiber mass linear density, may vary within a set of unidirectional fibers and / or between at least two sets of unidirectional fibers.

[0053] For example, flax fibers can be split bast and divided into smaller and smaller widths or gauges, or the bast can be used without splitting at all. The use of flax can be advantageous, considering that flax is readily available commercially.

[0054] The same is true for bamboo, which is a stem fiber and has a much larger carrying capacity at its maximum fiber size. The use of bamboo is particularly contemplated as a fiber material for localized reinforcement due to its high density, and also as the main fiber for larger luggage sections or entire cases that require more impact strength.

[0055] These options can thus further influence the physical and mechanical properties of the luggage part in a locally controlled manner beyond the axial orientation and number (i.e., number of sets of unidirectional fibers) used for the natural fiber material of the fiber reinforced material of the present invention.

[0056] Preferably, the matrix material is biodegradable and / or comprises recycled materials. Biodegradable materials that impart high impact capabilities to the finished luggage part are particularly preferred.

[0057] One possibility in this regard is to use a thermoplastic film of polylactic acid (PLA) as the matrix material or part thereof.

[0058] As mentioned above, the use of a biodegradable matrix material (for example the just mentioned matrix material based on or consisting of PLA) in combination with a reinforcing structure based on natural fiber materials makes the entire luggage part, or at least a large part of it, biodegradable, making it very attractive from a sustainability point of view. Alternatively, recycled materials may be used (still generally better than using virgin materials), although this is less preferred from a sustainability point of view, and has the advantage of a larger variety of materials to choose from, since biodegradable matrix materials / plastics are not as developed as recyclable materials and are not available in the same number and variety.

[0059] Bio-based polyethylene (PE), polypropylene (PP), polyamide-6 (PA6), polyamide-11 (PA11), polyamide-12 (PA12) and / or polycarbonate (PC) may also be used as the matrix material or part thereof. These materials are not (fully) biodegradable, but may be at least environmentally friendly with regard to their origin and production (compared to, for example, crude oil-based plastics).

[0060] In general, however, the matrix material used in the inventive portions of the luggage systems may comprise one or more of the following materials: an amorphous, crystalline or semi-crystalline thermoset resin; an amorphous, crystalline or semi-crystalline thermoplastic resin; a film of any of the thermoset or thermoplastic materials mentioned above; or any combination thereof.

[0061] All of these materials have advantages and disadvantages, which are generally known to those skilled in the art. Thus, the materials can be used and selected depending on the desired properties of the luggage part in which they are used. For example, thermoset resins are less preferred from a manufacturing standpoint because they require relatively long cycle times for curing, but may offer advantageous properties in the finished component, such as high impact capability.

[0062] Regardless of the base material, the natural fibers include the chemical makeup of the matrix material, allowing the inventive portions of the luggage system to be aluminum-free.

[0063] Although known to be unfavourable from a sustainability point of view, aluminium has been used for a long time and is still used in large quantities in all types of luggage on the market, either in the form of the entire luggage shell or as corner reinforcing and protective elements, for handlebar systems etc. The present invention provides an alternative to the use of this problematic material by providing said fibre reinforced material based on the use of natural fibre materials, which can still provide the products used with similar stability and lifespan, but with a much smaller environmental footprint.

[0064] A second aspect of the invention relates to a method for the manufacture of a luggage system or part of a luggage system according to the first aspect.

[0065] A person skilled in the art will understand that the embodiments, features and options described above with respect to the parts of the luggage system according to the first aspect of the invention are generally translated into corresponding features with respect to the manufacture of such parts. For this reason, the embodiments, features and options described above also apply to the second aspect of the invention described herein, i.e., the manufacture of such parts (as far as technically and physically applicable, of course), and therefore will not be repeated in their entirety again. Instead, in the following, some specific embodiments and options are described in more detail together with the advantages of the second aspect, and in all other respects reference is made to the detailed description given above in the context of the first aspect of the invention.

[0066] In one embodiment, the method includes the steps of providing a preform, heating the preform, transferring the preform to a mold having dimensions corresponding to the intended shape of the part, closing the mold, preferably under pressure, so that the preform conforms to the intended shape of the part, curing or hardening the preform, preferably under the application of heat, UV light and / or ultrasound and / or changes in temperature and / or humidity, and opening the mold and removing the part from the mold.

[0067] Preferably, curing occurs inside the mold, preferably while maintaining mold pressure at least partially or completely. However, it is contemplated that the order of method steps may be varied and the mold may be opened and parts removed before and / or during the curing process. Alternatively, mold pressure may be significantly reduced during curing. Alternatively, the mold may be opened and the part may remain inside the mold for curing.

[0068] Additionally, the substep of heating the preform prior to transferring it to the mold may be omitted, for example, if the preform does not need to be heated to make or maintain malleability (e.g., if the matrix material is still "wet"), and heating may be performed at least partially within the mold and / or during mold closure.

[0069] As has already been indicated many times, the part thus produced may be the shell or part of a shell of a hard case or of a trolley, but also the main body of a part of the main body of a different kind of luggage, it may also be or include the wheel assembly, the handlebar system, the internal structure, etc. of a luggage part. The dimensions and the geometric shape of the mould correspond to the nature of the part in question in a way that the skilled person can easily recognise.

[0070] The curing process depends on the composition of the matrix material used in a given process and will not be discussed further here.

[0071] For cases where the natural fiber material is intended as a laminated structure, preparing the preform may include the steps of providing one or more plies of unidirectional natural fibers, stacking the plies to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being aligned along a respective axis, and applying uncured matrix material to the plies and / or stack of unidirectional fibers, such that the uncured matrix material is at least partially absorbed by the natural fibers to form the preform.

[0072] That is, the uncured matrix material may be provided before, during or after layup of the laminate. If provided during layup, for example, the uncured matrix material may be added to the growing laminate continuously, or after the addition of a predetermined number of plies, or after other predetermined time intervals.

[0073] It is again noted that all of the layers of the laminate may have the same number of plies, or the number of plies (ie, sub-layers) may vary between two or more of the layers.

[0074] The plies may already be pre-oriented, for example before being added to the laminate, as they are stored in a suitable storage container, or the plies may be oriented directly when applied to the laminate.

[0075] Preparing the preform may further include fusing locations where fibers of different plies or layers intersect or overlap within the laminate, for example, by application of pressure, heat, UV light, and / or ultrasound.

[0076] This may not only simplify handling of the preform and subsequent steps in the manufacturing process, but may also increase the stability and strength of the overall manufactured part.

[0077] With respect to the case where the natural fiber material is intended as a woven structure, preparing the preform may include the steps of providing at least one natural fiber material in the form of a multiaxial fabric, providing at least one uncured matrix material in the form of a ribbon, sheet or film, and laminating the natural fiber material with the uncured matrix material, preferably under the application of heat and / or pressure, so that the natural fiber material at least partially absorbs the uncured matrix material to form the preform.

[0078] In either case (i.e. for laminated or woven structures), the present invention allows for a fundamentally environmentally friendly manufacturing process, e.g. from agriculture to final processing, by one of the following exemplary processes:

[0079] (a) Bast fibres are harvested either as a primary or secondary crop. In the latter case, the primary crop (flax seeds, bananas, hemp) is separated from the harvest. Depending on the plant type and climate, unwanted material is then removed by a number of different processes before it is dried. Depending on the desired stock fibre gauge, the stock may be divided into smaller sizes. The fibres are then provided as continuous fibres of one or more mixed types. The continuous bast fibres are woven into fabrics which may or may not be mixed with other fibre types (e.g. obtained from minerals, wood or bamboo) in the weaving process to obtain the desired mix, orientation and dimensions.

[0080] The one or more thermoplastic resins may be crude oil based but are preferably organic based, may be further reinforced with short or long fibers of any origin or modified to withstand high impact forces, may be dried to a desired degree / percentage of moisture, and may or may not be extruded through a die into a desired geometric shape, typically as a ribbon or continuous sheet.

[0081] A thermoplastic sheet or film is laminated to the woven fabric, primarily using heat and pressure, until the fibers are saturated with the thermoplastic resin, then partially cooled and cut to the desired size.

[0082] This preform is then used in a thermoforming process where a three-dimensional mold is contacted with the preform and the material is formed into the desired part with heat and pressure.

[0083] (b) Alternatively, a preform can be laminated with one or more fiber layers, after which a liquid epoxy can be applied through all layers of the preform to soak into the fibers and act as an adhesive that behaves similarly to a thermoplastic. The wet lay-up matrix and epoxy of the fiber layers can be applied directly to a three-dimensional mold, or prepared in flat conditions and then transferred to the three-dimensional mold. The three-dimensional mold usually has at least two sections for the cavity, typically a male and female section that define the molding cavity between them. Heat and pressure are then applied to the cavity sections to thermoset the epoxy into the desired shape.

[0084] Additionally, it is conceivable that after the fibers are saturated with resin / epoxy, they may be oriented (e.g., similar to a weaving process) and then melted via heat and pressure or via pressure and frequencies similar to ultrasonic welding wherever the saturated fibers overlap. This preform may then be thermoformed in either a wet or dry process.

[0085] (c) After either molding process, excess material may be cut away and additional holes may be drilled into the formed portion for attachment of any number of other components and fasteners inside and outside the final assembly.

[0086] A third aspect of the invention relates to a method for repair of a luggage system or part of a luggage system according to the first aspect of the invention.

[0087] With regard to the third aspect as well, the skilled person will understand that the embodiments, features and options described above with respect to the parts of the luggage system according to the first aspect of the invention and / or the manufacturing method according to the second aspect of the invention generally translate into corresponding features with respect to the repair of such parts. Therefore, in the following, some specific embodiments and options will be briefly mentioned together with the advantages of the third aspect, and in all other respects reference is made to the detailed description given above in the context of the first and / or second aspect of the invention.

[0088] In one embodiment, a method for repair includes the steps of applying uncured matrix material to a damaged area of ​​the part, allowing the applied uncured matrix material to be at least partially absorbed into the natural fiber material in the damaged area, applying pressure to the damaged area (e.g., to further promote absorption of the uncured matrix material and / or to reshape the damaged area to a desired shape), and curing or hardening the applied uncured matrix material, preferably under the application of heat, UV light and / or ultrasound and / or changes in temperature and / or humidity.

[0089] In another embodiment, a method for repair includes the steps of applying uncured matrix material to a damaged area of ​​the part, at least partially absorbing the applied uncured matrix material into the natural fiber material in the damaged area, and curing or hardening the applied uncured matrix material, preferably under application of pressure, heat, UV light and / or ultrasound, and / or changes in temperature and / or humidity.

[0090] The two immediately mentioned embodiments differ fundamentally in the way pressure is used during the process: in the first embodiment, the damaged area is subjected to pressure before the curing process, whereas in the second embodiment, pressure may or may not be applied during the curing process. Which option is more suitable and whether applying pressure is necessary at all may depend on the size and shape of the part in question, as well as the composition of the matrix material and the nature of the curing process.

[0091] In conventional fiber-reinforced materials based on mineral or synthetic materials, the fibers themselves are typically relatively hydrophobic and cannot absorb resins into the fibers at volumes approaching those of natural or organic fibers with a cellular structure. Mineral fibers are also relatively brittle. If a piece of luggage containing such materials is damaged, it is rarely possible to repair the piece. To patch such an area together requires additional material on the top and bottom of the affected area, with the original substrate placed between them. To increase strength, more holes must be added to the composite, which has a very high risk of becoming new weak points that cannot withstand repeated impacts.

[0092] The use of natural fibers as defined by the present invention solves this problem, since natural fibers are typically hydrophilic and therefore can absorb more resin into the damaged area during the repair / splicing process compared to fibers made of mineral or synthetic materials, which allows the repaired part to be strengthened rather than weakened. Also, the repair process can potentially occur many times, and in the event that the repair process is deemed exhaustive or economically unfeasible, as already mentioned above, the luggage part can be completely or at least mainly compostable or biodegradable.

[0093] In this context, components such as fabrics, handles, and wheels comprising the fiber reinforced materials with the disclosed natural fiber materials may be used for other purposes, such as repairing trolley shells made from such materials (e.g. after they have worn out). [Brief description of the drawings]

[0094] 4. Brief description of the drawings Possible embodiments of the invention will now be explained in more detail with reference to the following drawings, in which:

[0095] [Figure 1a-c] Examples of fiber reinforced materials, including natural fiber materials and matrix materials, that may be used in the present portions of luggage systems. [Diagram 2] 1 is an example of a method according to the invention for the manufacture of an inventive part of a luggage system. [Diagram 3] 4 is a further example of a method according to the invention for the manufacture of an inventive part of a luggage system. [Figure 4] 1 is an example of a portion of a luggage system according to the present invention using a biaxially woven natural fiber material. [Figure 5a-h] 1 shows an example of a luggage system according to the present invention in the form of a travel or cabin trolley. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0096] 5. Detailed Description of Possible Embodiments Possible embodiments of the different aspects of the invention are described below primarily with reference to travel or cabin trolleys, however, it is again emphasized that the different aspects of the invention may also be implemented in different types of luggage systems and are not limited to the specific embodiments described below.

[0097] Furthermore, it is mentioned that in the following only individual embodiments of the invention can be described in more detail. However, the skilled person will understand that the features, options and possible variations described with reference to these embodiments can also be further modified and / or combined with each other in different ways or in different subcombinations without departing from the scope of the invention. Individual features or sub-features may also be omitted if they are considered to be unnecessary to obtain the desired results. Therefore, to avoid redundancy, reference is made to the description in the previous section, which also applies to the detailed description below.

[0098] Figures 1a-1c show examples of fibre reinforced materials 100a, 100b, 100c comprising a natural fibre material having at least one set of unidirectional fibres embedded in and / or impregnated with a matrix material, which may be used in parts of a luggage system according to the present invention (examples of such parts are shown in Figures 4 and 5a-5h).

[0099] 1a shows a fiber reinforced material 100a comprising a natural fiber material including continuous natural fibers 110a. Discontinuous and / or particulate fibers may also be added to the fiber reinforced material 100a, but this is not shown and will not be described further herein.

[0100] The continuous natural fibers 110a may be provided as a plurality of fiber bundles / fiber threads. The natural fibers 110a form a set 120a of unidirectional fibers arranged along a longitudinal direction 101a in FIG. 1a. Also shown in FIG. 1a is a transverse direction 102a perpendicular to the longitudinal direction 101a. In a part of a luggage system made from or including the material 100a, the longitudinal direction 101a may be arranged, for example, along the direction of the longest spatial extension of the part, but this is not necessarily the case. In other words, the designations "longitudinal" and "transverse" directions are used primarily for ease of understanding the following examples and for clarity, but do not necessarily indicate a particular arrangement of the material 100a within the part of the luggage system in which it is used. For example, the longitudinal direction 101a may be disposed diagonally or diagonally relative to an edge of a hard shell case or trolley shell in which the material 100a is used (e.g., in one of the shells 510, 520 of the trolley 500 described further below).

[0101] The fibers 110a of the set 120a are embedded in the matrix material 130a. The fibers 110a may be "soaked up" by the matrix material 130a and thus may be saturated with the matrix material 130a. Moreover, while in the state shown in FIG. 1a the fibers 110a are completely embedded in the matrix material 130a (perhaps apart from their beginning and end), i.e. completely contained within the matrix material 130a, this need not necessarily be the case in all states. In other words, the fibers 110a may be only partially embedded in the matrix material 130a, or may be "on" the matrix material 130a, or may only contain the matrix material 130a internally, i.e. only saturated with the matrix material 130a and not externally surrounded or embedded in the matrix material 130a. These statements also apply to fiber-reinforced materials that include more than one set (i.e., n sets, where n>1) of unidirectional fibers, such as materials 100b and 100c described below, even if this is not explicitly repeated every time.

[0102] The fibers 110a of the natural fiber material may include, for example, one or more of the following materials: leaf fibers, bast fibers, or stem fibers.

[0103] For example, the use of flax, a bast fiber, for fiber 110a (or any of the natural fibers mentioned herein) may be beneficial since flax is readily available commercially. The use of bamboo, a stalk fiber, may also be considered as a fiber material, particularly for localized reinforcement due to its high density, and as the main fiber for larger luggage pieces or entire cases that require greater impact strength.

[0104] The matrix material 130a may include or consist of one or more of the following materials: an amorphous, crystalline or semi-crystalline thermoset resin, an amorphous, crystalline or semi-crystalline thermoplastic resin, or a film of any of the aforementioned thermoset or thermoplastic materials, or any combination thereof. Preferably, the matrix material 130a is biodegradable and / or comprises recycled materials.

[0105] One particular option is to use PLA as the matrix material 130a, or at least base the matrix material 130a on PLA, due to its known biodegradability. In general, any biodegradable, impact resistant, bio-based thermoplastic or resin is well suited for the present invention.

[0106] As an option, partially or fully bio-based PE, PP, PA6, PA11, PA12 and PC materials can also be considered, which, although they may not be (fully) biodegradable, are still considered to be more environmentally friendly than traditional plastics, e.g. based on crude oil.

[0107] Figure 1b shows on the left side another fibre reinforced material 100b, while on the right side of Figure 1b a cross section of material 100b taken along line B-B' is shown.

[0108] Material 100b includes a natural fiber material that includes continuous natural fibers 110b. Again, discontinuous and / or particulate fibers may be added to the fiber reinforced material 100b, but again, this is not shown and will not be described further herein.

[0109] The continuous natural fibers 110b are woven into a biaxial fabric and are provided in the form of fiber threads 115b arranged along a longitudinal axis (or machine direction) 101b or along a transverse axis (or cross direction) 102b. Again, this terminology is used primarily for clarity and not necessarily for limitation. See the corresponding explanation of directions 101a and 102a with respect to FIG. 1a above. In a weaving process used in creating a woven fabric from the fiber threads 115b, the longitudinal direction 101b can be, for example, the warp direction and the cross direction 102b can be the weft direction, or vice versa.

[0110] In the material 100b shown in FIG. 1b, there are two sets 120b and 121b of unidirectional fibres, set 120b formed from fibre threads 115b woven along the warp direction 101b and set 121b formed from fibre threads 115b woven along the cross direction 102b.

[0111] In the material 100b shown in Fig. 1b, the yarns and their axes of the two sets 120b and 121b cross at an angle of (approximately) 90°. However, in other embodiments, this crossing angle may differ from 90°. That is, the textile yarns 115b and their axes may be arranged at an oblique angle (≠90°) to each other. The advantages of using such a non-perpendicular arrangement have already been discussed in section 3 above, and therefore section 3 is referred to for the sake of brevity.

[0112] The fibers 110b in the material 100b may "soak up" the matrix material 130b and thus be saturated with the matrix material 130b. The fibers 110b may be at least partially embedded in or surrounded by the matrix material 130b. However, the fact that the fibers 110b are woven into a biaxial fabric in the material 100b shown in FIG. 1b already provides structural stability to their arrangement, so that the fibers 110b in this case do not necessarily have to be (partially) embedded in the matrix material 130b to fix their arrangement and obtain the desired overall stability of the material 100b; it may already be sufficient for the fibers 110b to be saturated with the matrix material 130b for that purpose.

[0113] The material composition of the natural fibers 110b and / or fiber threads 115b may vary not only between the two sets 120b and 121b, but also within one of the sets 120b, 121b of unidirectional fibers. Alternatively or in addition, one or more physical properties, such as the gauge of the fibers 110b and / or the mass linear density of the fibers 110b, may vary within one of the sets 120b, 121b of unidirectional fibers and / or between the two sets 120b and 121b. This allows for local fine-tuning of the physical and mechanical properties of the material 100b, beyond the "global" control provided, for example, by the choice of the layout and / or weave pattern used for the biaxial weaving of the material 100b.

[0114] With regard to the selection of suitable materials for the natural fibers 110b and / or matrix material 130b, for the sake of brevity, reference is made to the corresponding descriptions above (see, for example, the description of the fibers 110a and matrix material 130a given in relation to FIG. 1a).

[0115] 1c shows another fiber reinforced material 100c that includes a natural fiber material that includes continuous natural fibers 110c. Discontinuous and / or particulate fibers may be added to the fiber reinforced material 100c, but this is not shown and will not be described further herein.

[0116] The continuous natural fibers 110c may be provided as a plurality of fiber bundles / fiber threads 115c. The natural fibers 110c form n sets of unidirectional fibers, where n=4 for the embodiment shown in FIG. 1c. That is, there are now four sets 120c, 121c, 122c, 123c of unidirectional fibers, each set being arranged along a corresponding axis or direction. The fibers of two sets of the four sets 120c, 121c, 122c, 123c of unidirectional threads are non-parallel to each other, that is, they cross at an angle different from 0°. The fibers 110c are embedded in and / or saturated with a matrix material 130c.

[0117] A variant of material 100c (not shown) has three sets of unidirectional fibers 110c instead of four (i.e. n=3, triaxial weave), where the fibers of two sets of the three unidirectional yarns are non-parallel to each other, i.e. they cross at an angle different from 0°. Preferably, at least two of the three sets cross at an angle different from 60°, which provides the technical advantages described in section 3 above. Therefore, reference is made to section 3 in this regard.

[0118] In material 100c, the natural fiber material is provided as a laminated fabric, with eight plies 140c to 147c shown in the embodiment of Fig. 1c. Each of the plies 140c, 141c, ..., 147c further includes a plurality of plies of parallel oriented unidirectional fibers 110c. These plies are numbered as ply no. 1 to ply no. 48 in Fig. 1c. In other words, in the embodiment of Fig. 1c, each of the plies 140c, 141c, ..., 147c includes six plies.

[0119] In the embodiment of FIG. 1c, each of the four sets of unidirectional fibers 120c, 121c, 122c, 123c includes two of the layers 140c, 141c, . . . , 147c. The first set 120c includes layers 140c and 147c having plies No. 1 to 6 and No. 43 to 48, respectively, whose fibers are arranged at an angle of 0° to the transverse direction (here treated as a reference point without loss of generality). · The second set 121c includes layers 141c and 146c having plies No. 7-12 and No. 37-42, respectively, whose fibers are arranged at an angle of +45° to the transverse direction. · The third set 122c includes layers 142c and 145c having plies Nos. 13-18 and 31-36, respectively, with the fibers oriented at an angle of +90° to the transverse direction. · The fourth set 123c includes layers 143c and 144c having plies Nos. 19-24 and 25-30, respectively, whose fibers are oriented at an angle of −45° to the transverse direction.

[0120] Again (i.e. for situations where n>2), the material composition of the natural fibers 110c or fiber bundles / fiber yarns 115c may vary between two (or more) of the sets 120c-123c and may also vary within one of the sets 120c-123c of unidirectional fibers (e.g. between different layers, or even between different plies within one of the sets, or even within a ply). Alternatively or additionally, one or more physical properties, such as the gauge of the fibers 110c and / or the mass linear density of the fibers 110c, may vary within one of the sets 120c-123c of unidirectional fibers and / or may vary between two (or more) of the sets 120c-123c.

[0121] Figures 2 and 3 show schematic diagrams of examples of methods 200, 300 according to the invention for the manufacture of an inventive part of a luggage system (examples of such a part are shown in Figure 4 and Figures 5a-5h).

[0122] 2 begins by providing input materials to a production location for preparation of preforms 20 for manufacturing luggage portion 21, as generally indicated by reference numeral 210. The step of providing input materials 210 may include providing at least one uncured matrix material in the form of a ribbon, sheet or film, in addition to providing at least one natural fiber material in the form of a multiaxial woven fabric, among others.

[0123] Additional materials and components that may be provided in step 210 include, for example, adhesives such as adhesive powders, adhesive films, web adhesives, chopped glass, fibrous materials for further reinforcement, and foil materials.

[0124] Method 200 further includes a step, generally indicated by reference numeral 220, of laminating the natural fiber material with an uncured matrix material such that the natural fiber material at least partially imbibes the uncured matrix material to form preform 20. In the embodiment of method 200 shown in Figure 2, lamination is performed under application of heat (see reference numeral 221) and pressure (see reference numeral 222), followed by cooling of the laminated structure (see reference numeral 223) to stabilize preform 20.

[0125] The preform 20 may be stored in the form of a roll or sheet, as generally indicated by the reference numeral 230 .

[0126] After preparing the preform 20 in this way, the method 200 further comprises the (optional) step of heating the preform 20 (which may take place at least partially inside the mould 22 and / or during closing of the mould 22, but may be omitted entirely if the preform 20 does not need to be made or remain malleable), and the method 200 comprises the step of transferring the preform 20 to a mould 22 having dimensions corresponding to the intended shape of the part to be produced. This step is generally indicated by the reference numeral 240. The mould 22 is then closed, as indicated by the reference numeral 250, preferably under pressure, so that the preform 20 conforms to the shape and geometry defined by the moulding cavity, i.e. the intended shape of the part to be produced (at least its overall shape; this may be followed by further post-processing steps on the moulded and removed part, which may further change the shape and geometry of said part). Thereafter, the preform 20 is cured or hardened in the mold 22, preferably with the application of heat, UV light and / or ultrasound and / or with changes in temperature and / or humidity, as indicated by reference numeral 260 (mold pressure may or may not be maintained during curing). Finally, the mold 22 is opened and the molded part 21 of the luggage system is removed from the mold 22, as indicated by reference numeral 270. After the demolding step 270, further processing may take place as already mentioned above, for example the part 21 may be trimmed or post-processed, or holes, further components may be added, etc.

[0127] Again, the method 300 shown in FIG. 3 starts by providing input material to a production site for the preparation of a preform 30 for the manufacture of luggage parts 31, as generally indicated by reference number 310. This time, the step 310 of providing input material comprises providing one or more plies of unidirectional natural fibers. The method further comprises layering the plies to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being arranged along their respective axes. This step is generally indicated by reference number 320 in FIG. 3. As generally indicated by reference number 330 in FIG. 3, an uncured matrix material is added to the plies of unidirectional fibers and / or to the stack and is at least partially absorbed by the natural fibers to form the preform 30. It is emphasized that the order of steps 320 and 330 may be different from the situation shown here, i.e. the uncured matrix material may be provided before or during the stacking of the layers in step 320.

[0128] Method 300 may also include melting locations where fibers of different plies or layers intersect or overlap within the laminate while applying pressure, heat, UV light, and / or ultrasound (not shown in FIG. 3).

[0129] From there, method 300 may proceed similarly to method 200 described above. The preform 30 prepared as previously described may be heated (which may occur at least partially within the mold 32 and / or while closing the mold 32, but may be omitted entirely if the preform 30 does not need to be made or remain malleable), after which the preform 30 is transferred to a mold 32 having dimensions corresponding to the intended shape of the part to be produced. This step is generally indicated by reference numeral 340. The mold 32 is then closed, preferably under pressure, as indicated by reference numeral 350, so that the preform 30 conforms to the shape and geometry defined by the mold cavity and thus the intended shape of the part to be produced (again, further post-processing steps of the molded and removed part may be performed in due course). Thereafter, the preform 30 is cured or hardened in the mold 32, preferably with the application of heat, UV light and / or ultrasound and / or with changes in temperature and / or humidity, as indicated at 360 (again, mold pressure may or may not be maintained during curing). Finally, the mold 32 is opened and the molded portion 31 of the luggage system is removed from the mold 32, as indicated at 370. After the demolding step 370, further processing may take place, for example the portion 31 may be trimmed or post-processed, or holes or additional components may be added, etc.

[0130] The duration and process parameters of the different steps of the thermoforming / molding process, i.e. steps 240-270 and 340-370, may depend, for example, on the physical dimensions and the pressing capacity and materials of the molding equipment used for production. For example, the duration of the mold closing step 250, 350 may depend on the pressing capacity (e.g. maximum closing pressure) and the wicking behavior of the natural fibers contained in the preform 20, 30, while the duration of the curing step 260, 360 may depend on the chemical composition of the matrix material, the curing temperature in the mold, the duration and amount of pressure applied during the previous steps 250, 350, the molding pressure during curing, etc.

[0131] Some of the steps provided by the methods 200, 300 for manufacturing a portion of a luggage system may be utilized, possibly in slightly modified versions, to provide a method for replacing a damaged portion of a luggage system.

[0132] Such a method may include applying uncured matrix material to the damaged area of ​​the part (e.g., similar to step 330 of method 300) and allowing the applied uncured matrix material to be at least partially absorbed by the natural fiber material in the damaged area.

[0133] Pressure may then be applied to the damaged area, for example, within a mold (eg, similar to step 250 of method 200 or step 350 of method 300), or in a different manner.

[0134] The repair process may further include curing or hardening the applied uncured matrix material, preferably with the application of heat, UV light and / or ultrasound and / or changes in temperature and / or humidity during, after or without the application of pressure (e.g., similar to step 260 of method 200 or step 360 of method 300).

[0135] 4 shows a portion 400 of a luggage system made from the fiber reinforced material disclosed herein. The portion may be used, for example, as a front or back insert for a major surface of a hard shell case or trolley shell, such as trolley 500 described below. The fiber reinforced material is made from a natural fiber material and a matrix material, the natural fiber material including two sets of unidirectional natural fibers provided in the form of fiber yarns woven into a biaxially woven fabric. The fabric is embedded in and saturated with the matrix material.

[0136] In part 400 shown in FIG. 4, a biaxial natural fiber material 410 using flax fibers is used in combination with a thermosetting epoxy resin as the matrix material.

[0137] At the bottom of FIG. 4, a similar section 405 is shown after de-molding (e.g., after step 270 of method 200 or step 370 of method 300) but before being trimmed to final dimensions to more clearly show the woven structure of the biaxial flax-fiber material 410 involved therein.

[0138] Finally, Figures 5a-5h show a luggage system, i.e. a travel or cabin trolley 500, utilising a fibre reinforced material as disclosed herein, such as one of the materials 100a, 100b, 100c mentioned above.

[0139] The trolley 500 generally comprises a front shell 510 and a back shell 520 which are connected to each other in such a way that the two shells 510, 520 can be opened and closed relative to each other. The trolley 500 further comprises a closure means, in the embodiment shown a zipper mechanism 530, for securing the two shells 510, 520 in a closed state.

[0140] The trolley 500 further includes four swivel wheels 540 mounted in respective recesses 545 in the bottom four corners of the front and back shells 510, 520. The trolley 500 also includes a telescoping handle bar system 550 for pulling the trolley 500 along its wheels, as well as a side grip arrangement 560 for carrying the trolley 500 by hand.

[0141] Beneath the handlebar system 550 may be arranged a recess or storage space 570 which can be accessed when the handlebar system 550 is in its extended position (see FIG. 5d) and in which, for example, a USB power bank can be removably stored. At this point, explicit reference is made to the disclosures in the Applicant's previous applications DE 202017101957 U1 and WO 2018185016 A1, the disclosures of which are incorporated herein with regard to the handlebar system 550 and the storage space 570 of the trolley 500.

[0142] Figure 5a shows the front shell 510 without the additional components (wheels, handlebar system, zippers, etc.) and Figure 5b shows the back shell 520 without the additional components. Either or both of these shells 510, 520 can be made by the method of the present invention, i.e., using the disclosed embodiments of a fiber reinforced material based on natural fibers, such as materials 100a, 100b or 100c described above.

[0143] Figure 5c shows a front view of the entire trolley 500 with all of the additional components added, and Figure 5d shows a rear view of the entire trolley 500. In either case, the handlebar system 550 is in an extended or pulled out position.

[0144] Figure 5e shows the right side (relative to the front) of the trolley 500 with all of the additional components added, and Figure 5f shows the left side, and finally Figure 5g shows the top of the trolley with all of the additional components added and with the handlebar system 550 in the retracted or pushed in position, and Figure 5h shows a bottom view.

[0145] In addition to the front shell 510 and the back shell 520, any or all portions of the trolley 500 may include, be based on, or be made from the disclosed fiber reinforced materials.

[0146] Thus, the disclosed materials and methods may make it possible to provide a trolley 500 that is aluminum-free or at least contains a significantly reduced amount of aluminum and is based entirely or at least predominantly on natural and biodegradable materials, thereby reducing the environmental footprint of the luggage system 500 both at the beginning and end of its life.

Claims

1. A part (21; 31; 400) of a luggage system, comprising a fiber reinforced material (100a; 100b; 100c), said fiber reinforced material comprising: A natural fiber material (110a; 110b; 110c); A matrix material (130a; 130b; 130c) Including, the natural fiber material comprises at least one set (120a; 120b-121b; 120c-123c) of unidirectional fibers embedded in and / or permeated by the matrix material; Part of a luggage system.

2. 2. The portion of the luggage system of claim 1, wherein the natural fiber material comprises n sets of unidirectional fibers embedded in and / or impregnated with the matrix material, n being an integer greater than 1, and the n sets of unidirectional fibers being non-parallel to one another.

3. 3. Part of a luggage system according to claim 1 or 2, wherein each set of unidirectional fibres comprises a plurality of fibre bundles and / or fibre threads arranged along a respective axis.

4. Part of a luggage system according to claim 2 or 3, wherein n=2 and the natural fibre material is provided as a biaxial woven fabric.

5. 5. The part of a luggage system according to claim 4, wherein the two axes of the biaxial fabric intersect at an oblique angle.

6. Part of a luggage system according to claim 2 or 3, wherein n=3 and the natural fibre material is provided as a triaxial fabric.

7. 7. The part of a luggage system according to claim 6, wherein at least two of the axes of the triaxial fabric intersect at an angle different from 60[deg.].

8. Part of a luggage system according to any one of claims 1 to 7, wherein the fibres are continuous.

9. Part of a luggage system according to any of claims 1 to 8, wherein the natural fibre material is provided as a laminated woven fabric.

10. 10. The portion of the luggage system of claim 9, wherein each layer comprises multiple plies of parallel oriented unidirectional fibers.

11. Part of a luggage system according to any one of claims 1 to 8 in combination with claim 3, wherein the natural fibre material is provided as a woven fabric.

12. Part of a luggage system according to any of claims 1 to 11, wherein the natural fibre material comprises one or more of the following materials: leaf fibres, bast fibres or stem fibres.

13. Part of a luggage system according to any of the preceding claims, wherein the material composition of the natural fibre material varies within a set of unidirectional fibres and / or between at least two sets of unidirectional fibres.

14. Part of a luggage system according to any of claims 1 to 13, wherein one or more physical properties vary within a set of unidirectional fibres and / or between at least two sets of unidirectional fibres.

15. Part of a luggage system according to any of claims 1 to 14, wherein the matrix material is biodegradable and / or comprises recycled materials.

16. Part of a luggage system according to any one of claims 1 to 15, wherein the matrix material comprises one or more of an amorphous, crystalline or semi-crystalline thermosetting resin, an amorphous, crystalline or semi-crystalline thermoplastic resin, or a film of any of the aforementioned thermosetting or thermoplastic materials, or any combination thereof.

17. A part of a luggage system according to any preceding claim, wherein the part does not contain aluminium.

18. A method (200; 300) for the manufacture of a part of a luggage system, comprising: Prepare the preform, Heating the preform and transferring (240; 340) it to a mould (22; 32) having dimensions corresponding to the intended shape of the part, closing (260; 360) the mould (250; 350) so that the preform conforms to the intended shape of the part; Curing or hardening the preform; The mold is opened and the part is removed from the mold (270; 370). A method comprising the steps of:

19. Providing the preform comprises: providing one or more plies of unidirectional natural fibers (310); stacking the plies to form one or more layers of unidirectional fibers, the unidirectional fibers of each layer being aligned along a respective axis (320); Applying an uncured matrix material to the plies and / or laminates of unidirectional fibers, such that the uncured matrix material is at least partially absorbed by the natural fibers to form the preform (330).

20. The method of claim 18, comprising the steps of:

20. 20. The method of claim 19, wherein preparing the preform further comprises melting locations where fibers of the different plies or layers intersect or overlap in the laminate while applying pressure, heat, UV light and / or ultrasound.

21. Providing the preform comprises: providing (210) at least one natural fiber material in the form of a multiaxial fabric; providing (210) at least one uncured matrix material in the form of a ribbon, sheet or film; Laminating the natural fiber material with the uncured matrix material to at least partially imbibe the uncured matrix material into the natural fiber material to form the preform (220).

20. The method of claim 18, comprising the steps of:

22. 1. A method for repairing a damaged portion of a luggage system, comprising: adding uncured matrix material to the damaged area of ​​said portion; allowing the added uncured matrix material to be at least partially absorbed into the natural fiber material in the damaged area; applying pressure to the damaged area; hardening or curing the applied uncured matrix material; method.

23. 1. A method for repairing a damaged portion of a luggage system, comprising: adding uncured matrix material to the damaged area of ​​said portion; allowing the added uncured matrix material to be at least partially absorbed into the natural fiber material in the damaged area; hardening or curing the applied uncured matrix material; method.

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