Composite Luggage Shell Reinforcement for Corner Impact Resistance
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Solution Overview
Problem
Existing luggage made of thermoplastic materials are prone to damage and cracking during transportation due to impact, necessitating frequent replacement, and existing reinforcement methods do not adequately address structural weaknesses, especially at corners.
Innovation Solution
A manufacturing method involving vacuum molding of a thermoplastic sheet into a shell, application of a thermosetting carbon fiber plastic layer, and use of a reinforcing layer, such as a thermosetting carbon fiber or metal layer, combined through inflation and heating to enhance structural integrity and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic material is used for luggage, then ease of manufacture is improved, but structural strength deteriorates
Solution Approach 1:
The patent uses composite materials consisting of thermoplastic material combined with reinforcing materials (such as glass fiber, carbon fiber, or metal mesh) to create a luggage shell that maintains both ease of manufacture and high structural strength. The composite structure allows the thermoplastic to provide formability while the reinforcing materials provide the necessary strength and impact resistance.
2Ease of manufacture
If thermoplastic material is used for luggage, then ease of manufacture is improved, but impact resistance deteriorates
Solution Approach 1:
The composite structure incorporating reinforcing materials within the thermoplastic shell provides enhanced impact resistance while maintaining the ease of manufacture associated with thermoplastic forming processes.
Solution Approach 2:
The patent applies reinforcing materials specifically at vulnerable areas such as corners and edges of the luggage shell, providing localized impact resistance where it is most needed while maintaining overall ease of manufacture.
3Ease of manufacture
If thermoplastic material is used for luggage, then ease of manufacture is improved, but collision resistance deteriorates
Solution Approach 1:
The combination of thermoplastic material with reinforcing materials creates a composite shell that resists collision forces better than pure thermoplastic while still being manufactured using standard thermoplastic forming techniques.
Solution Approach 2:
Reinforcing materials are strategically placed at corners and edges where collision damage is most likely to occur, providing enhanced collision resistance at critical locations without compromising overall manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in luggage with improved structural strength and uniform impact resistance, particularly at corners, reducing the likelihood of damage and extending the lifespan of the luggage.
Implementation Method 1
heating the heating mold to heat the shell, the thermosetting carbon fiber plastic layer and the reinforcing layer in the inner cavity mold area, so that the shell, the thermosetting carbon fiber plastic layer and the reinforcing layer are combined with each other
Implementation Method 2
placing an airbag in the receiving area of the shell and inflate the airbag to support the inner surface of the thermosetting carbon fiber plastic layer and the reinforcing layer
Implementation Method 3
using a vacuum molding method to make a thermoplastic sheet into a shell
Data Source
AI summary
A method for manufacturing a luggage formed by composite material includes the steps: A) using a vacuum molding method to make a thermoplastic sheet into a shell; B) placing the shell in an inner cavity mold area of a heating mold to correspond the outer surface of the shell to the inner wall surface of the inner cavity mold area; C) setting the outer surface of the thermosetting carbon fiber plastic layer on the inner surface of the shell; D) setting the reinforcing layer on the inner surface of the thermosetting carbon fiber plastic layer at the location corresponding to the corner of the shell; and E) placing an airbag in the receiving area of the shell and inflating the airbag to support the inner surface of the thermosetting carbon fiber plastic layer and the reinforcing layer.