Felt Laminate Casing for Drop Resistance and Soft Texture
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Solution Overview
Problem
Conventional suitcase manufacturing methods fail to efficiently combine felt materials for a soft texture with drop resistance, as adhering felt fibers to rigid casings requires extensive time and manual effort, and existing solutions do not effectively utilize felt for rigid suitcase construction.
Innovation Solution
A laminate structure comprising a first felt layer, a support layer made from cured felt with a higher percentage of low-melting-point fibers, and a waterproof layer, where the support layer is formed by heating and die-pressing low-melting-point fibers while maintaining stuffing fibers' integrity, to create a rigid and drop-resistant casing with a soft texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If felt fibers are adhered to rigid casing material to achieve soft texture, then the suitcase has soft texture, but the manufacturing process requires considerable time and manual effort
Solution Approach 1:
The patent merges the felt layer and rigid support layer into a single integrated laminate structure through thermal bonding. The thermoplastic fibers in the felt layer are heated to melt and bond with the rigid support layer, creating a unified structure that provides both soft texture and structural integrity in one manufacturing step, eliminating the need for separate adhesion processes.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal properties of the felt layer. By incorporating thermoplastic fibers with specific melting points and applying controlled heat, the felt material transitions from a loose fibrous state to a bonded state with the rigid support layer. This parameter change enables automated thermal bonding processes that significantly reduce manual effort and manufacturing time.
2Strength
If conventional rigid casing material is used with adhered felt fibers to achieve drop resistance, then the suitcase has drop resistance, but the manufacturing process requires considerable time and manual efforts
Solution Approach 1:
The patent applies preliminary action by pre-incorporating thermoplastic binding fibers within the felt layer during felt manufacturing. These pre-integrated thermoplastic fibers are designed to activate upon heating, automatically bonding the felt to the rigid support layer. This preliminary preparation eliminates the need for subsequent manual adhesion steps, reducing manufacturing time while ensuring consistent drop resistance.
Solution Approach 2:
The patent replaces mechanical adhesion systems (manual stitching, gluing, or fastening) with a thermal bonding system. By applying heat to the thermoplastic fibers in the felt layer, the material undergoes phase change and chemically bonds to the rigid support layer through molecular diffusion and entanglement. This substitution of mechanical processes with thermal-chemical processes enables automated manufacturing, significantly reducing both time and manual labor requirements.
3Ease of operation
If felt material is used for the entire casing to achieve soft texture, then the suitcase has soft texture, but the casing lacks sufficient rigidity and drop resistance
Solution Approach 1:
The patent creates a composite laminate structure consisting of a felt layer containing thermoplastic fibers bonded to a rigid support layer. The felt layer provides the desired soft texture and aesthetic appearance, while the rigid support layer (made from materials like polycarbonate, ABS, or aluminum) provides structural strength and drop resistance. The thermoplastic fibers act as a bonding interface between the two dissimilar materials, creating a composite structure that exhibits properties of both constituent materials.
Solution Approach 2:
The patent applies local quality by differentiating the functional properties of different layers within the laminate. The outer felt layer is optimized for softness and aesthetics, while the inner rigid support layer is optimized for strength and rigidity. Each layer performs its specific function locally, and their combination through thermal bonding creates a unified structure that achieves both soft texture and drop resistance simultaneously.
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 laminate structure achieves efficient manufacturing with fewer steps, enhancing production yield and producing a drop-resistant suitcase that maintains a velvety texture, reducing the need for extensive manual effort and improving upon conventional methods.
Implementation Method 1
The support layer is made from felt and formed by curing a second felt layer. The first felt layer and the second felt layer have low-melting-point fibers
Implementation Method 2
The first surface of the support layer is melted and attached to the second surface of the first felt layer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present application describes a laminate (10) of a casing (2) integrally made from a first felt layer (11), a support layer (15) and a waterproof layer (13). The first felt layer (11) and the support layer (15) both have a first surface (111, 151) and a second surface (112, 152) opposing the first surface (111, 151). The first surface (151) of the support layer (15) is melted and attached to the second surface (112) of the first felt layer (11). The waterproof layer (13) is attached to the second surface (152) of the support layer (15). Through the structural design of the aforementioned laminate (10), the laminate (10) has the feature of soft texture because of the first felt layer (11) and the features of rigidness and drop resistance because of the support layer (15).