Foamed Plastic Suitcase Shell with Integrated Gas Channels
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Solution Overview
Problem
Current manufacturing methods for suitcases, such as deep-drawing and injection molding, face challenges in achieving a balance between cost-effectiveness, strength, weight, and design flexibility, with deep-drawing resulting in fragile edges and high costs, and injection molding producing heavier shells due to limited wall thickness ratios.
Innovation Solution
The integration of gas channels and foamed plastic with the TSG process, combined with variotherm and projectile injection techniques, allows for the production of lightweight, stiff, and cost-effective suitcase shells with improved surface quality and integrated features like wheel mounting axes and telescopic rod systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If deep-drawing method is used to produce suitcase shells with large dimensions and thin walls, then wall thickness to dimension ratio is improved, but edge strength and rigidity deteriorate
Solution Approach 1:
The shell edge is segmented into a frame structure with corner elements and side elements that are separately formed and then joined together. This segmentation allows each element to be optimized for strength while maintaining the overall thin-wall design, resolving the contradiction between large dimensions and edge strength.
Solution Approach 2:
The frame structure uses composite construction with corner elements and side elements that can be made from different materials or material configurations to optimize both strength and weight. This allows the edge to achieve the required strength without increasing the overall wall thickness of the shell.
2Ease of manufacture
If deep-drawing method is used to produce suitcase shells, then tooling costs are reduced, but per-piece production costs increase
Solution Approach 1:
Multiple shell components (front shell, rear shell, and frame elements) are merged into a single integrated structure through co-molding or pre-assembly techniques. This eliminates separate assembly operations and reduces the number of machining steps, thereby reducing per-piece production costs while maintaining the simplicity of deep-drawing tooling.
Solution Approach 2:
The frame elements are preliminarily formed as separate components during the molding process itself, rather than requiring post-molding machining or assembly. This preliminary formation of structural elements reduces the complexity of subsequent manufacturing steps and lowers per-piece costs.
3Productivity
If injection molding is used to produce suitcase shells, then per-piece production costs are reduced, but wall thickness to dimension ratio deteriorates
Solution Approach 1:
The shell is designed with local variations in wall thickness, where thicker sections are placed only at the frame and corner elements that require structural strength, while the main shell body maintains thin walls. This local quality differentiation allows injection molding to produce cost-effective shells without unnecessarily increasing overall material usage.
Solution Approach 2:
The frame structure adds a third dimension to the shell design by creating protruding edge elements that provide structural reinforcement without increasing the planar dimensions of the suitcase. This dimensional approach allows the shell to achieve required strength-to-weight ratio through geometric optimization rather than simply increasing wall thickness.
4Weight of moving object
If deep-drawing is used to produce suitcase shells, then lightweight shells can be produced, but manufacturing complexity and cycle time increase
Solution Approach 1:
The frame elements and shell body are merged into a single integrated component through co-molding techniques, eliminating the need for separate assembly operations. This merging of components simplifies the manufacturing process while maintaining the lightweight design, as the frame and shell are produced in one operation rather than requiring multiple steps.
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
This approach enables the production of suitcases with reduced weight, enhanced strength, and integrated features, while maintaining a smooth exterior design and facilitating recycling, thereby addressing the limitations of existing methods.
Implementation Method 1
Gas channels which transmit gas pressure with which the plate is transformed into a shell
Implementation Method 2
The shell is made of foamed plastic
Data Source
AI summary
An injection-molded container or shell, in particular a suitcase shell made of plastic, A) is made of foamed plastic and has gas channels and/or B) is made using physically or chemically foamed plastic and/or a plastic mixed with hollow fillers and/or C) is integrally made with wheel mounting axles and/or extendable rod buffers and/or extendable rod cavities.