Knitted Preform Composite Luggage Shell
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Solution Overview
Problem
Existing luggage shell production methods are costly, lack robustness, and are heavy, with limited aesthetic and structural possibilities due to the use of woven structures that only allow disjoint folds, restricting the ability to create three-dimensional shapes with continuous edges.
Innovation Solution
A method involving the production of a preform with a reinforcement structure comprising interconnected loops, which is then impregnated with a matrix material to form a composite shell, allowing for three-dimensional shaping and increased robustness through knitting techniques and varying loop pitches for enhanced mechanical stress resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If woven structures are used for the preform, then the structure allows disjoint folds and 2.5D shaping, but it cannot create continuous 3D shapes with intersecting folds and limits aesthetic possibilities
Solution Approach 1:
The patent uses a knitted preform structure instead of a woven structure. The knitted fabric's inherent flexibility and loop-based construction allow it to deform continuously in three dimensions, enabling intersecting folds and complex 3D shaping that woven structures cannot achieve. This resolves the contradiction by providing both the desired 3D shape capability and aesthetic versatility.
Solution Approach 2:
The knitted structure allows dynamic deformation during the molding process, where the loops can stretch and reconfigure to accommodate complex 3D geometries. This dynamic adaptability enables continuous shaping without the discontinuities inherent in woven structures, simultaneously achieving complex shapes and aesthetic flexibility.
2Reliability
If traditional production methods are used, then the manufacturing process is established, but the production cost is high and the shell lacks robustness while being heavy
Solution Approach 1:
The patent employs composite materials consisting of a knitted preform (providing structural framework) impregnated with matrix material (providing consolidation and environmental resistance). This composite construction achieves high robustness-to-weight ratio, as the knitted structure provides strength with minimal material while the matrix fills voids and protects the reinforcement, eliminating the need for heavy traditional constructions.
Solution Approach 2:
The knitted preform allows local variation in loop density and structure, enabling reinforcement in specific areas requiring higher robustness while maintaining lower weight in less critical areas. This localized optimization achieves overall robustness without uniformly increasing weight throughout the entire shell.
3Shape
If the preform structure is made flat, then it is easy to produce, but it cannot achieve the desired three-dimensional depth without complex folding
Solution Approach 1:
The knitted preform's flexibility allows it to be molded directly into three-dimensional shapes during the impregnation and curing process. The loops can stretch and conform to the mold cavity, achieving complex 3D depth without requiring pre-folding or complex assembly operations, thus maintaining production simplicity while achieving desired geometry.
Solution Approach 2:
The patent transitions from a two-dimensional flat preform to a three-dimensional shaped shell through the molding process. The knitted structure's ability to deform in the thickness dimension during impregnation allows direct formation of 3D shapes, eliminating the need for complex folding operations that would compromise structural continuity.
4Strength
If loops with varying pitch are used, then mechanical stress resistance is enhanced, but the structure complexity increases
Solution Approach 1:
The patent implements varying loop pitches in specific zones of the knitted preform to enhance mechanical stress resistance where needed. By concentrating structural complexity only in areas requiring enhanced strength while maintaining simpler patterns elsewhere, the overall device complexity is minimized while still achieving the necessary strength improvements.
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 simplifies production, reduces weight, and enhances the robustness and aesthetic possibilities of luggage shells by enabling continuous 3D shaping and uniform distribution of matrix and reinforcement materials, resulting in a lightweight, waterproof, and robust composite material.
Implementation Method 1
impregnating the reinforcement of the preform with a matrix material in order to produce a shell comprising a body, the body being made of composite material and comprising the matrix and the reinforcement
Data Source
AI summary
A method for producing a shell for luggage, comprising: a) producing a preform comprising a structure and including a reinforcement, the structure, which comprises a main zone, two longitudinal zones and two transverse zones, having loops successively forming rows of loops, the rows of loops being connected to each other, and b) placing the preform on a punch, c) impregnating the reinforcement of the preform with a matrix material in order to produce a shell comprising a body, the body being made of a composite material and comprising the matrix and the reinforcement, and the body having a main wall, two longitudinal walls and two transverse walls.