Luggage Shell with Thin Metal Covering Sheet

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Solution Overview

Problem

Conventional luggage shells are either lightweight but not resistant to deformation (plastic) or heavy and limited in shape options (metal), lacking a balance between aesthetics, mechanical resistance, and ease of decoration.

Innovation Solution

A luggage shell composed of a plastic structure with a thin metal covering sheet (25 μm to 1 mm thick) that provides both mechanical resistance and aesthetic appeal, using materials like titanium, stainless steel, or aluminum, and incorporating fiber fillers for added strength, with a folding design to fit the shell's shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If plastic luggage shells are used, then the luggage is lightweight, but the shell is not resistant to deformation

Engineering Contradiction:

Improveluggage weightVSAvoidresistance to deformation

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The invention uses a composite structure combining a plastic shell with a metal covering sheet. The plastic provides lightweight properties while the thin metal sheet (25 μm to 1 mm thick) adds mechanical strength and resistance to deformation, resolving the contradiction between weight and strength.

Inventive Principle:

Principle #40Composite materials

2Strength

If thick metal sheets (1.5 mm to 2 mm) are used for luggage shells, then the luggage is mechanically resistant, but the luggage becomes much heavier

Engineering Contradiction:

Improvemechanical resistanceVSAvoidluggage weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The invention replaces thick metal sheets with a composite structure using a thin metal covering sheet (25 μm to 1 mm) combined with a plastic shell. This provides sufficient mechanical resistance while dramatically reducing weight compared to traditional thick metal construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention uses a thin metal sheet covering that is flexible enough to be formed into various shapes while providing the necessary mechanical protection. The thin film approach allows for weight reduction while maintaining structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If stamping process with die is used for metal shells, then the manufacturing is simple, but the shape range is limited and fine details cannot be provided

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidshape variety and aesthetic detail

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The thin metal covering sheet can be more easily formed and shaped compared to thick metal sheets. It allows for greater shape variety and can accommodate aesthetic details while remaining manufacturable through adapted stamping or forming processes.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11528972B2Luggage shell, luggage comprising such a shell, and method for manufacturing a luggage shell

Publication Date: 2022.12.20 LOUIS VUITTON MALLETIER SA

AI summary

A luggage shell comprising a structure having a general shell shape defining an internal volume and formed of a material comprising plastic or a composite material, and at least one covering sheet fixed on an outer surface of the structure, said covering sheet being of metal and having a thickness of between 25 μm and 1 mm.