Luggage Shell Notch Folding and Corner Reinforcement
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Solution Overview
Problem
Current luggage options either lack protection against external forces due to their lightweight construction or are heavy and expensive to manufacture, as they require complex molding techniques.
Innovation Solution
A lightweight luggage design utilizing a stiff shell material, such as woven polypropylene thermoplastic composite, with a reinforced structure and notch configurations that allows for easy assembly and eliminates the need for expensive molding processes, providing both strength and affordability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If soft bags are used for lightweight construction, then weight is reduced, but protection against external forces deteriorates
Solution Approach 1:
The patent applies composite materials by combining a woven polypropylene fabric base with a thermoplastic coating layer. This composite structure provides both the lightness of fabric and the rigidity of plastic, achieving a balance between weight reduction and strength enhancement without requiring heavy rigid frames or complex molding processes.
2Strength
If rigid internal frames are added to soft bags for greater resistance to deformation, then strength is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent changes the physical and chemical parameters of the shell material by using a thermoplastic-coated woven fabric. The thermoplastic coating transforms the soft fabric into a semi-rigid structure that resists deformation without requiring heavy internal frames. The coating can be applied in controlled thicknesses to achieve the desired balance between rigidity and weight.
3Strength
If hard plastic material is used for bag construction, then resistance to deformation is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent segments the shell construction into distinct functional layers: a woven polypropylene fabric base layer providing structural framework and a thermoplastic coating layer providing rigidity and deformation resistance. This segmentation allows each layer to be manufactured separately using simple, inexpensive processes and then combined, avoiding the need for complex single-step molding operations.
Solution Approach 2:
The patent applies composite materials by combining a woven polypropylene fabric base with a thermoplastic coating layer. This composite structure provides both the lightness of fabric and the rigidity of plastic, achieving a balance between weight reduction and strength enhancement without requiring heavy rigid frames or complex molding processes.
4Strength
If complex molding techniques are used for hard bag production, then strength is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent segments the shell construction into distinct functional layers: a woven polypropylene fabric base layer providing structural framework and a thermoplastic coating layer providing rigidity and deformation resistance. This segmentation allows each layer to be manufactured separately using simple, inexpensive processes and then combined, avoiding the need for complex single-step molding operations.
Solution Approach 2:
The patent replaces complex mechanical molding systems with simpler coating and lamination processes. Instead of using expensive injection molding or compression molding equipment that requires precise temperature and pressure control, the invention applies thermoplastic material as a coating that is then activated (likely through heat or pressure) to bond with the fabric, significantly simplifying the manufacturing system.
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 solution results in a lightweight, high-strength luggage that offers protection against deformation while being cost-effective to produce, combining the benefits of both soft and hard bags without the drawbacks of complex manufacturing techniques.
Implementation Method 1
the at least one section of the stiff shell material includes a woven polypropylene thermoplastic composite
Data Source
Figure 1
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Figure 7
AI summary
A piece of luggage (2) including at least one section (10) of a stiff shell material is provided. The at least one section (10) of the stiff shell material defines a first face (12) of the piece of luggage and has at least one corner (46). A portion of the at least one section (10) has been removed to define at least one notch (48) proximate the at least one corner (46). First and second edges (50, 52) of the at least one section (10) adjacent the notch (48) are folded inward relative an inner surface (54) of the at least one section (10) forming first and second sides (14, 18). The first and second sides (14, 18) define second and third faces (22, 26) of the piece of luggage. The piece of luggage (2) further includes at least one rigid corner piece (56) secured to the first and second sides (14, 18) proximate the at least one notch (48).