Biaxially Oriented Polymer Laminate for Lightweight Luggage Shells
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Solution Overview
Problem
Existing hard side luggage materials are difficult to manufacture, require thickness and weight for strength, and are costly and time-consuming, lacking flexibility in molding processes.
Innovation Solution
A lightweight, impact-resistant laminate material composed of biaxially oriented thermoplastic polymer films, with a core and outer layers, that can be deep drawn into luggage shells using low heat and pressure, facilitating easy, fast, and inexpensive production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional formable materials are used for hard side luggage cases, then durability and support are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies composite materials by combining multiple layers including a knit fabric layer, a foam layer, and a thermoplastic polymer layer. This composite structure achieves the desired durability and support while being more forgiving during manufacturing compared to traditional solid materials, as each layer contributes different properties (structural integrity, cushioning, and formability).
Solution Approach 2:
The patent utilizes flexible shells and thin films through the use of a knit fabric layer and thermoplastic polymer layer that can be deep drawn and molded. These flexible materials allow for complex shaping and deep drawing operations with greater tolerance to process variations, reducing manufacturing complexity while maintaining strength.
2Strength
If traditional formable materials are used for luggage cases, then strength is improved, but weight increases
Solution Approach 1:
The patent employs thin film structures where a thermoplastic polymer layer (typically 10-50 microns thick) and foam layer provide structural strength and protection. This thin-film approach significantly reduces weight compared to traditional solid materials while maintaining adequate strength through the multi-layer composite design and deep drawing process that distributes stresses.
3Strength
If traditional materials are used for deep drawn articles, then durability is improved, but manufacturing time increases
Solution Approach 1:
The patent applies parameter changes by utilizing thermoplastic polymers with specific melting points and flow characteristics that enable rapid heating and forming. The material can be quickly heated to its forming temperature, deep drawn into complex shapes, and then cooled to set the final form, significantly reducing manufacturing cycle time while maintaining durability through the controlled thermal processing parameters.
4Object-affected harmful factors
If traditional materials are used for luggage shells, then impact resistance is reduced, but material thickness must increase
Solution Approach 1:
The patent uses composite materials with a foam layer providing impact absorption and energy dissipation, a knit fabric layer for structural integrity, and a thermoplastic polymer layer for surface protection. This composite structure achieves superior impact resistance without increasing overall thickness, as each layer contributes to impact mitigation through different mechanisms (cushioning, tensile strength, and surface hardness).
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 material results in a durable, thin, and deformation-resistant luggage shell with high-quality surface finish, overcoming manufacturing challenges and reducing material and process costs.
Implementation Method 1
The method requires relatively little heat and pressure
Implementation Method 2
amenable to being deep drawn into articles such as luggage shells
Data Source
AI summary
A laminate (110) of polypropylene films (100), a luggage shell (120) constructed of the laminate (110), a method (200) of making the laminate (110), and a method (280) of making the luggage shell (120) are provided. The films (100) include a core (102) and at least one outer layer (104). The laminate (110) includes a plurality of films (100). The laminate (110) may be formed by laminating a plurality of films 100 under predetermined pressure, temperature, and time conditions. The shell (120) may be formed by deep drawing a sheet of laminate (110) while applying heat and tension to the laminate (110).