Self-Reinforced Polypropylene Protective Case Design
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Solution Overview
Problem
Existing protective cases for sports and hobby equipment are often bulky, heavy, and require multiple bags for different items, leading to excessive storage space and expense, with materials like aluminum frames and ABS plastic increasing weight and having drawbacks such as high radar reflectivity and poor infrared shielding.
Innovation Solution
A flexible case design featuring removable side walls, top, and base portions with self-reinforced polypropylene (srPP) construction, allowing for customizable size adjustments and integration of wheels, which can be easily stored and transported, using a method that sandwiches foam substrates between srPP layers without thermoforming, enabling complex shapes and improved protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional protective cases use aluminum frames or ABS plastic for rigidity, then the case maintains structural strength, but the weight increases significantly
Solution Approach 1:
The patent uses self-reinforced polypropylene (srPP), a composite material that combines polypropylene resin with oriented polypropylene fibers. This composite provides high strength-to-weight ratio, achieving the required structural rigidity while maintaining lightweight properties. The srPP material delivers tensile strength comparable to aluminum frames without the associated weight penalty.
2Reliability
If multiple separate bags are purchased to accommodate different sports equipment items, then each item receives appropriate protection, but storage space and expense increase
Solution Approach 1:
The patent designs a universal protective case with adjustable internal configurations that can accommodate multiple types of sports equipment. The case features removable dividers and customizable compartments that allow a single case to protect different items such as bicycles, helmets, and other gear, eliminating the need for multiple specialized bags.
Solution Approach 2:
The case incorporates removable and reconfigurable internal dividers that segment the interior space into multiple compartments. These segmented sections can be adjusted or removed based on the specific equipment being transported, allowing optimal protection for different item configurations while maintaining a single case structure.
3Reliability
If traditional cases use fixed rigid structures, then protection is maintained, but the cases are bulky and heavy to move
Solution Approach 1:
The patent employs self-reinforced polypropylene material that changes its mechanical properties based on environmental conditions. The srPP material becomes more rigid at lower temperatures and more flexible at higher temperatures, allowing the case to maintain protection when needed while being easier to manipulate and transport under varying conditions.
Data Source
AI summary
Case for containing an item and method of manufacture comprising: a first panel having a perimeter edge and at least one hinge for folding the first panel. A second panel having a perimeter edge and at least one hinge for folding the second panel. A side panel. A first fastener configured to attach the side panel to the perimeter edge of the first panel. A second fastener configured to attach the side panel to the perimeter edge of the second panel. Method of manufacture of a layered material comprising the steps of: placing a substrate between a first and a second layer of self-reinforced polypropylene (srPP). Bonding the layers of srPP and substrate by: stitching, or riveting through the first layer of srPP, the substrate and the second layer of srPP; or gluing the first layer of srPP, the substrate and the second layer of srPP together.