Thermoformed Protrusions on Storage Device Outer Layer
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Solution Overview
Problem
There is a need for a simple and economic method to produce three-dimensional protrusions on storage devices, such as suitcases, which are durable and maintain their shape under applied forces.
Innovation Solution
A thermoforming process is used to create three-dimensional protrusions on an additional outer layer, which can be made of plastic, leather, or textile materials, and applied to the storage device's surface using an adhesive, allowing for varying shapes and structures, including rib-shaped protrusions with a triangular cross-section, and optionally formed with multiple stacked layers for added durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-dimensional protrusions are provided in the mold during production, then the protrusions are durable and maintain their shape, but the production process becomes complex and expensive
Solution Approach 1:
The protrusions are created as a separate additional layer on top of the base storage device, rather than integrating them into the base structure during molding. This separates the protrusion creation step from the base device production, allowing for simpler base device manufacturing while adding durable protrusions as a separate component layer.
Solution Approach 2:
An additional layer serves as an intermediary between the base storage device and the protrusions. This intermediate layer is applied to the base device and then receives the protrusions, enabling the protrusions to be added without complicating the base device production process while maintaining structural integrity.
2Reliability
If three-dimensional protrusions are added to enhance durability and shape retention, then the protrusions resist denting, but the production cost increases
Solution Approach 1:
The additional layer is implemented as a thin film or shell that is applied to the base device surface. This thin film approach provides the necessary structural support for dent-resistant protrusions without requiring expensive thick materials or complex multi-component assemblies, thereby controlling production costs while achieving the desired durability.
3Adaptability or versatility
If the shape of three-dimensional protrusions is varied as desired, then design flexibility is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The additional layer is designed as a flexible component that can be formed into various three-dimensional shapes through thermoforming or similar forming processes. This flexibility allows the same basic additional layer structure to accommodate different protrusion shapes and designs without requiring fundamentally different manufacturing processes, thereby maintaining process simplicity while achieving shape variability.
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 allows for the economical production of durable three-dimensional protrusions that maintain their shape and resist denting, enabling a long-lasting and adaptable design for storage devices.
Implementation Method 1
at least one three-dimensional protrusion formed therein by a thermoforming process
Data Source
AI summary
In a storage device, in particular a piece of baggage or a wallet, having at least one outer surface, it is provided that an additional outer layer is provided on the outer surface, said layer having at least one three-dimensional protrusion formed therein by a thermoforming process and protruding from the outer surface.