WO2022116124A1 - Suitcase having frame integrally formed from composite material and fabrication method therefor - Google Patents

Abstract

The invention is a suitcase having a frame integrally formed from a composite material and a fabrication method therefor. The method comprises the following steps: A) preparing a thermoplastic sheet into an outer housing; B) placing a housing body of the outer housing in an inner concave mold region of a heating mold, placing a housing edge of the housing in a frame mold region of the heating mold, and enabling an outer surface of the housing to correspond to an inner wall surface of the heating mold; C) placing an outer surface of a thermosetting carbon fiber plastic layer on an inner surface of the housing; D) providing a filling layer on an inner surface of the thermosetting carbon fiber plastic layer and located in the frame mold region; and E) using a balloon to expand against the thermosetting carbon fiber plastic layer and the filling layer, and heating same by means of the heating mold, such that the housing, the thermosetting carbon fiber plastic layer and the filling layer are bonded to one another.

Description

Luggage case with composite material integrally formed frame and manufacturing method thereof technical field

The invention relates to carbon fiber products, in particular to a luggage case with a composite material integrally formed frame and a manufacturing method thereof.

Background technique

The luggage currently sold on the market is usually made of thermoplastic or aluminum-magnesium alloy, such as a luggage frame device disclosed in Taiwan's new patent case No. M518022, which has two frame parts, each frame part They are respectively riveted on the periphery of the two oppositely opening and closing shells by means of rivets. When the two shells are closed, the frame parts will be embedded and clamped together. However, the manufacturing process of this type of luggage is cumbersome, and when the luggage is larger, the aluminum frame members are more likely to be deformed during the production or assembly (riveting) process, so that the accuracy of each frame member can be controlled. It is not easy, which further leads to the dislocation of each frame (inaccurate combination) when the two casings are closed.

SUMMARY OF THE INVENTION

The main purpose of the present invention is to provide a manufacturing method of a suitcase with a composite material integrally formed frame, which can obtain an integrally formed shell and frame structure in a one-time mold forming process, and the suitcase made by this manufacturing method It has the functions of high strength, light weight and high precision, so as to increase the durability of the luggage and improve the fit of the two frames when the two shells are closed, so as to improve the existing technology using bonding, riveting or stitching The suitcase that combines the shell and the frame by the craftsmanship has the disadvantages of complicated process and low combination accuracy.

In order to achieve the above-mentioned main purpose, the method for manufacturing a luggage case with a composite material integrally formed frame of the present invention comprises the following steps: A) using a vacuum molding method to make a thermoplastic sheet into an outer shell, the outer shell having A shell body, a shell edge disposed on the outer edge of the shell body, and an accommodating area surrounded by the shell body and the shell edge; B) providing a heating mold, the heating mold has an inner concave mold region and, a frame mold area and an inner wall surface, the frame mold area is located at the outer edge of the inner female mold area, the shell body is arranged in the inner female mold area, the shell edge is arranged in the frame mold area, and the The outer surface of the outer shell should heat the inner wall surface of the mold; C) provide a thermosetting carbon fiber plastic layer, and the outer surface of the thermosetting carbon fiber plastic layer is provided on the inner surface of the outer shell; D) provide a filling layer, the filling layer is arranged on The inner surface of the thermosetting carbon fiber plastic layer is located in the frame mold area; and E) disposing an airbag in the accommodating area of the outer shell, and inflating the airbag against the inner surface of the thermosetting carbon fiber plastic layer and the filling layer, and passing through The heating mold heats the shell body and the thermosetting carbon fiber plastic layer in the inner concave mold area, and the thermosetting carbon fiber plastic layer and the filling layer in the frame mold area, so that the shell, the thermosetting carbon fiber plastic layer And the filling layers are combined with each other.

Preferably, in step B) to step D), the frame mold area has an inner groove and an outer groove, the inner groove is adjacent to the inner wall surface of the heating mold and is spaced apart from the outer groove, The shell edge of the casing is placed in the inner groove, and the thermosetting carbon fiber plastic layer and the filling layer are placed in the inner groove and the outer groove.

Preferably, in step C) and step D), the thermosetting carbon fiber plastic layer is placed in the inner groove, and the filling layer is placed in the inner groove and the outer groove.

Preferably, the inner groove of the frame mold area is mainly composed of a plane, a first inclined plane and an inner wall surface of the heating mold, and two sides of the plane are respectively connected to the inner wall surface and the first inclined plane.

Preferably, in step B) to step D), the frame mold area has an inner protrusion, an outer protrusion and a groove, the inner protrusion protrudes from the inner wall surface of the heating mold, and the groove is located on the inner wall of the heating mold. Between the inner bump and the outer bump, the shell edge of the casing and the thermosetting carbon fiber plastic layer are placed on the inner bump and the groove, and the filling layer is placed in the groove and the outer bump .

Preferably, the groove of the frame mold area is mainly formed by connecting a second inclined surface and a third inclined surface.

Preferably, the filling layer is a thermosetting carbon fiber plastic.

Preferably, in step E), the thermosetting carbon fiber plastic layer and the filling layer are fused and solidified after being heated by the heating mold and are bonded to the inner surface of the casing.

Preferably, in step A), the thermoplastic sheet is a transparent material.

Preferably, in step A), the vacuum forming process is to provide a vacuum molding device with a mold, and put the thermoplastic plastic sheet into the vacuum forming device for heating and softening, and then the vacuum forming The apparatus generates negative pressure to adhere the thermoplastic sheet to the mold surface to form the housing.

Preferably, a step F) is further included after the step E), the airbag is moved out of the accommodating area of the shell, and the luggage case formed from the composite material is cooled.

Preferably, the present invention further provides a luggage case with a composite material integrally formed frame, which includes a first shell, a second shell, a first frame and a second frame, wherein the second shell can be The first frame is integrally formed with the first casing and is located at the outer edge of the first casing, and the second frame is integrally formed with the second casing and is located at the outer edge of the first casing. On the outer edge of the second casing, when the first casing and the second casing are closed, the second frame is embedded in the first frame.

Preferably, both the first shell and the second shell have a shell and a thermosetting carbon fiber plastic layer, and the thermosetting carbon fiber plastic layer is disposed on the inner surface of the shell.

Preferably, both the first frame and the second frame have a shell, a thermosetting carbon fiber plastic layer and a filling layer, the thermosetting carbon fiber plastic layer is disposed on the inner surface of the shell, and the filling layer is disposed on the thermosetting carbon fiber plastic layer inside.

Preferably, the first frame has a concave card slot, and the second frame has a protruding inserting member, and the inserting member is embedded in the card slot.

As can be seen from the above, the luggage case with the composite material integrally formed frame and the manufacturing method thereof of the present invention can obtain the integrally formed shell and frame structure in a one-time mold forming process. It has the functions of high strength, light weight and high precision, so as to increase the durability of the luggage and improve the fit of the two frames when the two shells are closed.

The detailed structure and features provided by the present invention will be described in the detailed description of the following embodiments. However, those with ordinary knowledge in the art should understand that these detailed descriptions and specific embodiments for implementing the present invention are only used to illustrate the present invention, and not to limit the protection scope of the claims of the present invention.

Description of drawings

FIG. 1 is an exploded perspective view of a luggage case with a composite material integrally formed frame according to the present invention.

FIG. 2 is a cross-sectional view of the luggage case with the composite material integrally formed frame of the present invention.

3 to 7 are schematic diagrams of a method for manufacturing a luggage case with an integrally formed frame of composite materials according to the present invention, which illustrate a manufacturing process of integrally forming the first shell and the first frame.

8 to 12 are schematic diagrams of a method for manufacturing a luggage case with an integrally formed frame of composite material according to the present invention, which illustrate a manufacturing process of integrally forming the second shell and the second frame.

10: Suitcase 20: First shell 21: Shell

211: Shell body 213: Shell side 215: Accommodating area

23: Thermosetting carbon fiber plastic layer 30: Second shell

31: Shell 33: Thermosetting carbon fiber plastic layer

40: First frame 41: Shell 43: Thermosetting carbon fiber plastic layer

45: Filling layer 47: Card slot 50: Second border

51: Shell 53: Thermosetting carbon fiber plastic layer

55: Filling layer 57: Insert card 60: Heating mold

61: Inner die area 63: Frame die area 631: Inner groove

632: Outer groove 634: Flat surface 635: First bevel

636: Inner bump 637: Outer bump 638: Groove

639: Second slope 640: Third slope 70: Airbag

S1-1: Step S1-2: Step S1-3: Step

S1-4: Step S1-5: Step S1-6: Step

S2-1: Step S2-2: Step S2-3: Step

S2-4: Step S2-5: Step S2-6: Step

Detailed ways

In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings.

The applicant first explains that in the entire specification, including the embodiments described below and the claims in the scope of the patent application, the terms related to the directionality are based on the directions in the figures. Next, in the embodiments and figures to be introduced below, the same element numbers represent the same or similar elements or their structural features.

Please refer to FIG. 1 and FIG. 2 first, the luggage case 10 with a composite material integrally formed frame of the present invention includes a first casing 20 , a second casing 30 , a first frame 40 and a second frame 50 .

The first casing 20 has a shell 21 and a thermosetting carbon fiber plastic layer 23 , and the thermosetting carbon fiber plastic layer 23 is disposed on the inner surface of the shell 21 .

The second casing 30 is foldably assembled to the first casing 20 , the second casing 30 has a casing 31 and a thermosetting carbon fiber plastic layer 33 , and the thermosetting carbon fiber plastic layer 33 is disposed on the inner surface of the casing 31 ;

The first frame 40 is integrally formed with the first casing 20 and is located at the outer edge of the first casing 20 . The first frame 40 has a shell 41 , a thermosetting carbon fiber plastic layer 43 , a filling layer 45 and a recessed card slot 47 . The thermosetting carbon fiber plastic layer 43 is provided on the inner surface of the casing 41 , and the filling layer 45 is provided on the inner surface of the thermosetting carbon fiber plastic layer 43 .

The second frame 50 is integrally formed with the second casing 30 and is located at the outer edge of the second casing 30 . The second frame 50 has a shell 51 , a thermosetting carbon fiber plastic layer 53 , a filling layer 55 and a protruding inlay The clip 57, the thermosetting carbon fiber plastic layer 53 is arranged on the inner surface of the shell 51, the filling layer 55 is arranged on the inner surface of the thermosetting carbon fiber plastic layer 53, when the first casing 20 and the second casing 30 are covered with each other, the second frame The inserting member 57 of 50 will be embedded in the slot 47 of the first frame 40 .

The manufacturing method of the luggage case 10 with the integrated frame of composite material of the present invention is divided into two parts, one is the manufacturing method of integrally forming the first shell 20 and the first frame 40, and the other is the second shell 30 and the second frame 50. Manufacturing method of integral molding. FIG. 2 to FIG. 7 illustrate the manufacturing method of integrally molding the first casing 20 and the first frame 40, which includes steps S1-1 to S1-7, as follows:

Step S1-1: Referring to FIG. 3, a thermoplastic plastic sheet is used to form shells 21, 41 by a vacuum molding method. The shells 21, 41 have a shell body 211 and a shell disposed on the outer edge of the shell body 211. The side 213 and an accommodating area 215 surrounded by the shell body 211 and the shell side, wherein the material of the thermoplastic plastic sheet is selected from PP polypropylene, ABS resin (Acrylonitrile Butadiene Styrene), PC polycarbonate or a combination thereof, of course Other thermoplastics or combinations of thermoplastics are also covered by the present invention. The aforementioned vacuum forming process (also known as a blister process) provides a vacuum forming device with a mold (not shown in the figure), and the mold is A male mold, and other auxiliary molds (such as protruding strips) can be set on the male mold to manufacture shells 21 and 41 with different shapes. The process is to put the thermoplastic sheet into the vacuum forming equipment for heating and softening, and then the vacuum forming equipment immediately A negative pressure is generated to attach the thermoplastic sheet to the surface of the mold to form the shell 21, 41, wherein the vacuum forming equipment heats and softens the thermoplastic sheet and generates a negative pressure to attach the thermoplastic sheet to the surface of the mold to form the shell The technical content is common knowledge and will not be repeated here.

Step S1-2: As shown in FIG. 3 , a heating mold 60 is provided. The heating mold 60 has an inner concave mold area 61 , a frame mold area 63 and an inner wall surface, and the frame mold area 63 is located outside the inner concave mold area 61 . The edge has an inner groove 631 and an outer groove 632. The inner groove 631 is adjacent to the inner wall surface of the heating mold 60 and is spaced from the outer groove 632. The inner groove 631 is mainly composed of a flat surface 634, a first The inclined surface 635 and the inner wall surface of the heating mold 60 are formed. The two sides of the plane 634 are respectively connected to the inner wall surface and the first inclined surface 635 for making the slot 47. The shell edge 213 is disposed in the inner groove 631 of the frame mold region 63 , so that the outer surfaces of the shells 21 and 41 correspond to the inner wall surface of the heating mold 60 . In addition, to display a pattern (such as a trademark or a modeling pattern) on the casing 21, a thermoplastic sheet of transparent material can be selected in step S1-1, and then the thermoplastic sheet is made into the casing 21, and in step S1 -1 or step S1-2, a pattern is provided on the inner surface of the housing 21 by painting, printing or labeling.

Step S1-3: As shown in FIG. 4, a thermosetting carbon fiber plastic layer 43 is provided, the thermosetting carbon fiber plastic layer 43 has an outer surface and an inner surface, the outer surface of the thermosetting carbon fiber plastic layer 43 is arranged on the inner surfaces of the casings 21, 41, and further For example, a part of the thermosetting carbon fiber plastic layer 43 will be placed in the inner die area 61 , and the other part will be placed in the inner groove 631 (or between the inner groove 631 and the outer groove 632 ) of the frame mold area 63 , wherein , the thermosetting plastic of the thermosetting carbon fiber plastic layer 43 is selected from epoxy resin or polyester. Of course, other thermosetting plastics or combinations of thermosetting plastics are also covered by the present invention.

Step S1-4: As shown in FIG. 5 , a filling layer 45 is provided. The filling layer 45 in this embodiment is a thermosetting carbon fiber plastic. The filling layer 45 is attached to the inner surface of the thermosetting carbon fiber plastic layer 43 and is located in the frame mold area 63 between the inner groove 631 and the outer groove 632 (or only the outer groove 632) to increase the amount of material at the frame.

Step S1-5: As shown in FIG. 6 , place an airbag 70 in the accommodating areas 215 of the casings 21 and 41, and expand the airbag 70 against the inner surface of the thermosetting carbon fiber plastic layer 43 and the filling layer 45, and heat the mold by heating the mold. 60 is heated to the shell body 211 and the thermosetting carbon fiber plastic layer 43 located in the inner female mold area 61 and the thermosetting carbon fiber plastic layer 43 and the filling layer 45 located in the frame mold area 63, so that the shells 21, 41, the thermosetting carbon fiber plastic layer 43 and The filling layers 45 are combined with each other and extruded into the inner groove 631 and the outer groove 632 of the frame die area 63, wherein the preferred heating temperature is between 140°C and 150°C, so that the thermosetting carbon fiber plastic layer 43 and the The filling layer 45 is cured and adhered to the inner surfaces of the casings 21 and 41 , so that the casings 21 and 41 , the thermosetting carbon fiber plastic layer 43 and the filling layer 45 are combined with each other, so that the first casing 20 and the first frame 40 are integrally formed.

Step S1-6: As shown in FIG. 7 , move the airbag 70 out of the housing area 215 of the housing, and cool the integrally formed first housing 20 and the first frame 40 to complete the first housing 20 and the first frame 40 . Manufacturing process of a frame 40 .

2 , FIGS. 8 to 12 illustrate the manufacturing method of integrally molding the second casing 30 and the second frame 50 , which includes steps S2-1 to S2-7, wherein steps S2-1 to S2-7 and step S1 The flow from -1 to step S1-7 is roughly the same, the difference lies in the following steps:

Step S2-2: As shown in FIG. 2 and FIG. 8 , the frame mold area 63 has an inner protrusion 636, an outer protrusion 637 and a groove 638. The inner protrusion 636 protrudes from the inner wall surface of the heating mold 60 and is concave. The groove 638 is located between the inner convex block 636 and the outer convex block 637, and the groove 638 is mainly formed by a second inclined surface 639 connected with a third inclined surface 640, so as to be used for making the insert 57, and the casing 31 The shell edges of the shells 31 and 51 are placed on the inner bumps 636 and the grooves 638 . Of course, the shell edges 213 of the outer shells 31 and 51 can be placed on the inner wall of the heating mold 60 and adjacent to the inner bump 636 as required.

Step S2-3: As shown in FIG. 9, the outer surface of the thermosetting carbon fiber plastic layer 43 is arranged on the inner surface of the shells 31 and 51. Further, a part of the thermosetting carbon fiber plastic layer 43 will be placed in the inner die area 61, The other part is placed in the inner bump 636 and the groove 638 .

Step S2-4: As shown in FIG. 10 , the filling layer 45 is placed in the grooves 638 and adjacent to the outer bumps 637 .

Step S2-5: As shown in FIG. 11 , set the airbag 70 in the accommodating area 215 of the housings 31 and 51 , expand the airbag 70 against the inner surface of the thermosetting carbon fiber plastic layer 43 and the filling layer 45 , and heat the mold 60 The shell 211 and the thermosetting carbon fiber plastic layer 43 located in the inner female mold area 61 and the thermosetting carbon fiber plastic layer 43 and the filling layer 45 located in the frame mold area 63 are heated, so that the shells 31, 51, the thermosetting carbon fiber plastic layer 43 and the filling layer 45 are heated. The layers 45 are combined with each other and squeezed into the grooves 638 of the frame mold area 63, so that the thermosetting carbon fiber plastic layer 43 and the filling layer 45 are cured and bonded to the inner surfaces of the shells 31, 51, and then the shells 31, 51, thermosetting The carbon fiber plastic layer 43 and the filling layer 45 are combined with each other, so that the second casing 30 and the second frame 50 are integrally formed.

Step S2-6: As shown in FIG. 12 , move the airbag out of the accommodating area 215 of the casings 31 and 51 , and cool the integrally formed second casing 30 and the second frame 50 to complete the second casing 30 and the manufacturing procedure of the second frame 50 .

To sum up, the luggage case with composite material integrally formed frame and the manufacturing method thereof of the present invention can obtain the integrally formed shell and frame structure in one-time mold forming processing, and the luggage made by this manufacturing method has both High strength, light weight and high precision, so as to increase the durability of the luggage and improve the fit of the two frames when the two shells are closed.

The specific embodiments described above further describe the purpose, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above-mentioned specific embodiments are only specific embodiments of the present invention, and are not intended to limit the present invention. Within the spirit and principle of the present invention, any modifications, equivalent replacements, improvements, etc. made should be included within the protection scope of the present invention.

Claims (16)

A method for manufacturing a suitcase with a composite material integrally formed frame, comprising the following steps: A) Using a vacuum molding method to make a thermoplastic sheet into a shell, the shell has a shell body, a shell edge disposed on the outer edge of the shell body, and a shell composed of the shell body and the shell edge enclosed accommodation area; B) provide a heating mold, the heating mold has an inner concave mold area and a frame mold area and an inner wall surface, the frame mold area is located at the outer edge of the inner concave mold area, and the shell body is arranged in the inner concave mold area. The mold area is set, and the shell edge is arranged in the frame mold area, and the outer surface of the shell should heat the inner wall surface of the mold; C) providing a thermosetting carbon fiber plastic layer, the outer surface of the thermosetting carbon fiber plastic layer is arranged on the inner surface of the shell; D) providing a filling layer, the filling layer is disposed on the inner surface of the thermosetting carbon fiber plastic layer and located in the frame mold area; and E) Disposing an airbag in the accommodating area of the outer shell, expanding the airbag against the inner surface of the thermosetting carbon fiber plastic layer and the filling layer, and passing the heating mold to the shell body located in the inner female mold area The thermosetting carbon fiber plastic layer, the thermosetting carbon fiber plastic layer and the filling layer in the frame mold area are heated, so that the shell, the thermosetting carbon fiber plastic layer and the filling layer are combined with each other. The method for manufacturing a luggage case as claimed in claim 1, wherein, in step B) to step D), the frame mold area has an inner groove and an outer groove, and the inner groove is adjacent to the heating mold. The inner wall surface and the outer groove are spaced apart from each other, the shell edge of the casing is placed in the inner groove, and the thermosetting carbon fiber plastic layer and the filling layer are placed in the inner groove and the outer groove. The manufacturing method of a luggage case as claimed in claim 2, wherein, in step C) and step D), the thermosetting carbon fiber plastic layer is placed in the inner groove, and the filling layer is placed in the inner groove and the inner groove. the outer groove. The manufacturing method of a luggage case as claimed in claim 2, wherein the inner groove of the frame mold area is mainly composed of a plane, a first inclined plane and an inner wall surface of the heating mold, and two sides of the plane are respectively connected to the inner groove. the wall surface and the first inclined surface. The manufacturing method of a luggage case as claimed in claim 1, wherein, in steps B) to D), the frame mold area has an inner bump, an outer bump and a groove, and the inner bump protrudes from On the inner wall surface of the heating mold, the groove is located between the inner bump and the outer bump, the shell edge of the casing and the thermosetting carbon fiber plastic layer are both placed on the inner bump and the groove, and the A filling layer is placed on the groove and the outer bump. The method for manufacturing a luggage case with an integrated frame of composite material as claimed in claim 5, wherein the groove of the frame mold area is mainly formed by connecting a second inclined surface and a third inclined surface. The method for manufacturing a luggage case frame formed by a composite material according to claim 1, wherein the filling layer is a thermosetting carbon fiber plastic. The method for manufacturing a luggage case as claimed in claim 1 , wherein, in step E), the thermosetting carbon fiber plastic layer and the filling layer are fused and solidified after being heated by the heating mold and are bonded to the inner surface of the outer shell. The method for manufacturing a luggage case according to claim 1, wherein, in step A), the thermoplastic plastic sheet is made of transparent material. The manufacturing method of a luggage case as claimed in claim 1, wherein, in step A), the vacuum forming process is to provide a vacuum molding device with a mold, and put the thermoplastic plastic sheet into The vacuum forming equipment is heated and softened, and then the vacuum forming equipment generates negative pressure to make the thermoplastic plastic sheet adhere to the surface of the mold to form the shell. The method for manufacturing a luggage case as claimed in claim 1, further comprising a step F) after the step E), removing the airbag from the accommodating area of the shell, and making the composite material molded luggage case. cool down. A suitcase made by the manufacturing method according to any one of claims 1 to 11, comprising: a first shell; a second casing, which can be assembled on the first casing; a first frame integrally formed with the first casing and located at the outer edge of the first casing; and A second frame is integrally formed with the second casing and is located at the outer edge of the second casing. When the first casing and the second casing are closed, the second frame is embedded in the first casing frame. The luggage case of claim 12 , wherein the first shell and the second shell both have an outer shell and a thermosetting carbon fiber plastic layer, and the thermosetting carbon fiber plastic layer is disposed on the inner surface of the outer shell. The luggage case of claim 12 , wherein the first frame and the second frame both have a shell, a thermosetting carbon fiber plastic layer and a filling layer, the thermosetting carbon fiber plastic layer is disposed on the inner surface of the shell, the The filling layer is arranged on the inner surface of the thermosetting carbon fiber plastic layer. The luggage case of claim 14, wherein the filling layer is a thermosetting carbon fiber plastic layer. The luggage case of claim 12 , wherein the first frame has a recessed card slot, the second frame has a protruding inserting member, and the inserting member is fitted into the card slot.

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