WO2022099540A1

WO2022099540A1 - Suitcase formed from composite material and manufacturing method therefor

Info

Publication number: WO2022099540A1
Application number: PCT/CN2020/128355
Authority: WO
Inventors: 廖元宏; 吴樹春
Original assignee: 东莞永湖复合材料有限公司
Priority date: 2020-11-12
Filing date: 2020-11-12
Publication date: 2022-05-19

Abstract

Disclosed are a suitcase formed from a composite material and a manufacturing method therefor. The method comprises the following steps: A) fabricating a housing using a thermoplastic sheet material by means of a vacuum forming process; B) disposing the housing in a recessed mold region of a heating mold, such that an outer surface of the housing corresponds to an inner wall surface of the recessed mold region; C) disposing an outer surface of a thermosetting carbon fiber plastic layer on an inner surface of the housing; D) disposing a reinforcement layer on an inner surface of the thermosetting carbon fiber plastic layer and at corners of the housing; and E) disposing an airbag in an accommodation region of the housing, such that the airbag is expanded and abuts the inner surface of the thermosetting carbon fiber plastic layer and the reinforcement layer, and simultaneously heating, by means of the heating mold, the housing, the thermosetting carbon fiber plastic layer and the reinforcement layer in the recessed mold region, such that the housing, the thermosetting carbon fiber plastic layer and the reinforcement layer are combined with each other.

Description

Luggage case formed by composite material and method of making the same

technical field

The present invention relates to a carbon fiber product, in particular to a manufacturing method of a composite material-shaped luggage case and a composite material-shaped luggage case produced by the manufacturing method.

Background technique

The luggage currently sold on the market is usually made of thermoplastic or aluminum-magnesium alloy. For luggage made of thermoplastic, the luggage is usually composed of two half shells. Manufacturers usually The fabric will be sewn on the inside of the half shell, the two half shells will be pivoted to each other, and the wheels and handles will be assembled to make the finished luggage. Therefore, some luggage made of thermoplastics (such as ABS resin) may be broken and damaged, which will cause inconvenience to travelers, and even need to buy a new luggage for replacement.

In order to overcome the above deficiencies, the applicant proposed a method for manufacturing a luggage case on 2018/06/20 (Taiwan Invention Patent No. 202003202A), which utilizes a vacuum forming process to make a thermoplastic sheet into a case, Then set the shell on the inner die area of the heating mold and make the outer surface of the shell correspond to the inner wall surface of the inner die area, then set the thermosetting plastic layer on the inner surface of the shell, and finally set the airbag on the inner surface of the shell. accommodating area, and make the airbag inflate against the thermosetting plastic layer, and at the same time make the heating mold heat the shell and the thermosetting plastic layer in the inner female mold area, so that the shell and the thermosetting plastic layer are combined with each other to make the luggage case shell , thereby achieving the effect of reinforcing the structural strength and reducing the overall weight of the luggage case.

In addition, in order to strengthen the strength of the corners of the luggage case, for example, Taiwan's new patent No. M579915 discloses a corner protection structure for a luggage case. The plastic shell at the corners of the box is not directly impacted to reduce the problem of cracking at the corners.

SUMMARY OF THE INVENTION

The main purpose of the present invention is to provide a method for manufacturing a suitcase formed by a composite material. The suitcase formed by the composite material produced by the method has the advantage of better structural strength, especially for the exterior of the suitcase that requires the composite material to be formed. In the case of uniform structure, it still has the effect of impact resistance and collision resistance at the corners.

In order to achieve the above-mentioned main purpose, the manufacturing method of the composite material-shaped suitcase of the present invention includes the following steps: A) using a vacuum molding process (vacuum molding method) to make a thermoplastic sheet into a shell, the shell has an outer surface, an inner surface, an accommodating area surrounded by the inner surface, and a corner; B) provide a heating mold, the heating mold has an inner female mold area, and the shell is arranged on the inner female mold C) provide a thermosetting carbon fiber plastic layer, the thermosetting carbon fiber plastic layer has an outer surface and an inner surface, the outer surface of the thermosetting carbon fiber plastic layer is provided on the inner surface of the shell; D) provide a reinforcement layer, the reinforcement layer is arranged on the inner surface of the thermosetting carbon fiber plastic layer and is located at the corner of the shell; and E) an airbag is arranged on the shell of the shell accommodating area, and make the air bag expand to support the inner surface of the thermosetting carbon fiber plastic layer and the reinforcing layer, and at the same time let the heating mold inwardly move the shell, the thermosetting carbon fiber plastic layer and the reinforcing layer in the concave mold area Heating is performed so that the shell, the thermosetting carbon fiber plastic layer and the reinforcing layer are bonded to each other.

Preferably, in step D), the reinforcing layer is a thermosetting carbon fiber plastic.

Preferably, in step E), the thermosetting carbon fiber plastic layer is cured after being heated by the heating mold and adhered to the inner surface of the casing.

Preferably, the reinforcing layer is a metal layer, and the manufacturing method further comprises the step of providing another thermosetting carbon fiber plastic layer, the other thermosetting carbon fiber plastic layer is disposed on the inner surface of the thermosetting carbon fiber plastic layer and the metal layer, the The airbag expands against the other thermosetting carbon fiber plastic layer, and at the same time, the heating mold is heated to the shell, the two thermosetting carbon fiber plastic layers and the metal layer in the inward concave mold area, so that the shell, the two thermosetting carbon fibers are heated. The plastic layers are combined with each other, and the metal layer is wrapped in the two thermosetting carbon fiber plastic layers.

Preferably, in step E), the heating temperature of the inner die zone is between 140 degrees and 150 degrees.

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

Preferably, the manufacturing method further includes the step of providing a pattern, and the pattern is provided on the inner surface of the casing by means of painting, printing or labeling.

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 molding device for heating and softening, and then the vacuum forming The apparatus generates negative pressure to attach 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 suitcase made of a composite material formed by the manufacturing method. The suitcase formed by the composite material includes a shell, a thermosetting carbon fiber plastic layer and a reinforcing layer, wherein the shell The body has an outer surface, an inner surface, an accommodating area surrounded by the inner surface, and a corner, the thermosetting carbon fiber plastic layer has an outer surface and an inner surface, and the outer surface of the thermosetting carbon fiber plastic layer is provided on the casing. On the inner surface, the reinforcing layer is arranged on the inner surface of the thermosetting carbon fiber plastic layer and is located at the corner of the shell.

It can be seen from the above that the composite material-shaped luggage case made by the composite material molding manufacturing method of the present invention can utilize the thermoplastic plastic sheet on the premise that the external structure of the composite material-shaped luggage case is uniform. The impact resistance characteristics of the thermosetting carbon fiber plastic layer, as well as the high strength and high bonding characteristics of the thermosetting carbon fiber plastic layer, and the reinforcing layer (thermosetting carbon fiber plastic layer or metal layer) is applied in a specific position according to the needs to achieve better impact resistance and collision resistance effect.

The detailed structure and features provided by the present invention will be described in the detailed description of the following embodiments. However, those skilled 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 present invention.

Description of drawings

1 to 3 are schematic diagrams of a method for manufacturing a luggage case formed from a composite material according to a first preferred embodiment of the present invention, which utilizes a vacuum forming process to form a shell from a thermoplastic sheet.

4 to 5 are schematic diagrams of a method for manufacturing a luggage case formed from a composite material according to the first preferred embodiment of the present invention, in which the casing is set in a heating mold.

FIG. 6 is a schematic diagram of a method for manufacturing a luggage case formed of a composite material according to the first preferred embodiment of the present invention, in which a thermosetting carbon fiber plastic layer is disposed on the inner surface of the shell.

7 is a schematic diagram of the first preferred embodiment of the method for manufacturing a suitcase made of composite materials, wherein a reinforcing layer (thermosetting carbon fiber plastic layer) is disposed on the inner surface of the thermosetting carbon fiber plastic layer and is located at a corner of the shell.

8 to 9 are schematic diagrams of a manufacturing method of a luggage case formed from a composite material according to the first preferred embodiment of the present invention, which utilizes an airbag to support the thermosetting carbon fiber plastic layer and the reinforcing layer.

FIG. 10 is a cross-sectional view of a luggage case formed by a composite material formed by the manufacturing method according to the first preferred embodiment of the present invention.

11 to 16 are schematic diagrams of a manufacturing method of a luggage case formed from a composite material according to a second preferred embodiment of the present invention, which is the same as the manufacturing method of FIGS. 1 to 6 .

17 is a schematic diagram of a manufacturing method of a luggage case formed of composite materials according to the second preferred embodiment of the present invention, wherein the reinforcing layer (metal layer) is arranged on the inner surface of the thermosetting carbon fiber plastic layer and is located at the corner of the shell.

18 is a schematic diagram of a manufacturing method of a luggage case formed from a composite material according to a second preferred embodiment of the present invention, wherein another thermosetting carbon fiber plastic layer is disposed on the inner surface of the shell and the reinforcing layer.

19-20 are schematic diagrams of a manufacturing method of a luggage case formed from a composite material according to a second preferred embodiment of the present invention, which utilizes an airbag to support the thermosetting carbon fiber plastic layer.

FIG. 21 is a cross-sectional view of a luggage case formed from a composite material produced by a manufacturing method according to a second preferred embodiment of the present invention.

10, 10': Composite molded luggage 20: Thermoplastic sheet

21: shell 211: outer surface 213: inner surface

215: accommodating area 217: corner 219: material edge

30: Thermosetting carbon fiber plastic layer 40: Vacuum forming equipment

42: Mould 50: Reinforcing layer (thermosetting carbon fiber plastic layer, metal layer)

60: Heating mold 62: Inner die area

64: Inner wall surface 72: 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 S2-7: 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 claims, the terms related to the directionality are based on the directions in the drawings. Next, in the embodiments to be introduced below and the accompanying drawings, the same element numbers represent the same or similar elements or their structural features.

Please refer to FIG. 1 to FIG. 10 first, which are the manufacturing method of the luggage case 10 formed by the composite material according to the first preferred embodiment of the present invention, which includes the following steps:

Step S1-1: As shown in FIG. 1 to FIG. 3 , a thermoplastic sheet 20 is formed into a shell 21 by a vacuum molding method, and the shell 21 has an outer surface 211 and an inner surface 213 , an accommodating area 215 surrounded by the inner surface 213 and a corner 217, the material of the thermoplastic sheet 20 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; further, the vacuum forming process (also known as the blister process) provided in the first embodiment provides a vacuum with a mold 42 Forming equipment 40, 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 with different shapes, wherein, the thermoplastic sheet 20 needs to be put into the vacuum forming equipment 40 for heating After softening, the vacuum forming apparatus 40 then generates negative pressure to make the thermoplastic sheet 20 adhere to the surface of the mold 42 to form the shell 21, wherein the vacuum forming apparatus 40 heats and softens the thermoplastic sheet 20 and generates negative pressure to make the thermoplastic The technical content of attaching the sheet 20 to the surface of the mold 42 to form the casing 21 is in the prior art, and will not be repeated here. In addition, when the shell 21 is formed by using the vacuum forming equipment 40 , a trim 219 will be left around the shell 21 , as shown in FIG. housing 21 shown.

Step S1-2: As shown in FIG. 4 to FIG. 5 , a heating mold 60 is provided, the heating mold 60 has an inner concave mold area 62 , the casing 21 is arranged in the inner concave mold area 62 , and the outer part of the casing 21 is formed. The surface 211 corresponds to the inner wall surface 64 of the inner die region 62 . In addition, if a pattern (such as a trademark or a modeling pattern) is to be displayed on the casing 21, a thermoplastic sheet 20 of transparent material can be selected in step S1-1, and then the thermoplastic sheet 20 is made into the casing 21, And in step S1-1 or step S1-2, a pattern is set on the inner surface 213 of the housing 21 by painting, printing or labeling.

Step S1-3: As shown in FIG. 6, a thermosetting carbon fiber plastic layer 30 is provided, the thermosetting carbon fiber plastic layer 30 has an outer surface and an inner surface, and the outer surface of the thermosetting carbon fiber plastic layer 30 is arranged on the inner surface 213 of the housing 21, wherein , the thermosetting plastic of the thermosetting carbon fiber plastic layer 30 is selected from epoxy resin (Epoxy resin) or polyester (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. 7 , a reinforcing layer 50 is provided. In the first embodiment, the reinforcing layer 50 is a thermosetting carbon fiber plastic, and the reinforcing layer 50 is arranged on the inner surface of the thermosetting carbon fiber plastic layer 30 And it is located at the corners of the casing 21 , thereby reinforcing the most easily damaged corners.

Step S1-5: As shown in FIG. 8 to FIG. 9 , an airbag 72 is placed in the accommodating area 215 of the housing 21 , and the airbag 72 is inflated and supported against the inner surface of the thermosetting carbon fiber plastic layer 30 and the reinforcing layer 50 , and at the same time Let the heating mold 60 heat the shell 21 , the thermosetting carbon fiber plastic layer 30 and the reinforcement layer 50 in the inner cavity 62 , so that the shell 21 , the thermosetting carbon fiber plastic layer 30 and the reinforcement layer 50 are combined with each other. The heating temperature is between 140 degrees Celsius and 150 degrees Celsius, so that the thermosetting carbon fiber plastic layer 30 and the reinforcing layer 50 are cured and bonded to the inner surface 213 of the casing 21, so that the casing 21, the thermosetting carbon fiber plastic layer 30 and the The reinforcing layers 50 are combined with each other to form the composite molded luggage case 10 .

Step S1-6: As shown in FIG. 9 to FIG. 10 , move the airbag 72 out of the accommodating area 215 of the housing 21, and cool the luggage case 10 formed by the composite material to complete the operation of the luggage case 10 formed by the composite material. manufacturing procedure.

Please refer to FIG. 11 to FIG. 21 again, which is a manufacturing method of a luggage case 10 ′ formed by a composite material according to a second preferred embodiment of the present invention, which includes the following steps:

Steps S2-1 to S2-3: As shown in FIGS. 11 to 16 , steps S2-1 to S2-3 of the second preferred embodiment of the present invention are the same as steps S1-1 to S1-3 of the first preferred embodiment , so it is not repeated here.

Step S2-4: As shown in FIG. 17 , a reinforcing layer 50 is provided. In the second embodiment, the reinforcing layer 50 is a metal layer, which can also be Kevlar fiber. The metal layer 50 is provided On the inner surface of the thermosetting carbon fiber plastic layer 30 and at the corner 217 of the casing 21 .

Step S2-5: As shown in FIG. 18 , another thermosetting carbon fiber plastic layer 30 is provided, and another thermosetting carbon fiber plastic layer 30 is disposed on the inner surface of the thermosetting carbon fiber plastic layer 30 and the metal layer 50 .

Step S2-6: As shown in FIGS. 19 to 20 , use the airbag 72 to expand and support the other thermosetting carbon fiber plastic layer 30 , and at the same time let the heating mold 60 face the shell 21 and the two thermosetting carbon fiber plastic layers 30 in the concave mold area 62 And the metal layer 50 is heated, so that the shell 21 and the two thermosetting carbon fiber plastic layers 30 are combined with each other, and the metal layer 50 is wrapped in the two thermosetting carbon fiber plastic layers 30 .

Step S2-7: As shown in FIGS. 20-21, the airbag 72 is moved out of the accommodating area 215 of the housing 21, and the composite material-shaped luggage case 10' is cooled to complete the composite material-shaped luggage case 10' manufacturing procedure.

To sum up, the suitcases 10 and 10' formed by composite materials made by the composite carbon fiber manufacturing method in the present invention can be used under the premise that the external structures of the suitcases 10 and 10' formed by composite materials are uniform. The impact resistance properties of the thermoplastic sheet 20, and the high strength and high bonding properties of the thermosetting carbon fiber plastic layer 30, and the reinforcing layer (thermosetting carbon fiber plastic layer or metal layer) 50 is applied at a specific position according to the requirements to achieve higher Excellent impact and collision resistance.

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

A manufacturing method of a suitcase formed by composite materials, comprising the following steps:

A) using a vacuum molding process (vacuum molding method) to form a thermoplastic sheet into a shell, the shell has an outer surface, an inner surface, a receiving area surrounded by the inner surface and a corner;

B) providing a heating mold, the heating mold has an inner female mold area, the shell is arranged in the inner female mold area, and the outer surface of the shell should correspond to the inner wall surface of the inner female mold area;

C) providing a thermosetting carbon fiber plastic layer, the thermosetting carbon fiber plastic layer has an outer surface and an inner surface, and the outer surface of the thermosetting carbon fiber plastic layer is provided on the inner surface of the housing;

D) providing a reinforcement layer, the reinforcement layer is disposed on the inner surface of the thermosetting carbon fiber plastic layer and at the corner of the shell; and

E) Disposing an airbag in the accommodating area of the housing, and inflating the airbag against the inner surface of the thermosetting carbon fiber plastic layer and the reinforcing layer, and at the same time allowing the heating mold to face the housing in the concave mold area , The thermosetting carbon fiber plastic layer and the reinforcing layer are heated, so that the shell, the thermosetting carbon fiber plastic layer and the reinforcing layer are combined with each other.
The manufacturing method of a luggage case according to claim 1, wherein the reinforcing 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 is heated by the heating mold and then cured and adhered to the inner surface of the shell.
The manufacturing method of a luggage case according to claim 1, wherein the reinforcing layer is a metal layer, and the manufacturing method further comprises the step of providing another thermosetting carbon fiber plastic layer, and disposing the other thermosetting carbon fiber plastic layer on the The inner surface of the thermosetting carbon fiber plastic layer and the metal layer, the airbag expands and supports the other thermosetting carbon fiber plastic layer, and at the same time, the heating mold is moved inward to the shell, the two thermosetting carbon fiber plastic layers and the metal layer in the female mold area Heating is performed so that the shell and the two thermosetting carbon fiber plastic layers are combined with each other, and the metal layer is wrapped in the two thermosetting carbon fiber plastic layers.
The method for manufacturing a luggage case according to claim 1, wherein, in step E), the heating temperature of the inner die area is between 140 degrees and 150 degrees.
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 the composite material-shaped suitcase, wherein the manufacturing method further includes the step of providing a pattern, and the pattern is provided on the inner surface of the shell by means of painting, printing or labeling.
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 manufacturing method of a luggage case as claimed in claim 1, further comprising a step F) after step E, removing the airbag from the accommodating area of the shell, and cooling the luggage case formed from the composite material.
A suitcase made of composite material formed by the manufacturing method according to any one of claims 1 to 9, comprising:

a casing, having an outer surface, an inner surface, an accommodating area surrounded by the inner surface, and a corner;

a thermosetting carbon fiber plastic layer having an outer surface and an inner surface, the outer surface of the thermosetting carbon fiber plastic layer is disposed on the inner surface of the casing; and

A reinforcing layer is arranged on the inner surface of the thermosetting carbon fiber plastic layer and is located at a corner of the shell.
The luggage case of claim 10, wherein the reinforcing layer is a thermosetting carbon fiber plastic layer.
The luggage case as claimed in claim 10, wherein the reinforcing layer is a metal layer, and the luggage case formed by the composite material further comprises providing another thermosetting carbon fiber plastic layer, and the another thermosetting carbon fiber plastic layer is disposed on the thermosetting carbon fiber The inner surface of the plastic layer and the metal layer, the shell and the two thermosetting carbon fiber plastic layers are combined with each other, and the metal layer is wrapped in the two thermosetting carbon fiber plastic layers.
The luggage case of claim 10 , wherein the composite material-molded luggage case further comprises a pattern, and the pattern is disposed on the inner surface of the shell.