NL2014222A

NL2014222A - A plastic component of a composite material, a shell for a suitcase, a suitcase.

Info

Publication number: NL2014222A
Application number: NL2014222A
Authority: NL
Inventors: Barbara Huizink
Original assignee: Royalty Bugaboo Gmbh
Priority date: 2014-02-21
Filing date: 2015-02-03
Publication date: 2015-08-25
Also published as: NL2014222B1

Description

A PLASTIC COMPONENT OF A COMPOSITE MATERIAL, A SHELL FOR A SUITCASE, A SUITCASE FIELD OF THE INVENTION

The invention relates to a plastic component made of a composite material that is made of two different thermoplastic materials. The invention further relates to a shell for a suitcase and to a suitcase. It also relates to a stroller and to a child seat comprising such a plastic component.

BACKGROUND ART

Document US4061817 discloses a manufacturing method of, according to the cited patent, a lightweight strong three dimensional luggage shells. The walls of the three dimensional luggage shells are made of a glass fiber reinforced thermoplastic sheet. Although, in the 70s, such a luggage shell was considered to be lightweight and strong, there is still a need to make luggage shells stronger without increasing the weight of the luggage shells, and/or also reducing the weight of the luggage shells.

SUMMARY OF THE INVENTION

One of the objects of the invention is to provide an improved plastic component.

As defined in the claims, an aspect of the invention provides a plastic component. A further aspect of the invention provides a shell for a suitcase. In yet another further embodiment of the invention, a suitcase is provided.

The plastic component comprises a wall made of a (fibrous) composite material.

The composite material comprises a first polymeric thermoplastic material as a matrix phase and a fabric of yarns comprising oriented fibers of a second polymeric thermoplastic material as reinforcement phase. A first melting temperature of the first thermoplastic material is lower than a second melting temperature of the second thermoplastic material. The plastic component is, for example, a shell for a suitcase, a part of a stroller or a part of a child seat for in a car.

The plastic component can be formed (e.g. by a deep drawing process under application of pressure and heat) from preconsolidated sheets or from fabrics that are made of yarns that comprise the fibers and comprise the first thermoplastic material. The preconsolidated sheets comprise, in an embodiment, one or more layers of the fabric and, in a further embodiment, the fabric is woven. It has been proven that the above described composite material is strong and lightweight and provides, as such, a huge improvement compared to plastic components made of other reinforced thermoplastic materials comprising, for example, glass fibers. The fabric comprises yarns that are made of fibers of the second thermoplastic material, which results in more reinforcement because the yarns are stronger than the individual fibers. It is to be noted that, in general, the yarn comprises a plurality of fibers, however, locally, the yarn may be formed by a single fiber which is in contact with other fibers at another position along the yarn. The yarns form a fabric which also increases the strength of the composite material without introducing additional weight.

The second thermoplastic material is provided as oriented fibers, which means that elongated fibers of the material is provided and that, locally seen, the fibers extend in a certain direction.

Embodiments are defined in the dependent claims.

Optionally, combinations of the first thermoplastic material and the material of the fibers are selected from the group of combinations: polypropylene as the matrix phase and polyethylene Terephthalate for the fibers, polypropylene as the matrix phase and nylon for the fibers, polyethylene as the matrix phase and polypropylene for the fibers. The Polyethylene Terephthalate fibers provide a strong reinforcement of the wall of the plastic component, and the matrix material of polypropylene is an advantageous thermoplastic matrix material to define the shape of the plastic component, for example, a shell of a suitcase. Polypropylene has a lower melting temperature than Polyethylene Terephthalate (PET) and, by carefully heating the composite material to a temperature in between the two melting temperature, the composite material may be formed into a specific shape, such as the shape of the suitcase shell, while the PET fibers remain intact.

The Polyethylene Terephthalate fibers may be obtained by means of extrusion. It may also be that the Polyethylene Terephthalate fibers are drawn fibers such that they have a higher strength.

As discussed above, the composite material, for example, in the form of a preconsolidated sheet or in the form of a fabric, may be heated and/or pressed in to a specific mold to obtain the shape of the suitcase shell. The composite material is in particular suitable for manufacturing plastic components that have curved regions. Thus, optionally, the wall of the plastic component comprises a base wall and upstanding side walls, wherein the wall of the plastic component comprises curved first transition regions between the base wall and the upstanding side walls. Optionally, the wall further comprises curved second transition regions between two neighboring upstanding side walls. The composite material provides also in the curved first and second transition regions enough strength because of its composition of a fabric of yarns of the fibers of second thermoplastic material (for example, PET) in a matrix of a first thermoplastic material, such as, for example, polypropylene. Optionally, a radius of the curved first transition regions are in between 5 mm and 20 mm, optionally, in between 8 mm and 17 mm. Optionally, a radius of the curved second transition regions is in between 30 mm and 90 mm, optionally, in between 40 mm and 80 mm. Shells for a suitcase have such a shape and as such, the composite material for manufacturing the wall of the shell of the suitcase provides many advantages such that an improved shell is obtained.

Optionally, when the plastic component has a shape similar to a shell of a suitcase, a ratio between length and width of the plastic component is between 1 and 2, optionally between 1.4 and 1.8. Optionally, a ratio between a depth of the plastic component and a width of the plastic component is in between 0.05 and 0.5, optionally between 0.08 and 0.44.

Optionally, the wall has an average thickness in between 0.5 and 2.5 mm, optionally in between 0.7 and 1.5 mm. In an embodiment, the average thickness of the wall is about 1.3 mm. In an embodiment, the average thickness of the wall is about 0.8 mm.

Optionally, the composite material comprises a plurality of layers of the fabric of the oriented fibers. Optionally, the composite material comprises at least 3 layers of the fabric. For example, when the plastic component is a shell of a suitcase, the wall of shell comprises 3, 4 or 5 layers of the fabric made of yarns of, for example, Polyethylene Terephthalate fibers.

Optionally, the yarns of the fabric are oriented in at least two different directions. This means that the yarns are subdivided into two or more groups and, within the fabric, yarns of a single group have a single orientation and in between the groups the orientations differ. By arranging the yarns in specific directions, strength in specific directions may be obtained - if this is done in at least two different directions, the strength may be obtained in at least two different directions. The two different directions may be perpendicular directions such that the suitcase shell is has a relatively large strength in all directions. Note that the at least two different directions follow the direction of the fabric, which means that, if we define the x- and y-dimension in a plane formed by the fabric (when the fabric is, e.g., laid flat), the two different directions are direction in the plane. This also means that the yarns of the two or more groups may have (slightly) varying directions in the z-dimension. For example, in a woven fabric, the longitudinal yarns (i.e. warps) and the lateral yarns (i.e. wefts) extend within the plane defined by the fabric in two perpendicular directions and, because, they are woven, their direction in a dimension perpendicular to the fabric slightly varies.

Optionally, the fabric is a woven fabric. The fact that the yarns are woven also results in additional strength without increasing the weight of the composite material. Thus, the wall of the plastic component may have a relatively high strength while only a relatively small number of fabric layers are used. A relatively small numbers of fabric layers also means that the weight of the plastic component is relatively low.

Optionally, the plastic component partially encloses a space, a portion of a surface of the wall of the plastic component is provided with another fabric, the portion of the surface of the wall faces towards the space. In other words, if the plastic component has a shape of a suitcase shell, the portion of the wall is the surface of the plastic component that faces towards an interior of the plastic component. The fabric may provide a friendlier look to the surface of the suitcase shell. In another embodiment, another portion of the surface of the wall may be provided with an additional layer of a third thermoplastic material. The third thermoplastic material may be equal to the first or second thermoplastic material, but may also be a different thermoplastic material.

According to a further aspect of the invention, a shell for a suitcase is provided. The shell for the suitcase comprises a plastic component according to any one of the above discussed embodiments.

According to another aspect of the invention, a suitcase is provided which comprises two shells for a suitcase according to the previously discussed embodiment of the shell for a suitcase.

According to another aspect of the invention, a stroller is provided which comprises the plastic component according to the previously discussed embodiments of the plastic component.

According to another aspect of the invention, a child seat is provided which comprises the plastic component according to the previously discussed embodiments of the plastic component.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter. In the drawings,

Fig.1 schematically shows, in a cross-sectional view, an embodiment of a portion of the wall of a plastic component,

Fig. 2 schematically shows, in a cross-sectional view, a further embodiment of a portion of the wall of a plastic component,

Figs. 3a and 3b schematically show embodiments of shells for a suitcase, e.g., a suitcase shell,

Fig. 4 schematically shows in a plurality of side-views an embodiment of a suitcase, and

Fig. 5 schematically shows a car seat for a child and a stroller according to an embodiment.

It should be noted that items which have the same reference numbers in different Figures, have the same structural features and the same functions. Where the function and/or structure of such an item has been explained, there is no necessity for repeated explanation thereof in the detailed description.

The Figures are purely diagrammatic and not drawn to scale. Particularly for clarity, some dimensions are exaggerated strongly.

DETAILED DESCRIPTION OF EMBODIMENTS

Fig. 1 schematically shows, in a cross-sectional view, a portion 100 of a wall of a plastic component. For example, the shown portion 100 is a portion of wall 302 of a suitcase shell 300 of Fig. 3. The wall is formed by a first thermoplastic matrix material 104 in which a fabric 110 of yarns 102 is provided. The yarns 102 comprise fibers of a second thermoplastic material. The matrix material 104 is, for example, polypropylene. The fibers are made of, for example, Polyethylene Terephthalate (PET). In some of the following paragraphs it is assumed that the fibers are made of PET and the matrix material 104 is polypropylene, but it must be noticed that other materials may be used as well as long as a first melting temperature of the first thermoplastic material is lower than a second melting temperature of the second thermoplastic material. Other possible combinations of the first thermoplastic material and the material for the fibers are: polypropylene as the matrix phase and nylon for the fibers, polyethylene as the matrix phase and polypropylene for the fibers. In Fig. 1 it is to be noted that the yarns 102 are subdivided into two groups and the yarns 102 within a single group have substantially the same orientation and yarns 102 of different groups have different orientations.

Fig. 2 schematically shows, in a cross-sectional view, a further embodiment of a portion 200 of the wall of the plastic component. For example, the plastic component is the suitcase shell 300 of Fig. 3. In the wall the first thermoplastic material 104, for example, polypropylene, is provided as a matrix phase. The wall comprises a woven fabric 210 that comprises yarns 202 that comprise fibers of the second thermoplastic material, for example, PET. In between the yarns 202 of the fabric (and optionally on top of and below the fabric) is provided the matrix material 204. It is to be noted that in the yarns 202 themselves also some first thermoplastic material may be present. In an embodiment (not shown), a plurality of woven fabric 210 layers may be provided and in between the layers, in between the yarns 202, and (optionally) on top of the plurality of layers and below the plurality of layers the matrix material 104 is provided.

As shown at the bottom end of Fig. 2, in a cross-sectional view, a cross-cut of a yarn 202 is presented. The yarn 202 may comprises a plurality of fibers 212 of the second thermoplastic material. Some of the first thermoplastic material 104 as the matrix phase may be provided also in between the fibers 212. As the result of specific manufacturing processing steps, the first thermoplastic material may locally be bonded to the fibers 212. For example, the surface of the fibers 212 may be treated with a specific material (e.g. a coating) such that the first thermoplastic material may bond to the fibers 212.

In Fig. 2 is also indicated a thickness th of the wall of the suitcase shell. It might be that the thickness th slightly varies along the whole wall, but an average thickness of the wall is in a range from 0.5 to 2.5 mm, and, in another embodiment, from 0.7 to 1.5 mm. The average thickness is, for example, 0.8 mm or 1.3 mm (depending on the required strength of the wall).

In short, the manufacturing process of the walls is as follows: Fibers of the first thermoplastic material and of the second thermoplastic material are manufactured by means of extrusion and/or drawing. These fibers are combined in a comingling process into comingled yarns that comprise the fibers of the first thermoplastic material and the fibers of the second thermoplastic material. The surfaces of the fibers may be treated in this process with a specific compositions such that the first thermoplastic material may bond to the fibers of the second thermoplastic material when the comingled fibers are heated to a temperature in between the first melting temperature of the first thermoplastic material and the second melting temperature of the second thermoplastic material. From the comingled yarns is, for example, in a weaving process, obtained a fabric of comingled yarns. Subsequently there are two different options. In one option, one or more layers of the fabric are placed on top of each other and under the influence of heat (and optionally pressure) preconsolidated sheets are manufactured. The first thermoplastic material is already (partially) present as the matrix phase in the preconsolidated sheets. The preconsolidated sheets may be used in a forming process to form the plastic component. In the forming process, the preconsolidated sheets are, during the forming process, heated towards a temperature that is in between first melting temperature of the first thermoplastic material and the second melting temperature of the second thermoplastic material. Such heated preconsolidated sheet may be pressed in a mold to give it its final shape, for example, by a deep-drawing process. In a second option, the manufacturing of the preconsolidated sheets is omitted and one or more layers of the fabric of the comingled yarns are used in the forming process. In both options, after the forming process most of the fibers of the first thermoplastic material are transformed towards the matrix phase of the composite material and bonds are formed between the first thermoplastic material and the fibers of the second thermoplastic material.

Fig. 3a schematically shows an embodiment of suitcase shell 300. The previously discussed plastic component may be the presented suitcase shell 300. Another term for the suitcase shell 300 is a shell of a suitcase. The suitcase shell 300 comprises a wall 302. The wall 302 of the suitcase shell is made of a composite material which comprises two thermoplastic materials having different melting temperatures. A thermoplastic material with a lower melting temperature forms a matrix material of the wall. The matrix material may be polypropylene. A thermoplastic material with a higher melting temperature is provided in the wall 302 in the form of oriented fibers of this material provided in the form of yarns that are formed into a fabric. The fibers may be drawn fibers (fibers may be extruded and stretched to increase the strength of the fibers). The fibers may be made of Polyethylene Terephthalate (PET), however, in other embodiments, the fibers may be made of another polyester, another thermoplastic material having a high enough melting temperature or, for example, nylon.

The wall 302 may be subdivided into a base wall 304 and upstanding side walls 306. The base wall 304 is about the largest (relatively flat) surface of the suitcase shell 300. The term “upstanding” of “upstanding side walls 306” refers to a situation in which the suitcase shell 300 is placed with its base wall 304 on the ground and then the side walls 306 extend in an upwards direction, in other words, they stand up. An angle between the upstanding side walls 306 and the base wall 304 may be in a range from 80 to 100 degrees, or, in an embodiment, between 87 and 97 degrees. In an embodiment, the angle between the upstanding sidewalls 306 and the base wall 304 is 93 degrees. Between the base wall 304 and the side walls 306 are curved first transition regions 310, 312 - in Fig. 3a only two curved first transition region 310, 312 are indicated with a reference number, but at all edges of the base wall 304 there is a curved first transition region. Also between neighboring upstanding side walls 306 are curved second transition regions 314 - in Fig. 3 only one curved second transition region 314 between neighboring upstanding sidewalls 306 is indicated, but between all neighboring upstanding side walls 306 such a curved second transition region 314 is present. The suitcase shell 300 also comprises curved corner regions between the base wall 304 and two neighboring upstanding side walls 306 - the curved corner regions do not exactly follow a surface of a sphere, because their shape is determined by the curvature of the curved first transition regions 310, 312 and the curvature of the curved second transition regions 314.

The curved first transition regions may have a cross-sectional shape that is circular or elliptic shaped. The radius of the circle of the circular shape may be in a range from 5 mm to 20 mm, or, in another embodiment, from 8 mm to 17 mm. For example, the radius of the curved first transition region is, for example, 10 mm or 15 mm. The curved second transition regions may have a cross-sectional shape that is circular or elliptic shaped. The radius of the circle of the circular shape may be in a range from 30 mm to 90 mm, or, in another embodiment, from 40 mm to 80 mm. For example, the radius of the curved second transition regions may be 50 mm or may be 70 mm.

The suitcase shell has a particular depth D, a particular length L and a particular width W. A ratio between the length L and the width W is in a range from 1 to 2 and, in another embodiment, in a range from 1.4 to 1.8. A ratio between the depth D and the width W is in a range from 0.05 to 0.5, and, in an embodiment 0.08 to 0.44.

In the above paragraphs a suitcase shell 300 having specific dimensions and a specific shape has been described. The composite material of which the wall 302 is made is in particular an advantageous material having a relatively high strength, while the weight is relatively low. The material is in particular suitable for manufacturing suitcase shells 300 having the curved first and second transition regions 310..314 without losing strength or having the need to increase a thickness of the wall to obtain such a strength (and thus, without having the need increasing the weight of the suitcase shell 300).

Fig. 3b also presents an embodiment of a suitcase shell 350 that is made of the same composite material as the composite material of the suitcase shell 300 of Fig. 3a or of the portion 100, 200 of the walls of Fig. 1 or Fig. 2. The suitcase shell 350 comprises a wall 352 that comprises a base wall 354 and upstanding side walls 356. Between the base wall 354 and upstanding side walls are present curved first transition regions 360, 362. Between two neighboring upstanding sidewalls curved second transition regions 364 are present. Also in Fig. 3b the geometrical parameters depth D, length L and width W of the suitcase shell 350 are indicated.

In an embodiment, the suitcase shell 300 and 350 of Fig. 3a and 3b, respectively, may have an additional layer of a plastic or thermoplastic material which protects the surface of the suitcase shell against, for example, scratches at an outer surface of the wall. Optionally, the layer may be provided on the outside surface that faces away from the suitcase shell, and, optionally, also at the outside surface that faces towards the interior of the suitcase shell.

In an embodiment, the suitcase shell may also be provided, at an outer surface of the wall, with a fabric which provides, for example, a friendlier look to the suitcase shell. Optionally, such a fabric is provided at outside surface that faces towards the interior of the suitcase shell. When the suitcase shell is pressed (also under the application of heat) into a mold, the fabric may also be pressed to the outside surface and the matrix polymer may become in contact with the fabric and provide a fastening of the fabric to the wall of the suitcase shell.

Fig. 4 schematically presents a suitcase 400. The suitcase 400 comprises two suitcase shells 408, 410 according to previously discussed embodiments. The suitcase shells 408, 410 are coupled to each other at one particular upstanding side wall by means of a hinging connection and may be coupled to each other at other upstanding side wall by means of, for example, releasable locking elements. Fig. 4 presents a top view 402 of the suitcase 400, a first side view 404 and a second side view 406. Because of the use of the composite material, the suitcase 400 has a relatively high strength and a relatively low weight. In Fig. 4, dimensions A, B, C and D of the suitcase are indicated. In an embodiment of a suitcase 400 that is suitable for being carried into the cabin of an aircraft, the values for A, B, C and D may be 350 mm, 550 mm, 180 mm, 30 mm, respectively. In an embodiment of a suitcase 400, a relatively large suitcase is provided which may be checked in at the airport for being transported in the cargo hold of an aircraft; for this particular suitcase the values for A, B, C and D may be 450 mm, 760 mm, 220 mm, 50 mm, respectively.

Fig. 5 schematically shows a car seat 500 fora child and a stroller 550. Parts of the car seat 500 and the stroller 550 can also be manufactured from the above discussed composite material. In particular plastic components that need to be relatively strong and which have a sort of wall may be shaped in a previously discussed forming process. For example, the car seat 500 may have a base structure 502 that is provided at the back side of the car seat 500. The composite material is strong enough to manufacture such a base structure 502. It might also be that other plastic components of the car seat 500 are made of the composite material, such as, for example, a plastic component 504 at a front side of the car seat 500 through which a strap for fastening the child is guided. The stroller 550 has several components that have a wall and that may be manufactured from the discussed composite material. For example, the cot or crib 554 in which the baby is laid may be the plastic component of this application. When the stroller is for carrying a child that sits up-right, a base of the seat (not shown) may be the plastic component. The stroller 550 has also a shopping basket that may be the plastic component of this application. Other parts that may be made of the composite material (depending on the required flexibility) are: luggage basket 556 provided below the crib 554 or the sun blind / screen 552 that may be unfolded and provided above the head of the baby.

It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims

A plastic component (300, 350, 408, 410, 502, 554, 556), such as, for example, a tray (300, 350, 408, 410) for a suitcase, a part of a pram (550) or a part of a child seat (500) for a car, the plastic component comprising a wall (302, 352) made of a composite material, the composite material comprising a first thermoplastic material (104) as a matrix phase and a fabric (110,210) of yarns (102 202) comprising oriented fibers (212) of a second thermoplastic material as a reinforcing phase, wherein a first melting temperature of the first thermoplastic material (104) is lower than a second melting temperature of the second thermoplastic material.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to claim 1, wherein combinations of the first thermoplastic material (104) and the material of the fibers are selected from the group of combinations: polypropylene as matrix phase and polyethylene terephthalate for the fibers, polypropylene as the matrix phase and nylon for the fibers, polyethylene as the matrix phase and polypropylene for the fibers.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to claim 1, wherein the wall (302, 352) comprises a base wall (304, 354) and upright side walls (306, 356), wherein the wall (302, 352) comprises at least one of: - curved first transition areas (310, 312, 362, 356) between the base wall (304, 354) and the upright side walls (306, 356), and - curved second transition areas ( 314, 364) between two adjacent upright side walls (302, 352).

A plastic component (300, 350, 408, 410, 502, 554, 556) according to claim 3, wherein a radius of the curved first transition regions (310, 312, 362, 356) is between 5 mm and 20 mm, optionally between 8 mm and 17 mm, and wherein a radius of the curved second transition regions (314, 364) is between 30 mm and 90 mm, and optionally between 40 mm and 80 mm.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any of the preceding claims, wherein the plastic component (300, 350, 408, 410, 502, 554, 556) has a shape similar to on a scale (300, 350, 408, 410) for a suitcase, with a ratio between the length (L, B) and width (W, a) of the plastic component (300, 350, 408, 410, 502,554, 556 ) is between 1 and 2, optionally between 1.4 and 1.8.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any of the preceding claims, wherein the plastic component (300, 350, 408, 410, 502, 554, 556) has a shape similar to on a scale (300, 350, 408, 410) for a suitcase, with a ratio between a depth (D) of the plastic component (300, 350, 408, 410, 502, 554, 556) and a width (W, A) of the plastic component (300, 350, 408, 410, 502, 554, 556) is between 0.05 and 0.5, and optionally between 0.08 and 0.44.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any one of the preceding claims, wherein the wall (302, 352) has an average thickness (th) between 0.5 and 2.5 mm, optionally between 0.7 and 1.5 mm.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any of the preceding claims, wherein the composite material comprises a plurality of layers of the fabric (110, 210) and optionally wherein the composite material is 3 or more layers of the fabric (110,210).

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any of the preceding claims, wherein the wires (102, 202) are oriented in at least two different directions.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any one of the preceding claims, wherein the fabric is a woven fabric.

A plastic component (300, 350, 408, 410, 502, 554, 556) according to any of the preceding claims, wherein the plastic component partially encloses a space, and wherein the plastic component (300, 350, 408, 410, 502, 554, 556) is provided on a portion of a surface of the wall (302, 352) with another fabric, the portion of the surface of the wall facing the space.

A tray (300, 350, 408, 410) for a case comprising the plastic component of any one of claims 1 to 11.

A suitcase (400) comprising two trays (300, 350, 408, 410) according to claim 12.

A pram (550) comprising at least one tray (300, 350, 408, 410) according to claim 12.

A child car seat (500) comprising at least one shell (300, 350, 408, 410) according to claim 12.