PART OF A LUGGAGE SYSTEM COMPRISING A NATURAL FIBER MATERIAL AND METHOD FOR ITS MANUFACTURE AND REPAIR

Abstract

The present invention relates to a part of a luggage system, in particular a shell of a hard-shell case or trolley, comprising a natural fiber material. The present invention further relates to a method for the manufacture and a method for the repair of such a part. A part of a luggage system is provided which comprises a fiber-reinforced material, wherein the fiber-reinforced material comprises a natural fiber material and a matrix material. The natural fiber material comprises at least one set of unidirectional fibers which are embedded in and/or impregnated with the matrix material.

Claims

1. A shell of a luggage system, the shell comprising a fiber-reinforced material, wherein the fiber-reinforced material comprises: a natural fiber material; and a matrix material, wherein the natural fiber material comprises at least one set of unidirectional fibers which are embedded in and/or impregnated with the matrix material.

2. The shell of claim 1, wherein the natural fiber material comprises n sets of unidirectional fibers which are embedded in and/or impregnated with the matrix material, wherein n is an integer number greater than 1, and wherein the n sets of unidirectional fibers are mutually non-parallel.

3. The shell of claim 2, wherein each set of unidirectional fibers comprises a plurality of fiber bundles and/or fibrous yarns that are arranged along a respective axis.

4. The shell of claim 2, wherein n=2 and the natural fiber material is provided as a bi-axial fabric.

5. The shell of claim 4, wherein the two axes of the bi-axial fabric intersect at an oblique angle.

6. The shell of claim 2, wherein n=3 and the natural fiber material is provided as a tri-axial fabric.

7. The shell of claim 6, wherein at least two of the axes of the tri-axial fabric intersect at an angle different from 60?.

8. The shell of claim 1, wherein the unidirectional fibers are continuous.

9. The shell of claim 1, wherein the natural fiber material is provided as a layered fabric.

10. The shell of claim 9, wherein each layer comprises several plies of parallel-oriented, unidirectional fibers.

11. The shell of claim 1, wherein the natural fiber material is provided as a woven fabric.

12. The shell of claim 1, wherein the natural fiber material comprises fibers of one or more of the following materials: leaf fibers, bast fibers, or stalk fibers.

13. The shell of claim 1, wherein a material composition of the natural fiber material varies within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers.

14. The shell of claim 1, wherein one or more physical properties vary within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers, wherein the one or more physical properties include one or both of a gauge of the unidirectional fibers and a linear mass density of the unidirectional fibers.

15. The shell of claim 1, wherein the matrix material is biodegradable and/or comprises recycled material.

16. The shell of claim 1, wherein the matrix material comprises one of more of the following materials: an amorphic, crystalline or semicrystalline thermoset resin; an amorphic, crystalline or semicrystalline thermoplastic resin; or a film of any of the beforementioned thermoset of thermoplastic materials or combinations thereof.

17. The shell of claim 1, wherein the shell is free from aluminum.

18. The shell of claim 1, wherein the luggage system comprises a hardshell case or a trolley.

19. A luggage system, comprising: a shell comprising a fiber-reinforced material, wherein the fiber-reinforced material comprises: a natural fiber material; and a matrix material, wherein the natural fiber material comprises at least one set of unidirectional fibers which are embedded in and/or impregnated with the matrix material.

20. A part of a luggage system, wherein the part comprises a fiber-reinforced material, wherein the fiber-reinforced material comprises: a natural fiber material; and a matrix material, wherein the natural fiber material comprises at least one set of unidirectional fibers which are embedded in and/or impregnated with the matrix material.

21-23. (canceled)

Description

BRIEF DESCRIPTION OF THE FIGURES

[0095] Possible embodiments of the present invention are described in more detail, with reference to the following figures:

[0096] FIGS. 1a-c: Examples of a fiber-reinforced material comprising a natural fiber material and a matrix material that may be used in an inventive part of a luggage system;

[0097] FIG. 2: Example of an inventive method for the manufacture of an inventive part of a luggage system;

[0098] FIG. 3: Further example of an inventive method for the manufacture of an inventive part of a luggage system;

[0099] FIG. 4: Example of an inventive part of a luggage system with a bi-axial, woven natural fiber material; and

[0100] FIGS. 5a-h: Example of an inventive luggage system in the form of a travel-or cabin trolley.

DETAILED DESCRIPTION OF POSSIBLE EMBODIMENTS

[0101] Possible embodiments of the different aspects of the present invention are described below, predominately with respect to travel- or cabin trolleys. It is, however, emphasized once again that the different aspects of the present invention may also be practiced in different kinds of luggage systems and are not limited to the specific embodiments set forth below.

[0102] Reference is further made to the fact that in the following only individual embodiments of the invention can be described in more detail. The skilled person will understand, however, that the features, options and possible modifications described with reference to these specific embodiments may also be further modified and/or combined with one another in a different manner or in different sub-combinations, without departing from the scope of the present invention. Individual features or sub-features may also be omitted, if they are deemed dispensable to obtain the desired result. In order to avoid redundancies, reference is therefore made to the explanations in the preceding sections, which also apply to the following detailed description.

[0103] FIGS. 1a-c show examples of fiber-reinforced materials 100a, 100b and 100c comprising a natural fiber material with at least one set of unidirectional fibers embedded in and/or impregnated with a matrix material, which may be used in a part of a luggage system according to the present invention (examples of such parts are shown in FIG. 4 and in FIGS. 5a-h).

[0104] FIG. 1a shows a fiber-reinforced material 100a comprising a natural fiber material that comprises continuous natural fibers 110a. Discontinuous and/or particulate fibers may also be added to the fiber-reinforced material 100a, but this is not shown and further discussed here.

[0105] The continuous natural fibers 110a can be provided as a plurality of fiber bundles/fibrous yarns. The natural fibers 110a form a set 120a of unidirectional fibers arranged along the longitudinal direction 101a in FIG. 1a. Also indicated in FIG. 1a is the transvers direction 102a, which is perpendicular to the longitudinal direction 101a. In the part of a luggage system made of or comprising the material 100a, the longitudinal direction 101a may be arranged, for example, along the direction of greatest spatial extension of the part, but this need not necessarily be the case. In other words, the designation as longitudinal and transverse directions are predominantly used to facilitate the understanding of the following explanations and for definiteness, but they do not necessarily mandate a specific arrangement of the material 100a within the part of a luggage system in which it is used. For example, the longitudinal direction 101a may also be arranged obliquely or diagonally with respect to the edges of a shell of a hard-shell case or trolley in which the material 100a is used (e.g., in one of the shells 510, 520 of the trolley 500 discussed further below).

[0106] The fibers 110a of the set 120a are embedded within a matrix material 130a. The fibers 110a may also have soaked up the matrix material 130a and hence be impregnated with the matrix material 130a. Moreover, while in the situation shown in FIG. 1a the fibers 110a are completely embedded in the matrix material 130a, i.e., fully contained therein (apart from may be their beginnings and ends), this need not necessarily be the case in all situations. In other words, the fibers 110a can also be only partially embedded within the matrix material 130a, or reside on top of the matrix material 130a, or only contain matrix material 130a within their inside, i.e., only be impregnated with the matrix material 130a but not be surrounded by or embedded in any matrix material 130a on their outsides. These statements also apply to fiber-reinforced materials containing more than one set (i.e., n sets with n>1) of unidirectional fibers, e.g., the materials 100b and 100c discussed in the following, even if this is not explicitly repeated again every single time.

[0107] The fibers 110a of the natural fiber material may, for example, comprise one or more of the following materials: leaf fibers, bast fibers, or stalk fibers.

[0108] For example, the use of flax, which is a bast fiber, for the fibers 110a (or for any of the natural fibers discussed herein) can be beneficial from the point of view that flax is easily commercially available. The use of bamboo, which is a stalk fiber, may also be considered, particularly as a fiber material for localized reinforcement, due to its higher density, but also as a primary fiber for larger luggage parts or entire cases that require more impact strength.

[0109] The matrix material 130a may comprise or be comprised of one or more of the following materials: an amorphic, crystalline or semicrystalline thermoset resin; an amorphic, crystalline or semicrystalline thermoplastic resin; or a film of any of the beforementioned thermoset of thermoplastic materials or combinations thereof. Preferably, the matrix material 130a is biodegradable and/or comprises recycled material.

[0110] One specific option is the use of PLA as the matrix material 130a, or at least base the matrix material 130a thereon, due to its known biodegradability. Generally, biodegradable and impact-resistant, bio-based thermoplastics or resins are well suited to the present invention.

[0111] As alternatives, partially or completely bio-based PE, PP, PA6, PA11, PA12 and PC materials can also be considered, even though these materials may not be (fully) biodegradable, but still be more environmentally friendly than conventional plastics based on crude oil, for example.

[0112] FIG. 1b shows, on the left-hand side, another fiber-reinforced material 100b. On the right-hand side of FIG. 1b, a cross-section along the line B-B through the material 100b is shown.

[0113] The material 100b comprises a natural fiber material that comprises continuous natural fibers 110b. Discontinuous and/or particulate fibers may again be added to the fiber-reinforced material 100b, but this is again not shown or further discussed here.

[0114] The continuous natural fibers 110b are provided in the form of fibrous yarns 115b which are woven into a bi-axial fabric and are arranged either along the longitudinal axis (or direction) 101b, or along the transverse axis (or direction) 102b. Again, this nomenclature is predominantly used for definiteness and not necessarily limitation, see the corresponding explanations about the directions 101a and 102a with regard to FIG. 1a above. The longitudinal direction 101b could, for example, be the warp direction and the transvers direction 102b could be the weft direction, or vice versa, in a weaving process used to create the woven fabric from the fibrous yarns 115b.

[0115] In the material 100b shown in FIG. 1b, there are thus two sets 120b and 121b of unidirectional fibers, the set 120b being formed of the fibrous yarns 115b woven along the longitudinal direction 101b, and the set 121b being formed of the fibrous yarns 115b woven along the transverse direction 102b.

[0116] In the material 100b shown in FIG. 1b, the yarns of the two sets 120b and 121b and their respective axes intersect at an angle of (approximately) 90?. In other embodiments, however, the intersection angle can be different from 90?, i.e. the fibrous yarns 115b and their respective axes can also be arranged at an oblique angle 90?) with respect to each other. The advantages of employing such a non-perpendicular arrangement have already discussed in section no. 3 above, to which reference is therefore made for conciseness.

[0117] The fibers 110b in the material 100b may have soaked up a matrix material 130b and may hence be impregnated with the matrix material 130b. The fibers 110b may also be at least partially embedded in or surrounded by matrix material 130b. However, the fact that the fibers 110b are woven into a bi-axial fabric in the material 100b shown in FIG. 1b already provides structural stability to their arrangement, such that the fibers 110b in this case need not necessarily be (partially) embedded in the matrix material 130b to fix their arrangement and to obtain the desired overall stability of the material 100b, but impregnating the fibers 110b with the matrix material 130b may already be sufficient for that purpose.

[0118] A material composition of the natural fibers 110b and/or the fibrous yarns 115b can vary not only between the two sets 120b and 121b, but also within a given one of the sets 120b, 121b of unidirectional fibers. Alternatively, or additionally, one or more physical properties, like a gauge of the fibers 110b and/or a linear mass density of the fibers 110b can vary within a given one of the two sets 120b, 121b of unidirectional fibers and/or between the two sets 120b and 121b of unidirectional fibers. This allows to locally fine-tune the physical and mechanical properties of the material 100b even further and beyond the global control exerted, for example, by the selection of the arrangement and/or weaving pattern used for the bi-axial fabric of the material 100b.

[0119] With regard to suitable material choices for the natural fibers 110b and/or the matrix material 130b, reference is made to the corresponding explanations above, for conciseness (see, e.g., the statements about the fibers 110a and the matrix material 130a made with regard to FIG. 1a).

[0120] FIG. 1c shows another fiber-reinforced material 100c comprising a natural fiber material that comprises continuous natural fibers 110c. Discontinuous and/or particulate fibers may also be added to the fiber-reinforced material 100c, but this again is not shown and further discussed here.

[0121] The continuous natural fibers 110c can be provided as a plurality of fiber bundles/fibrous yarns 115c. The natural fibers 110c form n sets of unidirectional fibers, wherein for the embodiment shown in FIG. 1c n=4, i.e., there are four sets 120c, 121c, 122c and 123c of unidirectional fibers here, each set being arranged along a corresponding axis or direction. The fibers of two of the four sets 120c, 121c, 122c, 123c of unidirectional yarns are mutually non-parallel, i.e. they intersect at an angle different from 0?. The fibers 110c are embedded in and/or impregnated with a matrix material 130c.

[0122] A modification (not shown) of the material 100c would have not four but three sets of unidirectional fibers 110c (i.e., n=3, a tri-axial fabric), wherein the fibers of two of the three sets of unidirectional yarns are mutually non-parallel, i.e. they intersect at an angle different from 0?. Preferably, at least two of the three sets would also intersect at an angle different from 60?, with the resultant technical advantages discussed in section no. 3 above, to which reference is therefore made in this regard.

[0123] In the material 100c, the natural fiber material is provided as a layered fabric, wherein eight layers 140c to 147c are shown in the embodiment of FIG. 1c. Each of the layers 140c, 141c, . . . , 147c further comprises several plies of parallel-oriented, unidirectional fibers 110c, which are numbered as ply no. 1 to ply no. 48 in FIG. 1c. In other words, in the embodiment of FIG. 1c, each of the layers 140c, 141c, . . . , 147c comprises six plies.

[0124] In the embodiment of FIG. 1c, each of the four sets 120c, 121c, 122c, 123c of unidirectional fibers includes two of the layers 140c, 141c, . . . , 147c:

[0125] The first set 120c comprises layers 140c and 147c with plies no. 1-6 and no. 43-48, respectively, in which the fibers are arranged at an angle of 0? with respect to the transvers direction (which is taken as the point of reference here without loss of generality).

[0126] The second set 121c comprises layers 141c and 146c with plies no. 7-12 and no. 37-42, respectively, in which the fibers are arranged at an angle of +45? with respect to the transvers direction.

[0127] The third set 122c comprises layers 142c and 145c with plies no. 13-18 and no. 31-36, respectively, in which the fibers are arranged at an angle of +90? with respect to the transvers direction.

[0128] The fourth set 123c comprises layers 143c and 144c with plies no. 19-24 and no. 25-30, respectively, in which the fibers are arranged at an angle of ?45? with respect to the transvers direction.

[0129] Also here (i.e., also for the situation n>2), a material composition of the natural fibers 110c or fiber bundles/fibrous yarns 115c can vary between two (or more) of the sets 120c-123c, and also within a given one of the sets 120c-123c of unidirectional fibers (for example, between different layers or even different plies contained in one of the sets, or even within a given ply). Alternatively, or additionally, one or more physical properties, like a gauge of the fibers 110c and/or a linear mass density of the fibers 110c, can vary within a given one of the sets 120c-123c and/or between two (or more) of the sets 120c-123c of unidirectional fibers.

[0130] FIGS. 2 and 3 show schematic illustrations of examples of an inventive method 200, 300 for the manufacture of an inventive part of a luggage system (examples of such parts are shown in FIG. 4 and in FIGS. 5a-h).

[0131] The method 200 of FIG. 2 starts, generally indicated by reference numeral 210, by providing input materials to a production site for the preparation of a pre-form 20 for the manufacture of the luggage part 21. The step 210 of providing the input materials can, in particular, comprise providing at least one natural fiber material in the form of a woven multiaxial fabric as well as providing at least one uncured matrix material in the form of a ribbon, sheet or film.

[0132] Further materials and components that may be provided in step 210 include, for example: adhesives, like adhesive powders, adhesives films, web adhesives; chopped glass; textile materials for further reinforcement; foils material.

[0133] The method 200 further comprises the step of laminating the natural fiber material with the uncured matrix material and allowing the natural fiber material to a least partially absorb the uncured matrix material to form the pre-form 20, generally indicated by reference numeral 220. In the embodiment of the method 200 shown in FIG. 2, the lamination is performed under the application of heat (see reference numeral 221) and pressure (see reference numeral 222), and the laminated structure is subsequently cooled down (see reference numeral 223), to stabilize the pre-form 20.

[0134] The pre-form 20 may be stored in the form of rolls or sheets, as generally indicated at reference numeral 230.

[0135] After providing the pre-form 20 in this manner, the method 200 further comprises the (optional) step of heating the pre-form 20 (the heating may also occur, at least partially, within the mold 22 and/or during closing of the mold 22, or be omitted completely if not necessary to make or keep the pre-form 20 malleable) and the method 200 comprises the step of transferring the pre-form 20 to a mold 22 having dimensions that correspond to the intended shape of the part that is manufactured. This step is generally indicated at reference numeral 240. The mold 22 is then closed, as indicated at reference numeral 250, preferably under the application of pressure, such that the pre-form 20 adopts the shape and geometry defined by the molding cavity, i.e. the intended shape of the part that is manufactured (at least its general shape; further post-processing steps on the demolded part may follow, which may also further alter the shape and geometry of the part). The pre-form 20 is then cured or it is allowed to cure within the mold 22 (the mold pressure may or may not be maintained during the curing), preferably under the application of: heat, UV light and/or ultrasonic waves, and/or under a change in: temperature and/or humidity, as indicated at reference numeral 260. Finally, as indicated at reference numeral 270, the mold 22 is opened and the molded part 21 of a luggage system is removed from the mold 22. After the demolding step 270, further processing may occur, as already indicted above, e.g., the part 21 may be trimmed or post-processed, holes or further component may be added, and so forth.

[0136] The method 300 illustrated in FIG. 3 again starts, generally indicated by reference numeral 310, by providing input materials to a production site for the preparation of a pre-form 30 for the manufacture of the luggage part 31. The step 310 of providing the input materials this time comprises providing one or more plies of unidirectional natural fibers. The method further comprises layering up the plies to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being arranged along a respective axis. This step is generally indicated by reference numeral 320 in FIG. 3. Uncured matrix material is applied to the plies of unidirectional fibers and/or to the layered stack, as generally indicated by reference numeral 330 in FIG. 3, and is allowed to be at least partially absorbed by the natural fibers to form the pre-form 30. It is emphasized that the sequence of the steps 320 and 330 may also be different to the situation shown here, i.e., the uncured matrix material may also be provided prior to or during stacking up of the layers in step 320.

[0137] Moreover, the method 300 may also comprise the step of fusing the locations where fibers of the different plies or layers cross or overlap within the stack under the application of: pressure, heat, UV light and/or ultrasonic waves (not shown in FIG. 3).

[0138] From there, the method 300 may proceed in a similar manner as the method 200 described above: The pre-form 30 provided as just described may be heated (the heating may also occur, at least partially, within the mold 32 and/or during closing of the mold 32, or be omitted completely if not necessary to make or keep the pre-form 30 malleable) and the pre-form 30 is then transferred to a mold 32 having dimensions that correspond to the intended shape of the part that is manufactured. This step is generally indicated at reference numeral 340. The mold 32 is then closed, as indicated at reference numeral 350, preferably under the application of pressure, such that the pre-form 30 adopts the shape and geometry defined by the molding cavity, and hence the intended shape of the part that is manufactured (again, further post-processing of the demolded part may yet occur). The pre-form 30 is then cured or it is allowed to cure within the mold 32 (again, the mold pressure may or may not be maintained during the curing), preferably under the application of: heat, UV light, and/or ultrasonic waves, and/or under a change in: temperature and/or humidity, as indicated at reference numeral 360. Finally, as indicated at reference numeral 370, the mold 32 is opened and the molded part 31 of a luggage system is removed from the mold 32. After the demolding step 370, further processing may again occur, e.g., the part 31 may be trimmed or post-processed, holes or further component may be added, and so forth.

[0139] The duration and processing parameters for the different steps of the thermoforming/molding operation, i.e., the steps 240-270 and 340-370, can depend, for example, on the physical dimensions and press capabilities of the molding equipment and the materials used for the manufacture. For example, the duration of the mold closing step 250, 350 may depend on the press capabilities (e.g., maximal closure pressure) and the impregnation behavior of the natural fibers contained in the pre-form 20, 30, while the duration of the curing step 260, 360 may depend on the chemical composition of the matrix material, the curing temperature within the mold, the duration and amount of pressure exerted during the preceding step 250, 350, the mold pressure during curing, and so forth.

[0140] Some of the steps provided by the methods 200, 300 for the manufacture of a part of a luggage system may also be utilized, potentially in a slightly modified version, to provide for a method of repairing a damaged part of a luggage system.

[0141] Such a method may comprise adding uncured matrix material to the damaged area of the part and allowing the natural fiber material in the damaged area to absorb the added uncured matrix material at least partially (e.g., similar to step 330 of the method 300).

[0142] Pressure may then be applied to the damaged area, for example within a mold (e.g., similar to step 250 of the method 200 or to step 350 of the method 300) or in a different manner.

[0143] The repair process may further include curing the added uncured matrix material or allowing it to cure, during, after or without the application of pressure, and preferably under the application of: heat, UV light and/or ultrasonic waves, and/or under a change in: temperature and/or humidity (e.g., similar to step 260 of the method 200 or step 360 of the method 300).

[0144] FIG. 4 shows a part 400 of a luggage system made from a fiber-reinforced material as disclosed herein. The part may be used, for example, as a front or back insert for the main face of a shell of a hard-shell case or trolley, like the trolley 500 discussed below. The fiber-reinforced material is made from a natural fiber material and a matrix material, wherein the natural fiber material comprises two sets of unidirectional natural fibers provided in the form of fibrous yarns that are woven to a bi-axial woven fabric. This fabric is embedded within and impregnated with the matrix material.

[0145] In the part 400 shown in FIG. 4, a bi-axial natural fiber material 410 using flax fibers is used in combination with a thermoset epoxy resin as matrix material.

[0146] At the bottom of FIG. 4, a similar part 405 is shown after demolding (e.g., after step 270 of the method 200 or step 370 of the method 300), but before being trimmed to its final dimensions, to make the woven structure of the included bi-axial flax-fiber material 410 more apparent.

[0147] Finally, FIGS. 5a-h show a luggage system, namely a travel- or cabin trolley 500, making use of a fiber-reinforced material as disclosed herein, for example one of the materials 100a, 100b or 100c discussed above.

[0148] The trolley 500 generally consists of a front shell 510 and a back shell 520, which are connected to each other in such a manner that the two shells 510, 520 can be opened and closed upon each other. The trolley 500 further comprises a closure means, in the embodiment shown here a zipper mechanism 530, from securing the two shells 510, 520 in their closed position.

[0149] The trolley 500 further comprises four spinning wheels 540 mounted in respective indentations 545 at the four bottom corners of the front and back shells 510, 520.

[0150] The trolley 500 also comprises a retractable handle-bar system 550 for pulling the trolley 500 along on its wheels, as well as a side grip arrangement 560 for carrying the trolley 500 by hand.

[0151] Beneath the handle-bar system 550, a recess or storage space 570 may be arranged, which is accessible when the handle-bar system 550 is in its protracted position (see FIG. 5d), and in which, for example, an USB powerbank may be releasable stored. Express reference is made at this position to the disclosure in the applicant's previous applications DE 20 2017 101 957 U1 and WO 2018 185016 A1, the disclosure of which is herewith incorporated in regard to the handle-bar system 550 and storage space 570 of the trolley 500.

[0152] FIG. 5a shows the front shell 510 without any of the additional components (wheels, handle-bar system, zipper, etc.), FIG. 5b shows the back shell 520 without any of the additional components. Either or both of these shells 510, 520 may be made in the inventive manner, i.e. using an embodiment of the disclosed fiber-reinforced material based on natural fibers, like the material 100a, 100b or 100c discussed above. Preferable, both shells 510 and 520 are made from such a material.

[0153] FIG. 5c shows a front view of the entire trolley 500 with all of the further components added, and FIG. 5d a back view of the entire trolley 500, in both cases with the handle-bar system 550 in protracted or pulled-out position.

[0154] FIG. 5e shows the right-hand side face (in relation to the front face) of the trolley 500 with all of the further components added, and FIG. 5f the left-hand side face. Finally, FIG. 5g shows the top of the trolley with all of the further components added and with the handle-bar system 550 in its contracted or pushed-in position, and FIG. 5h shows a bottom view.

[0155] Besides the front and back shell 510 and 520, any or all parts of the trolley 500 may comprise or be based on the disclosed fiber-reinforced material, or be made of such a material.

[0156] In this manner, the disclosed materials and methods may allow for the provision of a trolley 500 free from aluminum, or at least with a significantly reduced amount of aluminum, and completely or at least predominately based on natural and biodegradable materials. This lessens the environmental footprint left by the luggage system 500 both at the beginning and the end of its lifespan.

ADDITIONAL EMBODIMENTS

[0157] The following paragraphs describe additional embodiments.

[0158] In some embodiments, a method is utilized for the manufacture of a part of a luggage system. The method includes providing a pre-form, heating the pre-form and transferring (240; 340) the pre-form to a mold (22; 32) having dimensions that correspond to the intended shape of the part; closing the mold (250; 350), preferably under the application of pressure, such that the pre-form adopts the intended shape of the part; curing (260; 360) the pre-form or allowing it to cure, preferably under the application of: heat, UV light and/or ultrasonic waves, and/or under a change in: temperature and/or humidity; and opening (270; 370) the mold and demolding the part.

[0159] In some embodiments, providing the pre-form includes the steps of providing (310) one or more plies of unidirectional natural fibers; and layering up (320) the plies to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being arranged along a respective axis. Uncured matrix material may be applied (330) to the plies of unidirectional fibers and/or to the layered stack and may be allowed to be at least partially absorbed by the natural fibers to form the pre-form.

[0160] In some embodiments, providing the pre-form further includes fusing the locations where fibers of the different plies or layers cross or overlap within the stack under the application of: pressure, heat, UV light and/or ultrasonic waves.

[0161] In some embodiments, providing the pre-form includes the steps of providing (210) at least one natural fiber material in the form of a woven multi-axial fabric; providing (210) at least one uncured matrix material in the form of a ribbon, sheet or film; and laminating (220) the natural fiber material with the uncured matrix material, preferably under the application of: heat and/or pressure, and allowing the natural fiber material to a least partially absorb the uncured matrix material to form the pre-form.

[0162] In some embodiments, a method is described for the repair of a part of a luggage system that has been damaged. The method may include adding uncured matrix material to the damaged area of the part; allowing the natural fiber material in the damaged area to absorb the added uncured matrix material at least partially; applying pressure to the damaged area; and curing the added uncured matrix material or allowing it to cure, preferably under the application of: heat, UV light and/or ultrasonic waves, and/or under a change in: temperature and/or humidity.

[0163] In some embodiments, a method is described for the repair of a part of a luggage system that has been damaged. The method may include adding uncured matrix material to the damaged area of the part; allowing the natural fiber material in the damaged area to absorb the added uncured matrix material at least partially; and

[0164] curing the added uncured matrix material or allowing it to cure, preferably under the application of: pressure, heat, UV light and/or ultrasonic waves, and/or under a change in: temperature and/or humidity.