CONTAINER, ESPECIALLY SUITCASE, COMPRISING AT LEAST ONE HALF-SHELL COMPONENT OR SHELL

Abstract

An injection-molded container or shell, in particular a suitcase shell made of plastic, A) is made of foamed plastic and has gas channels and/or B) is made using physically or chemically foamed plastic and/or a plastic mixed with hollow fillers and/or C) is integrally made with wheel mounting axles and/or extendable rod buffers and/or extendable rod cavities.

Claims

1: An injection molded container or shell (5), especially suitcase shell made of plastic, wherein A) the shell is made of foamed plastic and has gas channels (1,2,3) and/or B) the shell (5) is made by physically or chemically foamed plastic and/or from a plastic mixed with hollow fillers and/or C) the shell is integrally made with wheel axle mounts (6) and/or pull rod buffer (11) and/or pull rod cavities (10).

2: The container or shell according to claim 1, wherein the fillers or additives are essentially round and have a diameter of less than 100 ?m.

3: The container or shell (5) according to claim 1, wherein the shell has ribs (17) inside, which do not appear as sink marks or other marks on the visible side (19) due to fillers or chemical/physical foaming.

4: The container or shell (5) according to claim 1, wherein the wheel axle mounts (6) are formed from the same plastic as the container or shell (5) and are integrally made with the container or the shell (5).

5: The container or shell (5) according to claim 1, wherein a receiving area for the wheel axle mounts is created by a provided thread (8) in the container or shell (5), which is integrally connected to the container or the shell (5).

6: The container or shell (5) according to claim 1, wherein the pull rod buffer (11) is integrally made with the container or the shell (5).

7: The container or shell (5) according to claim 1, wherein the container or shell (5) is integrally made with a frame (20), which stiffens the open edges of the shell and/or wheel axle mounts (6,7,8) and/or at least one pull rod buffer (11) and/or fixing points (25) for a sliding tube, and/or at least one closure element (24) and/or further devices for the attachment of additional components (22,23), in particular hinges, buckles, handle recesses (9), handles 5 and the like.

8: A method for producing the container or the shell (5) according to claim 1 by injection molding, wherein hollow fillers or additives are introduced into the plastic and/or a gas for producing a foam is introduced into the plastic by means of hollow fillers or additives and during the injection molding process, the gas escapes from the fillers or additives and the plastic is foamed by the gas.

9: The method according to claim 8, wherein the fillers or additives are essentially round and have a diameter of less than 100 ?m.

10: The method according to claim 8, wherein the plastic is injected into a cavity of an injection mold and a volume of the cavity is increased shortly after filling the cavity and the plastic is foamed in the process and completely fills the enlarged cavity.

11: The method according to claim 8, wherein the temperature of a tool surface of the injection mold is kept high during an injection process and is lowered for demolding of the component.

12: The method according to claim 8, wherein additives and/or fillers increasing the flow rate of the plastic are added to the plastic and the container or shell (5) is made with a wall thickness of less than 1.5 mm.

13: The method according to claim 8, wherein the pull rod cavity (10) is formed during the injection molding process by a projectile (14).

14: The method according to claim 8, wherein the pull rod cavity (10) is formed by gas injection or fluid injection.

15: The method according to claim 8, wherein the pull rod buffer (11) is produced by a slider (13), and/or wherein the slider (13) holds retaining devices for a projectile (14) and preferably the gas supply for the launch of the projectile is guided through the slider (13).

16: The method according to claim 8, wherein the wheel axle mounts (7) are placed as insert part in the injection mold, which is overmolded during the injection molding process of the shell.

17: A method for producing the shell or the container, in particular suitcase shell (5) according to claim 1, by injection molding, comprising the steps: providing an injection molding machine and plastic granules and an injection mold, which is equipped for the production of gas injection channels. Melting of the plastic granules; introducing the molten plastic into the injection mold, the gas injection being started even during the injection process of the plastic into the injection mold, that is, after only partial filling of the injection mold, and/or after complete filling of the injection mold and thus the occurring pressure of the gas injection supports the flow of the plastic in the mold and the complete filling of the injection mold and/or excess plastic mass is pressed into overflow cavities; wherein the plastic is foamed by physical or chemical blowing agents and the injection mold is heated to an elevated temperature at the injection time, which is suitable for keeping the plastic soft and flowing in the injection mold and the injection mold is cooled after complete filling of the mold for solidification of the plastic.

18: A method for producing the shell (5) or the container, in particular a suitcase shell, with an integrated extendable rod cavity (10) and/or integrated extendable rod buffer (11) according to claim 1 by injection molding, including the steps: providing an injection molding machine and plastic granules and an injection mold, which is equipped for a projectile; providing a slider with suitable dimensions for forming an extendable rod buffer (11), which slider is equipped with an integrated device for igniting a projectile (14) attached to it; melting the plastic granules. introducing the molten plastic into the injection mold after a partial filling of the injection mold and/or after a complete filling of the injection mold, whereby the projectile is driven by gas pressure or fluid pressure and the occurring pressure of the projectile or the displacement of the plastic by the projectile supports the flow of the plastic in the mold and the complete filling of the injection mold and/or excess mass is diverted into overflow cavities; forming a hollow channel (10) by the projectile in the shell, which channel is suitable for the attachment and/or guidance of extendable rod devices; retracting the slider, leaving behind a cross-section with suitable dimensions for forming an extendable rod buffer (11).

Description

[0132] The invention will be further explained in the following using preferred, non-restrictive examples with reference to the drawings. The figures show in detail:

[0133] FIGS. 1a and 1b show the same (suitcase) shell 5 from different perspective angles. Visible is a circumferential gas channel along the open edge of the shell 1, two exemplary gas channels 2 along the largely flat areas of the shell, and gas channels 3 at the rounded areas of the shell. The gas channels 3 open at their lower end into the areas of the wheel mounts 4 and at their upper end into the corners of the suitcase and are therefore strategically placed to reinforce highly stressed areas of the suitcase shell in a targeted manner. All gas channels are placed at a suitable distance from each other and can be used to drive the plastic into the thin-walled areas of the shell during the injection molding process. In FIG. 1b, integrated wheel mounting axles 6 are also recognizable, which in this example were made from the same plastic and during the same injection molding process as the shell.

[0134] FIG. 2 shows section A of FIG. 1a in perspective and additionally clarifies that the gas channels can be arranged in the inner area of the shell 5, whereby the externally visible area of the shell remains visually smooth, free to design, and undisturbed. It can be seen that the gas channel 1 along the open shell edge leads into an overlapping area 7 of the shell, which area serves for the connection with a possible second shell. The gas channel 1 can either be inside or outside the shell. If it is arranged inside the shell, as shown here as an example, an undercut 8 is created. It is therefore advantageous to gently shape the form of the gas channel 1 into the shell as shown, which makes it possible to forcibly remove the shell from the injection mold without slide tools.

[0135] FIG. 3a and FIG. 3b show further, non-restrictive exemplary embodiments of gas channels as they might be attached to containers or shells, where the number of possible variants and shapes are limited more by technical conditions than by imagination. FIG. 3a shows gas channels 2 in the form of an X on the largely flat areas of the shell, which stiffen them very well. Here, the gas channels stiffen the surface like beads. FIG. 3b shows two C-shaped gas channels 1, which could be particularly advantageously attached to the open edges of the shell.

[0136] The final choice of gas channel shape is closely linked to the function and load of the shell, as well as the injection point. Cross shapes as in FIG. 3a are, for example, more suitable for an injection point near the center of the cross. First, you would partially fill the shell through the injection point, with the thicker gas channels significantly accelerating the flow of the plastic in the mold. In a second step, the gas pressure pushes the plastic into all corners of the injection mold. In FIG. 3b, on the other hand, it might be more advantageous to choose the injection point at the bottom of the shell. The C-shaped gas channels are then suitable for pushing the plastic upwards in the mold and at the same time stiffening the open edges of the shell. Of course, a combination of different shapes and injection points is also conceivable, for example, C-shaped gas channels on the open edges of the shell and X-shaped gas channels on the flat areas, and so on.

[0137] FIGS. 4a, 4b, and 4c show examples of variants of the integration of wheel mounting axles into the shell 5, each as a section through the shell in the zone of the wheel mounting axles in the area of the wheel mount 4.

[0138] FIG. 4a shows wheel mounting axles 6 integrated in one piece with the shell 5, whereby the wheel mounting axles are injection molded as part of the shell. In the area of the connection of the wheel mounting axle to the shell, increased use of material is advantageous, possibly combined with stress-optimized shaping of the transitions between the shell and the wheel mounting axle. In this way, acting forces can be optimally distributed and derived.

[0139] FIG. 4b shows the variant of an overmolded insert 7 as a wheel mounting axle. For this purpose, the wheel mounting axle 7 is placed in the injection mold before the injection molding process and then overmolded with plastic in a single operation. The wheel mounting axle 7 can be provided with grooves and the like to ensure optimal hold of the wheel mounting axle in the shell 5.

[0140] FIG. 4c shows the variant of an integrated thread 8 in the shell 5, whereby the wheel mounting axle is subsequently attached in the shell by means of a thread and is thus replaceable.

[0141] FIG. 5 and FIG. 6, as well as FIGS. 7, 8a and 8b, with FIGS. 6, 7, 8a and 8b depicting the upper area of section B-B of FIG. 5, show a suitcase shell 5 with integratively produced largest tube 10 or telescopic rod cavity 10. The next smaller, movable tube 12 of the telescopic rod construction is shown in dashed lines. The movable tube 12 is guided in close tolerance by integratively produced telescopic rod buffers 11, while the integratively produced telescopic rod cavity 10 of the telescopic rod construction provides further tolerance for the movable tube 12. The handle recess 9 is also produced integrally with the shell 5 and serves to store the extendable handle (not shown).

[0142] FIG. 6 shows that the shell 5 is also simultaneously part of the largest tube 10 of the telescopic rod construction.

[0143] The length of the largest tube or telescopic rod cavity 10 can be arbitrarily determined and depends on the number of tubes that can be telescoped into each other, the height to be reached by the telescopic rod handle in the use position, as well as the dimensions of the suitcase.

[0144] The next smaller movable tube 12 can be made in such a way that fixation and holding of the tube 12 in 11 or 10 is made possible by movable pins, automatic locks, triggers and the like (not shown). Such pins and triggers are well known in the state of the art in various versions. FIG. 7 schematically shows the device for producing the integratively produced elements 10, 11 with the shell 5. For this purpose, a slide 13 is used to form the telescopic rod buffer 11, at the end of which a projectile 14 is attached. First, the injection mold is (partially) filled with plastic, then the projectile is fired and thus forms the largest tube or the telescopic rod cavity 10. In the last step, the slide 13 is withdrawn from the mold.

[0145] The end of the largest tube or telescopic rod cavity 10 can be shaped as desired, with the injection mold either being able to provide devices for removing the projectile 14, thereby saving weight in the suitcase, or alternatively the projectile can also remain in the suitcase and after its path through the shell, it merges with the plastic at the tube end or end of the telescopic rod cavity 10. The telescopic rod cavity 10 can also bend along with the radius of the suitcase shell at the bottom end of the suitcase, thereby additionally stiffening the suitcase shell in this area.

[0146] FIGS. 8a and 8b each show variants that are less complex in manufacture and dispense with the formation of the largest tube or telescopic rod cavity. Instead, only the telescopic rod buffer 11 and the handle recess 9 are integratively produced with the shell 5. This obviates the relatively complex use of the projectile 14 from FIG. 7. The disadvantage is that the projectile can no longer be used as a flow aid for the plastic, making it more difficult to produce the shell 5 as thin-walled as possible. Also disadvantageous is that the no longer existing integratively produced largest tube 10 can no longer serve to stiffen the shell accordingly.

[0147] The embodiment of FIG. 8a provides that the shell 5 largely recedes parallel to the profile of the movable tube 12 in the area of the tube 12. In the stowage position, the movable tube 12 is thus visible from the outside. This massively influences the design of the suitcase from the outside, but on the other hand, a particularly low weight of the suitcase is achieved. The shell 5 delimits the tube 12 from the interior of the suitcase.

[0148] In contrast, the embodiment of FIG. 8b provides that the shell 5 remains on the outside and an additional cover 15 is provided, which delimits the movable tube 12 from the clothing in the interior of the suitcase.

[0149] FIG. 9 shows the section C-C in perspective from FIG. 5. The telescopic rod cavity 10 is integratively produced with the shell 5 and transitioned with a large radius 16, which allows the plastic to flow into the thinner area of the shell 5. The profile of the telescopic rod cavity is oval in this example, but could also be shaped differently. The profile of the telescopic rod cavity is formed internally by the projectile. It is also exemplarily visible that the telescopic rod cavity in area 17, where the wall of the suitcase shell transitions via a large radius into the bottom surface of the suitcase shell, flows together with the suitcase shell towards the inside. After that, the telescopic rod cavity ends. This formation of the telescopic rod cavity additionally increases the stiffness between the wall and the bottom of the suitcase shell.

[0150] In this embodiment, the telescopic rod cavity is also supplemented with gas channels 1 and 3, with the circumferential gas channel 1 stiffening the open edge of the shell and transitioning into an overlap area 7. Alternatively, the gas channel 1 could also not be fully circumferential, but in the form of two Cs, as shown in FIG. 3b. The gas channels 3 are parallel to the telescopic rod cavity 10 and transition fluidly, that is, stress-optimized, into the wheel areas 4, thus stiffening these high-stress areas.

[0151] FIG. 10 shows a cross-section through the sidewall and a part of the flat area of the shell 5. This shell 5 was made using fillers and/or flow aids 18, which allow the production of a very thin wall thickness of less than 1.5 mm. The shell 5 has an inwardly standing circumferential frame 20, as well as numerous internal ribs 17. Due to the fillers 18, the ribs 17 are not visible on the outside 19 of the shell 5, or the ribbings 17 do not show through due to sinks. The outside 19 thus remains smooth and aesthetically pleasing. The circumferential frame 20 and the ribs 17 could in principle also be attached to the outside, which would make the injection mold less complex. However, suitcases, especially hand luggage suitcases, are limited in their maximum dimensions by the specifications of airlines, and frames protruding to the outside would thus reduce the usable volume of the suitcase.

[0152] FIG. 11 shows a cross-section through the sidewall and a part of the flat area of the shell 5. In this implementation example, it is shown that the volume of the shell 5 filled with foamed plastic is expanded after the injection process around areas 21a and 21b. This can be achieved by negative injection compression or core pulls. This significantly increases the stiffness in these regions without increasing the mass of plastic in the shell. For example, 21a is expanded towards the inside of the basic wall thickness of the shell, while 21b is expanded towards the outside.

[0153] The foamed plastic can be produced by chemical or physical foaming or also by using hollow fillers filled with gas, which burst during the injection molding process due to chemical or physical conditions and release their gas. In addition, the shell in this example has a circumferential frame 20 and ribbings 17.

[0154] FIG. 12 shows a perspective view of a shell 5, with mainly the inside of the shell visible. Numerous ribbings 17 can be seen on the sidewalls and on the surface of the shell. The telescopic rod buffer 11 (here drawn exemplarily according to FIG. 8b) is integrally produced with the shell. In this example a production using internal and external sliders in the injection mold would be conceivable. The telescopic rod buffer 11 seamlessly transitions into a grip recess 9, which is intended to accommodate the telescopic handle.

[0155] The ribs are reinforced in the area where the telescopic rod will be moved and also serve to guide the telescopic rod. To allow the rods to lock in a specific height at different positions, locking points 25 are provided. The pin of the telescopic rod mechanism can lock into these locking points, thereby fixing the rod at different heights. The uppermost locking point is located within the telescopic rod buffer 11. In this example, the locking points 25 are created by interruptions of the ribs, but could also be manufactured in many other forms. In any case, the locking points are integrally manufactured with the shell.

[0156] The shell also features fastening elements 23 for attachments, which are developed for the tool-less attachment of hinges. In addition, there is a reinforced area with holes 22, which serves for the attachment of a handle. The buckles 24 are also integrally manufactured with the shell in this example. In this case, the buckles would function like a snap closure and lock into the corresponding shell (not shown).

[0157] The wheel axles 6 are also integrally made with the shell. The shell also has a circumferential, in its profile L-shaped frame 20, with openings 26, which are intended for the attachment of a divider-fabric. The L-shape of the frame creates an overlap to the opposite shell, which keeps the two shells in position relative to each other. If a rubber buffer is also attached to the frame, the shell can theoretically also be sealed watertight.