Abstract
The invention relates to a method for producing a suitcase (1) comprising at least one suitcase shell (Ia, Ib) and at least one functional attachment (31) which is more heavily loaded during use and which is connected to the at least one suitcase shell (Ia, Ib) at a position provided for this purpose, wherein the suitcase shell (Ia, Ib) and the attachment (31) are at least partly made of a thermoplastic material. The invention also relates to a suitcase (1) produced using the aforementioned method. According to the invention, the attachment (31) is provided with a surface (10) at least on a part of the face facing the suitcase shell (Ia, Ib), said surface corresponding to the surface of the suitcase shell (Ia, Ib) at the specified position and complementing same after the connection process; the attachment (31) is positioned at the specified position on the suitcase shell (Ia, Ib); the attachment (31) is bonded to the suitcase shell (Ia, Ib); and the interior of the suitcase shell (Ia, Ib) is designed to be smooth, free of disruptions, and substantially free of interruptions.
Claims
1. Method for producing a suitcase (1) comprising at least one suitcase shell (1a, 1b) and at least one functional attachment (31) which is more heavily loaded during use, such as a handle holder (2), a wheel housing (3), a stopper (4), a holding device (5) for a pull-out rod or the like, which at least one attachment (31) is connected to the at least one suitcase shell (1a, 1b) at a position provided for this purpose, wherein the at least one suitcase shell (1a, 1b) is at least partially made of thermoplastic material, the at least one attachment (31) is made at least partially of a thermoplastic material, characterized in that the at least one attachment (31) is provided at least partially on the side facing the suitcase shell (1a, 1b) with a complementary surface (10) corresponding to the surface of the at least one suitcase shell (1a, 1b) at the provided position after the connection process, the at least one attachment (31) is positioned at the provided position on the at least one suitcase shell (1a, 1b), the at least one attachment (31) is materially bonded to the at least one suitcase shell (1a, 1b) and the at least one suitcase shell (1a, 1b) is configured to be smooth and free from disruptions and substantially free from interruptions in the interior.
2. Method according to claim 1, characterized in that the at least one attachment (31) is materially bonded to the at least one suitcase shell (1a, 1b) by plastic welding, for example, ultrasound welding, vibration welding or laser welding.
3. Method according to claim 2, characterized in that the at least one attachment (31) is positioned at the provided position on the at least one suitcase shell (1a, 1b) by means of a holding device (23).
4. Method according to claim 2 or 3, characterized in that the at least one attachment (31) is provided with protrusions (6, 7) at the surface (10) facing the at least one suitcase shell (1a, 1b) and/or the at least one suitcase shell (1a, 1b) is provided with protrusions at the position provided for connection to the at least one attachment (31).
5. Method according to claim 1, characterized in that the at least one attachment (31) is materially bonded to the at least one suitcase shell (1a, 1b) by overmoulding the at least one attachment (31) on the at least one suitcase shell (1a, 1b), whereby an overmoulding mould (25) with a cavity corresponding to the at least one attachment (31) is positioned at the provided position on the suitcase shell (1a, 1b) and the at least one attachment (31) is produced and materially bonded to the at least one suitcase shell (1a, 1b) by introducing the plastic into the cavity of the overmoulding mould (25) and the suitcase (1) is removed from the overmoulding mould (25) after cooling.
6. Method according to claim 1, characterized in that the at least one attachment (31) is materially bonded to the at least one suitcase shell (1a, 1b) by adhesive bonding.
7. Method according to one of claims 1 to 6, characterized in that the at least one attachment (31) and/or the at least one suitcase shell (1a, 1b) is reinforced with carbon, aramid or glass fibres and/or metal parts.
8. Suitcase (1) comprising at least one suitcase shell (1a, 1b) and at least one functional attachment (31) which is more heavily loaded during use, such as a handle holder (2), a wheel housing (3), a stopper (4), a holding device (5) for a pull-out rod or the like, which at least one attachment (31) can be connected to the at least one suitcase shell (1a, 1b) at a position provided for this purpose, wherein the at least one suitcase shell (1a, 1b) consists at least partially of thermoplastic material, the at least one attachment (31) consists at least partially of a thermoplastic material, characterized in that the at least one attachment (31) is provided at least partially on the side facing the suitcase shell (1a, 1b) with a complementary surface (10) corresponding to the surface of the at least one suitcase shell (1a, 1b) at the provided position after the connection process, the at least one attachment (31) is materially bonded to the at least one suitcase shell (1a, 1b) and the at least one suitcase shell (1a, 1b) is configured to be smooth and free from disruptions and substantially free from interruptions in the interior.
9. Suitcase (1) according to claim 8, characterized in that the at least one attachment (31) and/or the at least one suitcase shell (1a, 1b) is reinforced with carbon, aramid or glass fibres or metal parts.
10. Suitcase (1) according to claim 8 or 9, characterized in that the at least one attachment (31) is provided with protrusions (6, 7) at the surface (10) facing the at least one suitcase shell (1a, 1b) and/or the at least one suitcase shell (1a, 1b) is provided with protrusions at the position provided for connection to the at least one attachment (31).
Description
[0034] The invention will be explained further hereinafter with reference to preferred non-restrictive exemplary embodiments with reference to the drawings. In the drawings
[0035] FIG. 1 shows a schematic view of a suitcase with two suitcase shells with attachments arranged thereon;
[0036] FIGS. 2a and 2b show sectional views of the connection of a wheel housing as attachment to a suitcase shell of a suitcase according to the conventional method and the method according to the invention;
[0037] FIG. 3 shows a method of producing a suitcase according to the invention by means of ultrasound welding;
[0038] FIG. 4 shows a further method of producing a suitcase according to the invention by means of vibration welding;
[0039] FIG. 5 shows a method of producing a suitcase according to the invention by means of laser welding;
[0040] FIGS. 6 to 9 show various methods of producing a suitcase according to the invention by overmoulding an attachment;
[0041] FIG. 10 shows a conventional method of producing a suitcase by means of screws;
[0042] FIG. 11 shows a semi-automated method of producing a suitcase according to the invention by means of ultrasound welding;
[0043] FIGS. 12a and 12b show schematically a conventional connection of a wheel housing as attachment to a suitcase with a suitcase shell;
[0044] FIGS. 13a to 13c show various possible designs of the attachments according to the invention and/or suitcase shell of a suitcase; and
[0045] FIG. 14 shows a cutaway view of a section of a suitcase with attachment according to the invention and cover elements arranged thereon.
[0046] FIG. 1 shows a suitcase 1 consisting of two suitcase shells 1a, 1b with various attachments 31 arranged thereon and connected thereto, such as handle holders 2, wheel housings 3, a stopper 4 or a holding device 5 for a pull-out rod.
[0047] FIGS. 2a and 2b show in sectional views comparatively different constructions of attachments 31, in this example, wheel housing 3, wherein the connection is made in a conventional manner by means of screws (FIG. 2a) and in a manner according to the invention (FIG. 2b).
[0048] FIG. 2a shows an exemplary conventional attachment 31. The exemplary conventional wheel housing 3 has an outer element 14a and an inner element 12 which clamp the suitcase shell 1a, 1b of the suitcase 1 provided with openings 19 between them by placing screws 11 from inside into the screw dome 15 of the outer element 14a of the attachment 31. The outer element 14a and the inner element 12 each cover the openings 19 in the suitcase shell 1a, 1b by means of an overlap D. As a result of the necessary height of the screw dome 15, the outer element 14a only lies on the suitcase shell 1a, 1b at a few points 20. Located inside the suitcase 1 is a cover 13, usually made of fabric, which visually covers the screws 11 and the inner element 12. The vertical axle 16a for the wheels can be produced as an overmoulded metal part or in one piece with the outer element 14a.
[0049] FIG. 2b on the other hand shows an attachment 31 according to the invention which nestles against the suitcase shell 1a, 1b along a comparatively large surface 10 and is attached there by the production method according to the invention. No inner element and no inner cover is provided or necessary. The exemplary wheel housing 3, 14b nestles harmoniously and without stress peaks against the suitcase shell 1a, 1b without interrupting this. The suitcase shell 1a, 1b is therefore designed without holes and need not be covered by a cover in its interior. In this variant the wheel housing 3 is designed in one piece and in this case already integrates the axle 16b for the wheel in a form which optimally absorbs forces and diverts them to the suitcase shell 1a, 1b over a large area. In this example there is a hollow region between suitcase shell and attachment.
[0050] FIG. 3 shows a method for producing a suitcase 1 according to the invention by ultrasound welding. In this case the attachment 31 is provided at the position provided for it on the suitcase shell 1a, 1b. A sonotrode 24 of the ultrasound welding device vibrates the attachment 31 in the vertical direction and against a fixing element 23 or counterpiece at a frequency which is suitable for fusing the surface of the attachment 31 and/or the suitcase shell 1a, 1b and thereby produce a durable connection between suitcase shell 1a, 1b and attachment 31.
[0051] FIG. 4 shows an alternative production method according to the invention as in FIG. 3 but in this example the attachment 31 is not fused by vertical movements of the sonotrode 24 but by horizontal movements of the sonotrode 24 during vibration welding.
[0052] FIG. 5 shows an alternative production method according to the invention but in this example the attachment 31 and/or the suitcase shell 1a, 1b is fused by the action of a laser 29.
[0053] FIGS. 6 to 8 show production methods according to the invention corresponding to FIGS. 3 to 5 with the difference that the attachments 31 contain an overmoulded metal part 30 to improve functionality and/or the strength.
[0054] FIG. 9 shows a production method according to the invention, wherein the attachment 31 is produced directly on the suitcase shell 1a, 1b in the initially molten state. For this purpose the suitcase shell 1a, 1b is fixed in the interior at least in some places by means of a fixing element 26 and an overmoulding mould 25 is pressed from outside onto the suitcase shell 1a, 1b. The molten plastic 27 is pressed through a channel 28 into a cavity in the overmoulding mould 25 and cools down and solidifies there. Then overmoulding mould 25 and fixing element 26 are removed. This process can be fully automated which however is associated with high investment costs. A disadvantage is furthermore that the attachments 31 are subject to various process-dependent restrictions in their design.
[0055] FIG. 10 shows a conventional production method wherein an outer element 14a and an inner element 12 of a wheel housing 3 are fixed by means of screws 11 which act in screw dome 15 on the suitcase shell 1a, 1b with openings 19 provided for this purpose.
[0056] FIG. 11 shows an exemplary semi-automated production method of a suitcase 1 according to the invention with the aid of a prepared holding device 23. In this case, the attachments 31 are firstly inserted into the positions provided for the attachments 31 in the holding device 23, then the suitcase shell 1a, 1b is inserted and fixed by means of fixing elements 24. Now the attachments 31 are connected to the suitcase shell 1a, 1b by ultrasound welding by means of sonotrodes 24 and then the successfully connected combination of suitcase shell 1a, 1b and attachments 31 is removed from the holding device 23 for further processing. This method manages with relatively low investment costs. The individual production steps can be carried out by hand or by robot.
[0057] FIG. 12a shows the composition of a typical conventional attachment 31, in this case a wheel housing 3, in an exploded view. This shows the outer element 14a with screw domes 15, two inner elements 12 and the wheel element 22 which, for example, is fixed by means of screws or rivets 23 on the outer element 14a. As a result of the necessary height of the screw dome 15, the outer element 14a only abuts against the suitcase shell 1a, 1b of the suitcase 1 at a few points 20.
[0058] FIG. 12b shows a three-dimensional view of a typical broken suitcase shell 1a, 1b from practical experience, wherein forces on the outer element 14a were too great and the suitcase shell 1a, 1b has broken at an opening 19 for the screw or rivet 23 and the suitcase shell 1a, 1b has been destroyed.
[0059] FIGS. 13a, 13b and 13c show attachments 31 with small protrusions 6, 7 to be fused in detail. The protrusions 6, 7 are appropriately integrated in the attachments 31 according to the invention on the side facing the suitcase shell 1a, 1b or surface 10 or contact surface between attachment 31 and suitcase shell 1a, 1b and/or also on the suitcase shell 1a, 1b itself (not shown). As a result of friction or vibration processes according to FIGS. 3 and 4, these protrusions 6, 7 are heated and fuse, whereby a very firm and permanent connection of attachment 31 and suitcase shell 1a, 1b is made possible. FIG. 13a shows a view of protrusions 6 in three-dimensional view, FIG. 13b shows various exemplary paths of protrusions 7 on exemplary surfaces or contact surfaces of attachments 31 which can be selected depending on the action of force and component shape. FIG. 13c shows a three-dimensional view of a one-piece attachment 31 according to the invention in the form of an exemplary wheel housing 3 with protrusions 6, 7 at many strategically suitable points which can be fused when connected by means of ultrasound welding and produce the materially bonded connection to the suitcase shell 1a, 1b. The position, size and shape of the protrusions 6, 7 is selected so that this is optimal for the process and the selected devices and machines.
[0060] FIG. 14 shows a possible two-or multi-part embodiment of an attachment 31 or wheel housing 3 which nestles against the suitcase shell 1a, 1b of the piece of luggage 1 or suitcase 21 along the largest possible surface 10 and is attached there by the production method according to the invention. The suitcase shell 1a, 1b is designed without holes and need not be covered by a cover in its interior. In this variant, the attachment 31, for example, the wheel housing 3 is designed to be two-part, wherein the attachment 31 is designed so that it is suitable for detachable fastening of the axle part 3C. Various known mechanical methods are known for fixing the axle part 3C, for example, a bayonet closure or various other locks and the like. In this variant, the vertical axis 16c for the wheel consists of metal which was overmoulded with plastic.
