Abstract:
A composite comprising a first layer formed of a transparent or translucent plastic material; a second layer formed of a semi-rigid or rigid plastic material; and a third layer, securely positioned between the first and second layers, formed of a material having reflective properties on at least a side facing the first layer. A method for forming a composite comprising providing a first transparent or translucent plastic material, a second semi-rigid or rigid plastic material, and a third material having reflective properties on at least one side; positioning the first material adjacent the at least one side of the third material having reflective properties and the second material on an opposing side of the foil material; and heating the first material and the second material to a temperature of between about 110° C. and about 130° C. to form a bond between the first material, the second material, and the third material.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 62/094,636, filed Dec. 19, 2014, the disclosure of which is hereby incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Many materials, such as those used in luggage, lack a lightweight, durable, and aesthetically pleasing construction. There is a need for a material or materials exhibiting a combination of these qualities. 
       SUMMARY 
       [0003]    The present disclosure is directed to a material comprising a first layer formed of a transparent or translucent plastic material; a second layer formed of a semi-rigid or rigid plastic material; and a third layer, securely positioned between the first and second layers, formed of a material having reflective properties on at least a side facing the first layer. In an embodiment, the composite may be used to form a main body section of a piece of luggage or other container. 
         [0004]    The transparent or translucent plastic material of the first layer, in various embodiments, may include one of polyethylene terephthalate (PET), polyvinyl chloride (PVC), polystyrene (PS), polyethylene (PE), and acrylonitrile butadiene styrene (ABS), or a combination thereof. In various embodiments, the first layer may be between about 0.07 mm and 0.15 mm thick. The first layer may be sufficiently transparent or translucent to allow light to penetrate through the first plastic layer and reflect off of the third foil layer. The semi-rigid or rigid plastic material of the second layer, in various embodiments, may include one of polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polyethylene terephthalate (PET), and acrylonitrile butadiene styrene (ABS), or a combination thereof. In various embodiments, the second layer may be between about 0.1 mm and about 2 mm thick. The third layer, in various embodiments, may be between about 0.05 mm and 0.25 mm thick. 
         [0005]    The composite, in various embodiments, may further comprise a fourth layer formed from a transparent or translucent colored material. The fourth layer, in various embodiments, may be disposed between the third layer and the first layer. In an embodiment, transparent or translucent colored material of the fourth layer is a plastic film. In an embodiment, the fourth layer may be about 0.03 mm thick. The fourth layer may be sufficiently transparent or translucent to allow light to penetrate through the fourth color layer and reflect off of the third foil layer. 
         [0006]    The composite, in various embodiments, may be substantially planar in cross-section, or may have a patterned cross-section. In an embodiment, the patterned cross-section may be latticed. In another embodiment, the patterned cross-section may be defined by a series of alternating peaks and valleys on at least one side of the composite. 
         [0007]    In another aspect, the present disclosure is direct to a method for manufacturing a composite comprising providing a first transparent or translucent plastic material, a second semi-rigid or rigid plastic material, and a third material having reflective properties on at least one side; positioning the first material adjacent the at least one side of the third material having reflective properties and the second material on an opposing side of the foil material; and heating the first material and the second material to a temperature of between about 110° C. and about 130° C. to form a bond between the first material, the second material, and the third material. In an embodiment, the method may include manufacturing a main body of a piece of luggage or other container from the composite. 
         [0008]    In an embodiment, prior to the step of positioning, the first material and the third material may be placed in contact and exposed to about 220° C. for about 1 minute per meter of material. The step of positioning, in an embodiment, may further include positioning a fourth transparent or translucent colored material between the first material and the third material. The step of heating the first material and the second material to a temperature of between about 110° C. and about 130° C., in an embodiment, may be performed for about three minutes per meter of material. The method, in an embodiment, may further include the step of maintaining the heated materials at about 110° C. for about 48 hours. In various embodiments, the method may further comprise imparting a pattern into the composite. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0009]      FIG. 1A  depicts a cross-sectional view of a composite, in accordance with an embodiment of the present disclosure; 
           [0010]      FIG. 1B  depicts a close-up cross-sectional view of a thermoplastic foil layer of the composite of  FIG. 1A , in accordance with an embodiment of the present disclosure; 
           [0011]      FIG. 2  depicts a cross-sectional view of a composite, in accordance with another embodiment of the present disclosure; 
           [0012]      FIG. 3  depicts a cross-sectional view of a composite, in accordance with yet another embodiment of the present disclosure; 
           [0013]      FIG. 4  depicts a front perspective view of a piece of luggage, in accordance with an embodiment of the present disclosure; 
           [0014]      FIG. 5  depicts a rear perspective view of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; 
           [0015]      FIG. 6  depicts a first outer corner protection component of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; 
           [0016]      FIG. 7  depicts a first inner corner protection component of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; 
           [0017]      FIG. 8  depicts a second outer corner protection component of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; 
           [0018]      FIG. 9  depicts a second inner corner protection component of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; 
           [0019]      FIG. 10  depicts a corner protection and wheel assembly of the piece of luggage of  FIG. 4 , in accordance with an embodiment of the present disclosure; and 
           [0020]      FIG. 11  depicts a piece of luggage having a main body formed of a patterned composite, in accordance with an embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Embodiments of the present disclosure provide a durable, lightweight material that can be used in a wide variety of products. 
       Composite  100   
       [0022]      FIG. 1A  illustrates a cross-sectional view of an exemplary composite  100  according to various aspects of the disclosure. Composite  100 , in various embodiments, may generally include a thermoplastic film layer (TFL)  1  and a layer  2  formed of a plastic material. 
         [0023]      FIG. 1B  illustrates a close-up view of the exemplary composite  100 , and shows further detail regarding the construction of TFL  1 . TFL  1 , in various embodiments, may generally comprise a layer  11  formed from a plastic material, a layer  12  formed from a foil material, and a layer  13  formed from a colored material. As shown in  FIG. 1 , in various embodiments, plastic layer  11  may form an outer surface of TFL  1 . Foil layer  12  may be situated on an opposing side of plastic layer  11  and may form an opposing outer surface of TFL  1 . Color layer  13  may optionally be included in TFL  1 , and in an embodiment, may be situated between plastic layer  11  and foil layer  12 . 
         [0024]    It should be recognized that, while from time to time, plastic layer  11 , foil layer  12 , and color layer  13  may be associated with one another throughout the specification in the context of forming TFL  1  of composite  100 , the present disclosure is not intended to be limited only to embodiments where these layers are necessarily combined to first form a distinct material such as TFL  1  that may be subsequently joined with plastic layer  2 . Instead, any suitable construction is intended within the scope of the present disclosure. 
         [0025]    Plastic layer  11 , in various embodiments, may be formed from any suitable thermoplastic material such as, without limitation, polyethylene terephthalate (PET), polyvinyl chloride (PVC), polystyrene (PS), polyethylene (PE), acrylonitrile butadiene styrene (ABS), or any suitable combination thereof. In a preferred embodiment, plastic layer  11  may be formed from polyethylene terephthalate (PET). Plastic layer  11  may be of any suitable thickness for providing structural strength to TFL  1  and for protecting foil layer  12  and color layer  13  from damage. For example, in an embodiment, plastic layer  11  may have a thickness ranging between about 0.07 mm to 0.15 mm, but could be any other suitable thickness. In a preferred embodiment, plastic layer  11  may have a thickness of about 0.11 mm. In various embodiments, plastic layer  11  may be sufficiently transparent or translucent so as to allow light to penetrate through the plastic layer  11  and reflect off of foil layer  12 . 
         [0026]    Foil layer  12 , in various embodiments, may be formed from a metallic foil material, such as an aluminum foil material. In various other embodiments, foil layer  12  may instead be formed from other suitable materials such as, without limitation, ABS, polycarbonate (PC), polyethylene (PET), O-phenylphenol (OPP), or any suitable a combination thereof. Foil layer  12  may be of any suitable thickness for reflecting at least a portion of any light that may penetrate plastic layer  11  and/or color layer  13 . For example, in an embodiment, foil layer  12  may have a thickness ranging between about 0.05 mm to 0.25 mm, but could be any other suitable thickness. In a preferred embodiment, foil layer  12  may have a thickness of about 0.07 mm. In various embodiments, foil layer  12  may have reflective properties, and may be configured to provide visual texture to composite  100  in the way it reflects light that may penetrate through plastic layer  11  and/or color layer  13 . Depending on the application, this can provide an aesthetic quality to composite  100 , amongst other purposes. Although an aluminum foil material is provided as an illustrative example herein, any other material having reflective properties could be used to form foil layer  12 . 
         [0027]    Color layer  13 , in various embodiments, may be formed from any suitable material having a colored property. In an embodiment, color layer  13  may be a plastic film. Ink or any other suitable substance may be used to impart color to color layer  13 . Color layer  13  may be of any suitable thickness. For example, in a preferred embodiment, color layer  13  may have a thickness of about 0.03 mm. Color layer  13 , in various embodiments, may be situated between plastic layer  11  and foil layer  12 , as shown. In some embodiments, the color layer  13  may be sufficiently transparent or translucent to allow light to penetrate to foil layer  12 , and thereby provide a colored effect to light reflecting off of foil layer  12  back through color layer  13  and plastic layer  11 . 
         [0028]    Plastic layer  2  of composite  100 , in various embodiments, may be formed from any suitable thermoplastic material such as, without limitation, polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), or any suitable combination thereof. In a preferred embodiment, plastic layer  2  may be formed from polypropylene (PP). Plastic layer  2  may be of any suitable thickness for supporting TFL  1  and providing overall structural strength to composite  100 . For example, in an embodiment, plastic layer  2  may have a thickness ranging between about 0.1 mm to about 2 mm, but could be any other suitable thickness. In a preferred embodiment, plastic layer  2  may have a thickness of about 1 mm. In an embodiment, plastic layer  2  may be made from the same material as plastic layer  11  of TFL  1 . 
         [0029]    TFL  1  and plastic layer  2  of composite  100  may be formed in any desired size, shape, and configuration.  FIG. 2  illustrates a cross-sectional view of an embodiment whereby TFL  1  and plastic layer  2  are configured in a convex/concave pattern such that composite  100  contains a series of alternating grooves (i.e. peaks and valleys) on either side. The grooves may be of any desired depth and width, and need not necessarily be uniform across the entire surface of composite  100 . In some embodiments, the grooves on one side of composite  100  may also be of a different size, shape, and/or configuration than grooves on the other side of composite  100 . In alternate embodiments, the grooves may be formed on just one side of composite  100 .  FIG. 3  illustrates another embodiment of composite  100 , in which composite  100  is contains a latticed pattern. In the embodiment shown, composite  100  is shown as being latticed in an angle of 45°. The pattern on composite  100  can be likewise modified and configured according to a wide variety of desired visual effects and textures. Patterned embodiments of composite  100  may provide for enhancing any aesthetic visual effect created when light is reflected off of foil layer  12 , and may further have the advantages of thickness, structural strength, durability, and can help provide an anti-slip surface. 
         [0030]    Composite  100  may provide a number of advantages over other materials. In one aspect, plastic layer  2  not only provides mechanical strength to composite  100 , but also may be waterproof, thereby protecting foil layer  12  from oxidation through that side of composite  100 . Similarly, plastic layer  11 , when configured as the opposing outer surface of composite  100 , can protect foil layer  12  from oxidation as well. Composite  100  is also lightweight and very durable compared to other materials. In various embodiments, such characteristics may make composite  100  a favorable material for use in luggage products, amongst others. 
         [0031]    Composite  100  may be manufactured in any suitable manner. In various embodiments, TFL  1  may be separately formed, and subsequently combined with plastic layer  2  to form composite  100 . TFL  1  of composite  100  may be manufactured, in various embodiments, by arranging plastic layer  11 , foil layer  12 , and color layer  13  as previously described (i.e.,  11 — 13 — 12 ), and exposing them to heat. In an embodiment, this may be done at a temperature of about 220° C.±10° C. for about 1 minute/meter. Of course, exposure may be at any other suitable temperature, for any other suitable amount of time, and any suitable combination thereof. In various embodiments, the three layers  11 ,  12 ,  13  may also be pressed together during and/or after heating to help form TFL  1 . In an embodiment, a force ranging between about 30 kg and 50 kg may be applied to the layers during this pressing step. Afterwards, the combined layers  11 ,  12 ,  13  may be kept at about 70° C. for about 48 hours to complete the combination process. It should be recognized that this finishing step may be accomplished at other suitable combinations of temperature and time as well. 
         [0032]    TFL  1  and plastic layer  2  may then be placed in contact and exposed to heat to join these materials. In an embodiment, this may be done at a temperature of about 120° C.±10° C. for about 3 minute/meter. In various embodiments, TFL  1  and plastic layer  2  may also be pressed together during and/or after heating to help form composite  100 . In an embodiment, a force ranging between about 30 kg and about 50 kg may be applied to TFL  1  and plastic layer  2  during this pressing step. Afterwards, the combined TFL  1  and plastic layer  2  may be kept at about 70° C. for about 48 hours to complete the process of forming composite  100 . 
         [0033]    In various other embodiments, rather than forming composite  100  in the aforementioned piecemeal manner (i.e., form TFL  1 , then join TFL  1  with plastic layer  2 ), composite  100  may be formed by combining layers  11 ,  12 ,  13 , and  2  at once. One of ordinary skill in the art will recognize, in light of the above disclosure, suitable temperatures, durations, and pressures for providing such a combination. 
         [0034]    Referring back to  FIGS. 2 and 3 , composite  100  may be manufactured with various shapes in any suitable manner. In various embodiments, composite  100  may be formed against a mold to impart a given shape, such as the previously described grooved and latticed shapes. In another embodiment, composite  100  may be stamped at some point during the heating process to impart a given shape. Various patterns may also be imparted to composite  100  during or after its formation. Such patterns may serve to increase the intensity and thickness of the material and also provide anti-slip properties to the material. In an embodiment, a pattern may be imparted in the material using a roller machine or an embossing machine. In an embodiment, patterns may be applied to composite  100  under high temperature (e.g., 120° C. ±10° C.). Exemplary patterns on luggage made with composite  100  are shown in  FIG. 11 , as later described. 
       Example 1—Luggage  200   
       [0035]      FIGS. 4-11  illustrate embodiments of luggage  200  and luggage components according to various embodiments of the disclosure. In this example, the piece of luggage  200  includes a main body  201  comprising a left body  205  and right body  204  through zipper  207 . There is the first extrusion forming section  202  at the upper four corners of the main body  201  and there is the second extrusion forming section  203  at the bottom four corners of the main body  201  and the first extrusion forming section  202  and second extrusion forming section  203  are fixed to the main body  201  by thread. The first extrusion forming two sections includes the first outer corner protection  211  outside the main body  201  and the related first inner corner protection  212  inside the main body  201 . The second extrusion forming section  203  includes the second outer corner protection  213  outside the main body  201  and the related second inner corner protection  214  inside the main body  201  as shown in  FIGS. 8 and 9 . 
         [0036]    There are seven first bolted caps  215  with internal thread inside the first outer corner protection  211  and there are seven first fixed legs  216  with holes related to the first bolted caps  215  inside the first inner corner protection  212 . The first fixed leg  216  can be fixed by the bolt through the hole with the first bolted cap  215 . The construction of the first outer corner protection  211  is in three directions, the first outer corner protection  211  includes in camber A- 1 , B- 1  and C- 1 . There is one first bolted cap  215  on the camber A- 1 , there are three first bolted caps  215  with space on each of camber B- 1  and camber C- 1 . The first inner corner protection  212  is with the related three direction construction to the first outer corner protection  211 , the first inner corner protection  212  consists in camber A- 2 , B- 2  and C- 2 . There is one first fixed leg  216  with hole on camber A- 2  related to the first bolted cap  215  on camber A- 1 , there are three first fixed legs  216  with hole on each of camber B- 2  and C- 2  related to the first bolted caps  215  on camber B- 1  and C- 1 . 
         [0037]    There are three second bolted caps  217  with internal thread inside the second outer corner protection  213  and there are three second fixed legs  218  with holes related to the second bolted caps  217  inside the second inner corner protection  214 . The second fixed leg  218  can be fixed by the bolt through the hole with the second bolted caps  217 . The construction of the second outer corner protection  213  is in three directions, the second outer corner protection  213  consists in camber D- 1 , E- 1  and F- 1 . There is one second bolted caps  217  on the camber D- 1 , there are two second bolted caps  217  with space on camber E- 1  and there is one second bolted caps  217  on camber F- 1 . The second inner corner protection  214  is with the related three direction construction to the second outer corner protection  213 , the second inner corner protection  214  consists in camber D- 2 , E- 2  and F- 2 . There is one second fixed leg  218  with hole on camber D- 2  related to the second bolted caps  217  on camber D- 1 , there are two second fixed legs  218  with hole on camber E- 2  related to the second bolted caps  217  on camber E- 1  and there is one second fixed legs  218  with hole on camber F- 2  related to the second bolted caps  217  on camber F- 1 . 
         [0038]    Through the occlusion of the bolted caps inside the first outer corner protection  211  and the second outer corner protection  213  to the related fixed legs on the first inner corner protection  212  and the second inner corner protection  214  and then the matched bolt, the outer corner protection and inner corner protection come together firmly. In some embodiments, the body of the luggage  200  can be shaped through extruding into a stereo structure, thus removing the need for any mold, and thereby helping to reduce the cost to produce the luggage  200 . 
         [0039]    Exemplary embodiments of such luggage  200  may also include a telescoping handle  210 . Such luggage  200  may also include a lock  208  (such as a TSA-approved lock) on the main body  201  matching to the zipper  207 . In some embodiments, a user can unlock the lock  208  using a password defined by the user or by using a key. In this example, the lock  208  is at the upper of one side of the left body  205  to provide easy access for locking and unlocking. 
         [0040]    There are wheels  206  at the bottom of all the four second extrusion forming three of the main body  201  and they are mute omni-directional wheels. The 360° mute omni-directional wheels is strong enough for long term use and designed with reasonable height, it can disperse the weight easily without reducing the loads, it can also be rolled smoothly in rugged area. The handle  209  allows a user to carry the luggage  200  when on a surface not suitable for rolling. 
         [0041]    A pattern or other markings may be formed or imparted to composite  100  included as part of the luggage  200 . In the example of the luggage  200  shown in  FIGS. 4-11 , marks are made on both outside and inside corner of the plastic material first and then the first outer corner protection  211 , the first inner corner protection  212 , the second outer corner protection  213  and the second inner corner protection  214  are combined by the thread at the marked positions. The left body  205  and right body  204  can be shaped through extruding by this way into stereo structure. The main body  201  extruded into stereo structure in this way at the corners by the first extrusion forming section  202  and second extrusion forming section  203  can be done without molds and this can cut down the cost and in the meanwhile there is the corner protection at the first extrusion forming section  202  and second extrusion forming section  203 , this can have the advantage of firm and the corners are not easy to deform. 
         [0042]    In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
         [0043]    In various embodiments, the methods described herein are implemented using the various particular machines described herein. The methods described herein may be implemented using the below particular machines, and those hereinafter developed, in any suitable combination, as would be appreciated immediately by one skilled in the art. Further, as is unambiguous from this disclosure, the methods described herein may result in various transformations of certain articles. 
         [0044]    The connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. 
         [0045]    Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. 
         [0046]    All structural, chemical, and functional equivalents to the elements of the above-described exemplary embodiments that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present disclosure, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. 
         [0047]    Where a phrase similar to “at least one of A, B, or C,” “at least one of A, B, and C,” “one or more A, B, or C,” or “one or more of A, B, and C” is used, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
         [0048]    Changes and modifications may be made to the disclosed embodiments without departing from the scope of the present disclosure. These and other changes or modifications are intended to be included within the scope of the present disclosure, as expressed in the following claims.