Abstract: Luggage cases usually include wheels to aid in their transport. The wheels and their mounting systems must themselves be extremely sturdy, and should not cause weakness or mechanical failure of the luggage case to which they are mounted. The disclosed cantilever wheel mounting assembly 18 includes an axle 22 with a protruding end 26 that fits into an elastomeric mounting block 20 that in turn is received in a corresponding cavity in a molded luggage case shell. A screw fastener 38 passes through one of the walls 15 of the cavity, and through a corresponding hole 44 in the mounting block and through a hole 28 through the end of the axle 22 to hold the assembly in place while permitting the axle to pivot about the fastener when the elastomeric block flexes in response to vibrations and impacts in use.

Abstract: The inventive process forms a thermoformable preform by pressure laminating a layer of cloth fabric to one face of the thermoplastic substrate, preferably as the substrate is extruded and while still hot from the extrusion process. This fabric/thermoplastic laminated preform can be easily processed in a matched mold press. The fabric should be of a non-stretch type. This non-stretch characteristic, together with its intimate bonding to the thermoplastic substrate, prevents the substrate from thinning in the corner regions. Indeed, because the intimately bonded fabric drags or pulls the substrate from a number of directions as the corner regions are formed, the thermoplastic substrate accumulates and actually thickens in the corner regions, leading to a shell which is remarkably durable and aesthetically pleasing.