U.S. patent application number 09/920111 was filed with the patent office on 2002-03-07 for carrying case and a method of making thereof.
Invention is credited to Diaz, James, Revels, Eric.
Application Number | 20020028029 09/920111 |
Document ID | / |
Family ID | 22459365 |
Filed Date | 2002-03-07 |
United States Patent
Application |
20020028029 |
Kind Code |
A1 |
Revels, Eric ; et
al. |
March 7, 2002 |
Carrying case and a method of making thereof
Abstract
The invention relates to a soft-sided carrying case and a method
of manufacture thereof. The carrying case is made from
moisture-impermeable, flexible, stretchable material, particularly
adapted for outdoor use. A main body of the bag is secured by
dielectric welding with a pair of drop-shaped end panels to form
the carrying case. The main body, being cut on a bias, allows
stretching of narrow ends of the main body to substantially conform
to the drop-shaped end panels and form a wrinkle-free
attachment.
Inventors: |
Revels, Eric; (Leicester,
NC) ; Diaz, James; (Asheville, NC) |
Correspondence
Address: |
THOMAS S. KEATY
KEATY PROFESSIONAL LAW CORP.
2140 WORLD TRADE CENTER
NO. 2 CANAL STREET
NEW ORLEANS
LA
70130
US
|
Family ID: |
22459365 |
Appl. No.: |
09/920111 |
Filed: |
August 2, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09920111 |
Aug 2, 2001 |
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09133591 |
Aug 13, 1998 |
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Current U.S.
Class: |
383/6 ; 383/113;
383/116; 383/118; 383/13; 383/35; 383/63; 383/89; 383/907 |
Current CPC
Class: |
A45C 11/22 20130101;
A45C 13/1023 20130101; B29K 2313/00 20130101; A45C 13/1076
20130101; Y10S 383/907 20130101; Y10S 206/811 20130101; A45C 3/001
20130101; A45C 3/10 20130101; B29C 65/04 20130101; B29K 2075/00
20130101; B29L 2031/742 20130101 |
Class at
Publication: |
383/6 ; 383/118;
383/113; 383/116; 383/907; 383/13; 383/63; 383/35; 383/89 |
International
Class: |
B65D 033/10; B65D
030/08; B65D 030/02 |
Claims
We claim:
1. A method of manufacturing a soft-sided carrying case, comprising
the steps of: forming a main body from a piece of material cut on a
bias, said main body having narrow ends and elongated sides;
forming a pair of drop-shaped end panels; securing at least one
handle to the main body by dielectric welding, thereby fusing said
at least one handle to the main body; securing a first end panel to
a first narrow end of the main body by stretching the first narrow
end to generally conform to the size and shape of the first end
panel and by performing a dielectric welding of the first end panel
with the main body; securing a second end panel to a second narrow
end of the main body by stretching the second narrow end to
generally conform to the size and shape of the second end panel and
by performing a dielectric welding of the second end panel to the
main body; and securing a closure member between elongated sides of
the main body by dielectric welding.
2. The method of claim 1, wherein said closure member has a
zip-lock closing elements along substantially entire length
thereof.
3. The method of claim 1, wherein said dielectric welding is
conducted for a period of 2-4 seconds.
4. The method of claim 1, wherein each end of said at least one
handle carries an attachment member to facilitate securing of said
at least one handle to the main body.
5. The method of claim 1, wherein said main body and said end
panels are made of a flexible, stretchable moisture-impermeable
material.
6. The method of claim 1, wherein said material contains embossed
polyurethane.
7. The method of claim 1, further comprising a step of securing an
end sleeve over at least a portion of said main body and said
closure member by dielectric welding, and wherein said end sleeve
is provided with a reservoir for retaining melted material created
during attachment of said end sleeve to said main body.
8. A soft-sided carrying case, comprising: a main body; a pair of
end panels securely attached to opposite ends of the main body,
each of said end panels having a drop-shaped configuration; and at
least one carrying handle securely attached to said main body.
9. The device of claim 8, wherein said main body and said end
panels are formed from a flexible, stretchable,
moisture-impermeable material.
10. The device of claim 9, wherein said material contains embossed
polyurethane.
11. The device of claim 8, wherein said end panels are attached to
said main body in a substantially seamless, wrinkle-free
manner.
12. The device of claim 11, wherein said end panels are secured to
main body by dielectric welding.
13. The device of claim 8, further comprising a closure member
secured along substantially entire length of the main body.
14. The device of claim 13, wherein said closure member is provided
with zip-lock closing elements.
15. The device of claim 13, further comprising a pair of end
sleeves secured adjacent opposite ends of said main body and said
closure member by dielectric welding, said end sleeve being
provided with a reservoir for receiving melted material created
during attachment of said end sleeve.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a carrying case and a
method of manufacturing thereof, and more particularly to a bag and
method of manufacturing soft-sided bags particularly adapted for
outdoor activities.
[0002] People engaged in outdoor activities usually carry a number
of items, such as food supplies, ammunition for hunting guns, and
other similar items that need to be protected from moisture. Under
such conditions, provision of a moisture-impermeable carrying case
or container becomes essential.
[0003] Conventional carrying cases or containers are not, as a
general rule, completely watertight. Moisture can seep through the
line of closure, through zippers, openings under the zippers and
cause deterioration of the contents of the carrying case. Even bags
or carrying cases constructed from water repellent material suffer
from imperfections in construction, as they do not allow creation
of truly a watertight enclosure.
[0004] The present invention contemplates elimination of drawbacks
associated with the prior art and provision of a carrying case and
a method of manufacturing a moisture-impermeable bag that can serve
as a container for moisture-sensitive items.
SUMMARY OF THE INVENTION
[0005] It is, therefore, an object of the present invention to
provide a bag and a method of manufacturing a moisture-impermeable
carrying case.
[0006] It is another object of the present invention to provide a
carrying case and a method of making same, such the bag is
moisture-impermeable.
[0007] It is a further object of the present invention to provide a
bag and a method of manufacturing a moisture-impermeable carrying
case with a flexible body.
[0008] These and other objects of the present invention are
achieved through a provision of a bag and a method for
manufacturing soft-sided moisture-proof carrying case. The method
comprises the steps of forming a main body having opposite narrow
ends and elongated sides. The main body is made from material cut
on a bias.
[0009] A pair of end panels, having a generally drop-shaped
configuration are cut from the same material. Each end panel is
attached to a respective narrow end of the main body by dielectric
welding. To avoid wrinkles in the finished product, the narrow ends
of the main body are stretched to confirm to the size and shape of
the end panel.
[0010] The soft-sided bag can be manufactured with one or more
handles, each carrying securing buckles, if desired. A zip-lock
closure member is secured by dielectric welding to the open end of
the bag after the end panels have been secured. The closure member
can be made from extruded plastic material and provided with
pull-out tabs to facilitate opening of the bag.
[0011] To prevent tearing of the closure adjacent its line of
attachment to the main body, an end sleeve is secured to the main
body and to the closure member, slightly overlapping the closure
member and the main body. The end sleeve is provided with a
reservoir to accommodate melted material, which is created when the
closure element is exposed to radio frequency, or dielectric
welding.
[0012] The soft-sided carrying case manufactured in accordance with
the method of the present invention can be made in the shape of a
duffel bag, a gun carrying case, or any other desired shape. By
using double-coated embossed polyurethane for the main body and the
end panels, as well as zip-lock closure member, a
moisture-impermeable body is created. The main body is coated with
#420 denier nylon for better appearance and variations in color and
texture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Reference will now be made to the drawings, wherein like
parts are designated by like numerals, and wherein
[0014] FIG. 1 is a perspective view of the bag manufactured in
accordance with the present invention.
[0015] FIG. 2 is a top view of the bag main body, before
welding.
[0016] FIG. 3 is a top view of a bag end panel.
[0017] FIG. 3 is a second end piece for use in the bag manufactured
in accordance with the present invention.
[0018] FIG. 4 is a side view of a closure member.
[0019] FIG. 5 is a detail cross-sectional view of the closure
member taken along line 5-5 of FIG. 4.
[0020] FIG. 6 is a perspective detail view of an end sleeve and the
corner of the bag, wherein the sleeve is positioned.
[0021] FIG. 7 is a perspective detail view of the end sleeve
secured on the main body.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Turning now to the drawings in more detail, reference will
now be made to the drawings, presented for illustrative purposes
only, wherein numeral 10 designates the bag manufactured according
to the method of the present invention. The main body of the bag 11
is made from a moisture-impermeable material, for example, double
coated embossed polyurethane, with a base layer of #420 denier
nylon. Of course, other materials can be used to manufacture bags
of the present invention, as long as the materials are similar in
physical and chemical characteristics to polyurethane.
[0023] The main body 11 is provided with four corner tabs 12, which
are used for stretching the main body 11 over a weld form, as will
be explained in more detail hereinafter. The main body 11 is cut
from a sheet of polyurethane material, cut on a bias of
approximately 45 degrees. By cutting the material on a bias,
certain stretching and "giving" of the material is achieved, which
facilitates wrinkle-free attachment of the end panels to the main
body 10.
[0024] FIG. 3 illustrates the drop-shaped end panels 14 and 16 that
are attached to the main body 11 during making of the bag 10. The
end panels 14 and 16 comprise a rounded portion 14a and 16a, as
well as an elongated extended portions 14b and 16b.
[0025] FIG. 1 illustrates a first handle 20 secured on the main
body 11. The handle 20 is made from a narrow strip of a strong,
tear-resistant fabric that can be folded in two, if necessary, and
stitched together to provide further thickness and strength to the
handle 20. The main body of the handle is secured to attachment
elements 22, which are made from scraps of the same material as the
main body 11. The ends of the handle 20 carry female buckle
elements 24 secured to the handle 20 in a conventional manner.
[0026] Although not shown in the drawings, a second carrying
handle, made from the same material as the handle 20 is attached,
at the opposite side of the main body 11, in a mirror-image
position to the handle 20. Each end of the second handle carries a
male end of a buckle. The buckle elements of the second handle are
sized and shaped to engage with the female buckle elements 24 of
the handle 20 to facilitate carrying of the bag.
[0027] FIGS. 4 and 5 illustrate a zip-lock closure member 30. The
zip-lock closure member comprises a first portion 32 and a second
portion 34. The first portion 32 is provided with a pair of
elongated ribs 36 and 38 extending in a parallel relationship along
the length of the portion 32. The second portion 34 is provided
with three parallel ribs 40, 42 and 44, spaced from each other and
defining engagement channels 46 and 48 for receiving the ribs 36
and 38 therein when the lock is closed. The closure member 30 has a
length substantially equal to or smaller than the length of the
main body 11.
[0028] A pair of pull out tabs 50 is provided on each portion 32
and 34 for grasping by a user to pull the two portions of the
closure elements apart and allow the user to gain access to the
interior of the bag 10, once it is constructed.
[0029] To prevent tearing of the closure member 30 during repeated
opening of the bag 10, an end sleeve 52 is provided for attachment
to the bag main body 11 and the closure member 30 about the line of
attachment between these two structural members. The sleeve 52
comprises a folded piece of material stitched adjacent one end, as
at 54 (see FIGS. 6 and 7) and open at the opposite end 56. During
manufacture, the end sleeve 52 is positioned over a corner 60 and
the closure element 30 adjacent its end (see FIG. 6). A similar end
sleeve 62 is secured on the opposite end of the bag 10 (see FIG.
1).
[0030] If desired, the end sleeves 52 and 62 can carry a male
element 58 and 64, respectively, of a buckle for engagement with
female buckle elements 66 (only one is shown in FIG. 1), which are
fixedly attached to the end panels 14 and 16.
[0031] In the manufacturing process of the present invention, the
elements are secured together with the use of radio frequency in a
process conventionally identified as RF, or dielectric welding.
This method is used for joining polymers that have strong dipoles,
including polyurethane. During dielectric welding method, a high
intensity alternating electromagnetic field is applied to the
dipoles. As the dipoles alternate with the changing field polarity,
some of the field energy is converted into heat creating a weld
seam between the two items. The weld times usually range from 1-6
seconds, depending on the material, thickness of the material, as
well as the area being welded.
[0032] The apparatus for performing dielectric welding is available
on the market, from, for example, Hall Dielectric Machinery Co.,
Inc. of Rock Hill, S.C. The instrumentation uses microprocessors to
insure the necessary control during the weld cycle and wrinkle-free
welding. The RF frequency generating machines can generate
frequency in the range of 27.120 MHz.+-.0.06%. The instrumentation
produces under 1 MW/sq. cm. of magnetic and electric radiation.
[0033] Turning now to the process of making the bag 10, the main
body 11 is cut on a bias, and four corner tabs 12 are made in the
body 11. Then, end panels 14 and 16 are either cut or stamped out
of the remainder of material, after the main body 11 has been cut.
The attachment members 15, 22 and end sleeves 52, 62 are cut from
scraps remaining g after the end panels 14 and 16 have been cut
out.
[0034] The process continues with the attachment of the handles 20
and 26 to the main body 10. The handles, having secured thereon the
buckles 24 are secured to the attachment members 22. One of the
handles is then positioned adjacent a first narrow end 70 on the
main body 11, so that the underside of the attachment piece 22 lies
flat against the outer surface of the main body 11.
[0035] The position of the handle 20 and the attachment members 22
may be temporarily secured by removable conductor members formed
from a material suitable for conducting radio waves therethrough.
The body 11 with the handle 20 positioned at a predetermined
location thereon is exposed to radio frequency waves for 2-4
seconds, allowing a cool down time of 1-2 seconds after the welding
has been completed.
[0036] Once exposed to the radio frequency waves, the attachment
members 22 become welded to the main body 11 in a secure, seamless
manner. The same procedure is completed for the second handle,
which is positioned adjacent a second narrow end 72 of the main
body 11, in a mirror-image position to the handle 20. Of course,
simultaneous positioning of both handles and exposure of the
attachment members 22 to radio frequency waves can be accomplished,
if desired.
[0037] The process continues with the securing of the female
portions of buckles 66 to the end panels 14 and 16. The attachment
members 15 are positioned with their inner surfaces contacting the
outer surfaces of the end panels, in the central portions 14a and
16a. A RF-conductive conductive member is then positioned on top of
the attachment elements 15, and the end panels 14 and 16 are
exposed to radio frequency waves. The welding process continues for
2-4 seconds after which time the attachment members 15 become
fused, or welded to the end pieces 14 and 16, thereby fixedly
securing the buckle portions 15 on the end panels.
[0038] The process continues with attachment of the end panels 14
and 16 to the main body 11. First, the body 11 is secured on a
vertically oriented RF-conductive stand (not shown), while the
material of the main body 11 is stretched to conform to the stand
configuration. The narrow end 70 or 72, while being stretched,
approximates the size and shape of the end panel 14 or 16.
[0039] The tabs 12 are secured on the stand with a clamp,
preventing shifting of the main body 11 during welding. The end
piece 14 is then laid over the stand, covering at least a portion
of the main body 11. An RF-conductive member is then positioned
over the end piece 14, and the main body 11 with the end piece 14
is then exposed to RF waves for a predetermined period of time of
about 2-4 seconds, followed by a cool-down time of about 1-2
seconds. During this step, the end piece 14 becomes permanently
attached, in effect fused to the main body 11.
[0040] The same process is repeated for the second end panel, which
is secured to the opposite narrow end 72 of the main body 10. The
ends of the bag are formed as drop-shaped portions, which is
different from conventional round end portions typically found in a
duffel bag. The tabs 12 are then trimmed off, so as to present a
neat overall appearance of the end portions of the bag 10.
[0041] The next step in the process is the attachment of the
zip-lock closure member 30 to the bag body 11. For this purpose,
the elongated sides 74 and 76 of the main body 11 are brought
together, with one side 74 contacting one portion 32 of the closure
30, with the opposite elongated side 76 contacting the opposite
portion 34 of the closure member 30. An elongated RF-conductive
platen is then removably positioned between the closure portions 32
and 34. An additional RF-conductive platen is positioned under the
main body 11 and a third RF-conductive platen is positioned over
the four-layered fold.
[0042] This fold is then exposed to RF waves for a predetermined
period of time, 4-6 seconds. The longer exposure is necessary to
insure fusion or welding of the closure member 30 to the main body
11. During testing, it was observed that some of the material of
the closure member 30 melts and tends to form an unsightly drop of
molten plastic. To prevent such an undesirable effect, the present
invention provides for a small reservoir 80 formed in each end
sleeve 52 and 62 (see FIGS. 4 and 7). The reservoirs 80 are formed
in the interior of the sleeves 52 and 62 and are large enough to
accommodate the melted plastic from the closure member 30.
[0043] The bag manufactured in accordance with the present
invention is flexible, somewhat stretchable, watertight and allows
to retain a number of moisture-sensitive objects therein. It can be
easily carried to a desired location by the flexible handles,
transporting the supplies and/or sport ammunition to an outdoor
location. Of course, other shapes can be used for the manufacture
of the carrying case of the present invention. For example, a
gun-carrying case can be made according to the same method and
using drop-shaped end panels. The method of manufacturing the
soft-sided bag, or carrying case takes advantage of the radio
frequency, or dielectric welding for the production of a seamless,
wrinkle-free bag.
[0044] The types of materials used in the method of the present
invention for the manufacturing of the bag can vary, depending on
the particular purpose of the bag. The plastic material,
double-coated embossed polyurethane is readily available on the
market from, for example, URETEK, Inc. of New Haven, Conn. One of
the tested materials had a polyether polyurethane coating of 4
oz./sq. yd. The fabric layer was #420 denier nylon, 50.times.40
threads/inch. The weight of the fabric was 8 oz./sq. yd. The
material tested with the method of the present invention has a
tensile strength warp 400 lbs., fill 300 lbs., puncture resistance
-80 lbs. The zip-lock closure member 30 made from extruded plastic
is likewise readily available on the market in a roll form,
allowing to cut the required length for manufacturing of a
designated size of a bag. The buckles can be conventional slide
release buckles with D-rings; they are readily available from a
number of manufacturers.
[0045] Depending on the desired size of the resultant product, the
dimensions of the main body 11 and the end panels 14 and 16 would
differ, as well as the length of the handles and of the closure
member 30.
[0046] Many changes and modifications can be made in the design and
method of the present invention without departing from the spirit
thereof. We, therefore, pray that our rights to the present
invention be limited only by the scope of the appended claims.
* * * * *