U.S. patent application number 14/399210 was filed with the patent office on 2015-04-30 for soft sided luggage frame.
The applicant listed for this patent is Travelpro International, Inc.. Invention is credited to David L. Mathieu, Joseph Paul.
Application Number | 20150114776 14/399210 |
Document ID | / |
Family ID | 49551125 |
Filed Date | 2015-04-30 |
United States Patent
Application |
20150114776 |
Kind Code |
A1 |
Mathieu; David L. ; et
al. |
April 30, 2015 |
SOFT SIDED LUGGAGE FRAME
Abstract
Accordingly an aspect of the present invention provides a frame
structure for a soft sided luggage case comprising a frame that can
be thermoformed from a single piece of thermoplastic material and
folded into a final form to provide structure for a soft sided
luggage case. Conveniently, combinations of a base and at least one
side portions of the bag can hingeably connected with living hinges
to provide easy and fast assembly while permitting more efficient
stacking for packing and shipping. In accordance with another
aspect of the invention, there is provided a frame for a soft sided
luggage case. The frame includes a base portion having a
perimeter.
Inventors: |
Mathieu; David L.;
(Colchester, CT) ; Paul; Joseph; (Thomaston,
CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Travelpro International, Inc. |
Boca Raton |
FL |
US |
|
|
Family ID: |
49551125 |
Appl. No.: |
14/399210 |
Filed: |
March 14, 2013 |
PCT Filed: |
March 14, 2013 |
PCT NO: |
PCT/US13/31199 |
371 Date: |
November 6, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61645368 |
May 10, 2012 |
|
|
|
Current U.S.
Class: |
190/127 |
Current CPC
Class: |
A45C 5/02 20130101; A45C
5/03 20130101; A45C 7/0054 20130101; A45C 2007/0004 20130101; A45C
7/0036 20130101; A45C 13/04 20130101 |
Class at
Publication: |
190/127 |
International
Class: |
A45C 13/04 20060101
A45C013/04; A45C 5/03 20060101 A45C005/03 |
Claims
1. A frame for a soft sided luggage case comprising: a base portion
having a perimeter; and a side portion connected to the perimeter
of the base portion, wherein the base portion and the side portion
are formed from a single piece of material, and wherein the side
portion is movable from a first position to a second position
supporting a wall of the luggage case.
2. The frame of claim 1, wherein the side portion is connected to
the base portion with a hinge.
3. The frame of claim 2, wherein the hinge is a living hinge.
4. The frame of claim 1, wherein the single piece of material
comprises thermoplastic.
5. The frame of claim 4, wherein the single piece of material
includes apertures for weight reduction of the luggage case.
6. The frame of claim 1, further comprising bracing disposed at
least one of the base portion or the side portion, the bracing for
providing additional support.
7. The frame of claim 6, wherein the bracing is formed from the
single piece of material.
8. The frame of claim 1, wherein the side portion includes a flare
for stretching the fabric.
9. The frame of claim 1, further comprising a second side portion
connected to the perimeter of the base portion, the second side
portion movable from a first position to a second position.
10. The frame of claim 9, wherein the first side portion is
configured to support the wall of the luggage case and the second
side portion is configured to support a second wall of the luggage
case.
11. The frame of claim 10, wherein the first side portion includes
a first L-shaped edge and the second side portion includes a second
L-shaped edge, the first L-shaped edge configured to cooperate with
the second L-shaped edge when the first side portion is in the
second position and the second side portion is in the second
position.
12. A frame for a soft sided luggage case comprising: a base
portion having a perimeter; and a side portion connected to the
perimeter of the base portion, wherein the base portion and the
side portion are integrally formed.
13. The frame of claim 12, wherein the base portion and the side
portion are formed using a thermoforming process.
14. The frame of claim 13, wherein the side portion is connected to
the base portion with a hinge.
15. The frame of claim 14, wherein the hinge is a living hinge.
16. The frame of claim 12, further comprising bracing disposed at
least one of the base portion or the side portion, the bracing for
providing additional support.
17. The frame of claim 16, wherein the bracing is formed from the
single piece of material.
18. The frame of claim 17, wherein the single piece of material
includes apertures for weight reduction of the luggage case.
19. The frame of claim 12, wherein the side portion includes a
flare for stretching the fabric.
20. The frame of claim 12, further comprising a second side portion
connected to the perimeter of the base portion, the second side
portion movable from a first position to a second position.
21. The frame of claim 12, wherein the first side portion is
configured to support the wall of the luggage case and the second
side portion is configured to support a second wall of the luggage
case.
22. The frame of claim 21, wherein the first side portion includes
a first L-shaped edge and the second side portion includes a second
L-shaped edge, the first L-shaped edge configured to cooperate with
the second L-shaped edge when the first side portion is in the
second position and the second side portion is in the second
position.
23. A luggage case comprising: a base; a frame connected to the
base, the frame having a base portion and a side portion connected
to the base portion, wherein the base portion and the side portion
are formed using a thermoforming process; and a soft covering
disposed over the frame.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to soft sided luggage, and
particularly to frames that can be formed from generally flat,
unitary materials and folded to quickly and easily define an
interior volume and provide a stable structure for soft sided
luggage.
BACKGROUND
[0002] Hard sided luggage cases have existed for many years, but
they tend to be heavy, and can dent or crack if dealt a hard blow.
As a result, soft sided luggage cases have become more popular over
recent years because they offer good durability, reasonable
protection, and often have expandable packing chambers. They
typically come with wheels and pull straps and because of their
reduced weight relative to hard luggage cases, they usually glide
successfully through airports and on hotel carpets.
[0003] While soft sided luggage has numerous advantages compared to
hard sided luggage, in order for the contents of the luggage to be
protected, and to ensure that the luggage does not excessively
deform when lifted or transported, it is advantageous to
incorporate a frame inside the soft sided luggage. The frame acts
to support the sides of the luggage in both a loaded and unloaded
state.
[0004] Various approaches have been taken to constructing frames,
but they involve relatively complex designs incorporating numerous
components. This increases manufacturing complexity and costs for
materials (design, manufacture and handling) and the labor required
to assemble and install the frame. Alternate designs that employ
rigid box structures as a frame are inflexible, necessitate strict
production tolerances on fabric shells, and are expensive to store
and ship due to their fixed volume.
SUMMARY OF THE DISCLOSURE
[0005] Accordingly an aspect of the present disclosure provides a
frame structure for a soft sided luggage case comprising a frame
that can be thermoformed from a single piece of thermoplastic
material and folded into a final form to provide structure for a
soft sided luggage case.
[0006] Conveniently, combinations of a base and at least one side
portions of the bag can hingeably connected with living hinges to
provide easy and fast assemble while permitting more efficient
stacking for packing and shipping.
[0007] In accordance with another aspect of the disclosure, there
is provided a frame for a soft sided luggage case. The frame
includes a base portion having a perimeter. The frame further
includes a side portion connected to the perimeter of the base
portion. The base portion and the side portion are formed from a
single piece of material. The side portion is movable from a first
position to a second position supporting a wall of the luggage
case.
[0008] The side portion may be connected to the base portion with a
hinge.
[0009] The hinge may be a living hinge.
[0010] The single piece of material may be a thermoplastic.
[0011] The single piece of material may include apertures for
weight reduction of the luggage case.
[0012] The frame may further include bracing disposed at least one
of the base portion or the side portion. The bracing may be for
providing additional support.
[0013] The bracing may be formed from the single piece of
material.
[0014] The side portion may include a flare for stretching the
fabric.
[0015] The frame may further include a second side portion
connected to the perimeter of the base portion. The second side
portion may be movable from a first position to a second
position.
[0016] The first side portion may be configured to support the wall
of the luggage case. The second side portion may also be configured
to support a second wall of the luggage case.
[0017] The first side portion may include a first L-shaped edge and
the second side portion may include a second L-shaped edge. The
first L-shaped edge may be configured to cooperate with the second
L-shaped edge when the first side portion is in the second position
and the second side portion is in the second position.
[0018] In accordance with another aspect of the disclosure, there
is provided a frame for a soft sided luggage case. The frame
includes a base portion having a perimeter. The frame further
includes a side portion connected to the perimeter of the base
portion. The base portion and the side portion are integrally
formed.
[0019] The base portion and the side portion may be formed using a
thermoforming process.
[0020] The side portion may be connected to the base portion with a
hinge.
[0021] The hinge may be a living hinge.
[0022] The frame may further include bracing disposed at least one
of the base portion or the side portion. The bracing may be for
providing additional support.
[0023] The bracing may be formed from the single piece of
material.
[0024] The single piece of material may include apertures for
weight reduction of the luggage case.
[0025] The side portion may include a flare for stretching the
fabric.
[0026] The frame may further include a second side portion
connected to the perimeter of the base portion. The second side
portion may be movable from a first position to a second
position.
[0027] The first side portion may be configured to support the wall
of the luggage case and the second side portion may be configured
to support a second wall of the luggage case.
[0028] The first side portion may include a first L-shaped edge and
the second side portion may include a second L-shaped edge. The
first L-shaped edge may be configured to cooperate with the second
L-shaped edge when the first side portion is in the second position
and the second side portion is in the second position.
[0029] In accordance with another aspect of the disclosure, there
is provided a luggage case. The luggage case includes a base. The
luggage case further includes a frame connected to the base. The
frame has a base portion and a side portion connected to the base
portion. The base portion and the side portion are formed using a
thermoforming process. The luggage case also includes a soft
covering disposed over the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Luggage and luggage frames are illustrated in the figures of
the accompanying drawings, which are meant to be illustrative and
not limiting, and in which like references are intended to refer to
like or corresponding parts, and in which:
[0031] FIG. 1 is a perspective view of an illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0032] FIG. 2 is a front elevation view of the illustrative frame
shown in FIG. 1 in an unfolded state.
[0033] FIG. 3 is a plan view of the illustrative frame shown in
FIG. 1 in an unfolded state.
[0034] FIG. 4 a side elevation view of the illustrative frame shown
in FIG. 1 in an unfolded state.
[0035] FIG. 5 is a perspective view of the illustrative frame shown
in FIG. 1 showing one side portion in a folded state.
[0036] FIG. 6 is a perspective view of the illustrative frame shown
in FIG. 1 showing two side portions in a folded state.
[0037] FIG. 7 is a front elevation view of the illustrative frame
shown in FIG. 1 in a folded state.
[0038] FIG. 8 is a side elevation view of the illustrative frame
shown in FIG. 1 in a folded state.
[0039] FIG. 9 is a plan view of the illustrative frame shown in
FIG. 1 in a folded state.
[0040] FIG. 10 is a front perspective view of the illustrative
frame shown in FIG. 1 showing a base portion and three side
portions in a folded state.
[0041] FIG. 11 is a rear perspective view of the illustrative frame
shown in FIG. 1 showing a base portion and three side portions in a
folded state.
[0042] FIG. 12 is a perspective view of the illustrative frame
shown in FIG. 1 showing a base portion and three side portions in a
folded state, a base, and a plurality of wheel assemblies.
[0043] FIG. 13 is an exploded perspective view of the illustrative
frame shown in FIG. 1 showing a base portion and three side
portions in a folded state, a base, and a plurality of wheel
assemblies.
[0044] FIG. 14 is a front elevation view of the illustrative frame
shown in FIG. 1 showing a base portion and three side portions in a
folded state, a base, and a plurality of wheel assemblies.
[0045] FIG. 15 is a side elevation view of the illustrative frame
shown in FIG. 1 showing a base portion and three side portions in a
folded state, a base, and a plurality of wheel assemblies.
[0046] FIG. 16 is a plan view of the illustrative frame shown in
FIG. 1 showing a base portion and three side portions in a folded
state, a base, and a plurality of wheel assemblies.
[0047] FIG. 17 is a partial perspective view of the illustrative
frame shown in FIG. 1 showing a base portion, one side portion in a
folded state, a base, and a plurality of wheel assemblies.
[0048] FIG. 18 is a partial plan view of a living hinge of the
illustrative frame shown in FIG. 1.
[0049] FIG. 19 is a partial perspective view of the illustrative
frame shown in FIG. 1 showing a base portion and two side portions
in a folded state, and an L-beam flange connecting one side portion
with the second side portion.
[0050] FIG. 20 is a front perspective view of the illustrative
frame shown in FIG. 1 showing a base portion and three side
portions in a folded state, a base, and a plurality of wheel
assemblies, and a partial view of a soft cover connected to the
frame.
[0051] FIG. 21 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0052] FIG. 22 is a right side view of the frame in accordance with
the embodiment of FIG. 21.
[0053] FIG. 23 is a front view of the frame in accordance with the
embodiment of FIG. 21.
[0054] FIG. 24 is a left side view of the frame in accordance with
the embodiment of FIG. 21.
[0055] FIG. 25 is a rear view of the frame in accordance with the
embodiment of FIG. 21.
[0056] FIG. 26 is a top view of the frame in accordance with the
embodiment of FIG. 21.
[0057] FIG. 27 is a bottom view of the frame in accordance with the
embodiment of FIG. 21.
[0058] FIG. 28 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0059] FIG. 29 is a right side view of the frame in accordance with
the embodiment of FIG. 28.
[0060] FIG. 30 is a front view of the frame in accordance with the
embodiment of FIG. 28.
[0061] FIG. 31 is a left side view of the frame in accordance with
the embodiment of FIG. 28.
[0062] FIG. 32 is a rear view of the frame in accordance with the
embodiment of FIG. 28.
[0063] FIG. 33 is a top view of the frame in accordance with the
embodiment of FIG. 28.
[0064] FIG. 34 is a bottom view of the frame in accordance with the
embodiment of FIG. 28.
[0065] FIG. 35 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0066] FIG. 36 is a right side view of the frame in accordance with
the embodiment of FIG. 35.
[0067] FIG. 37 is a front view of the frame in accordance with the
embodiment of FIG. 35.
[0068] FIG. 38 is a left side view of the frame in accordance with
the embodiment of FIG. 35.
[0069] FIG. 39 is a rear view of the frame in accordance with the
embodiment of FIG. 35.
[0070] FIG. 40 is a top view of the frame in accordance with the
embodiment of FIG. 35.
[0071] FIG. 41 is a bottom view of the frame in accordance with the
embodiment of FIG. 35.
[0072] FIG. 42 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0073] FIG. 43 is a right side view of the frame in accordance with
the embodiment of FIG. 42.
[0074] FIG. 44 is a front view of the frame in accordance with the
embodiment of FIG. 42.
[0075] FIG. 45 is a left side view of the frame in accordance with
the embodiment of FIG. 42.
[0076] FIG. 46 is a rear view of the frame in accordance with the
embodiment of FIG. 42.
[0077] FIG. 47 is a top view of the frame in accordance with the
embodiment of FIG. 42.
[0078] FIG. 48 is a bottom view of the frame in accordance with the
embodiment of FIG. 42.
[0079] FIG. 49 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0080] FIG. 50 is a right side view of the frame in accordance with
the embodiment of FIG. 49.
[0081] FIG. 51 is a front view of the frame in accordance with the
embodiment of FIG. 49.
[0082] FIG. 52 is a left side view of the frame in accordance with
the embodiment of FIG. 49.
[0083] FIG. 53 is a rear view of the frame in accordance with the
embodiment of FIG. 49.
[0084] FIG. 54 is a top view of the frame in accordance with the
embodiment of FIG. 49.
[0085] FIG. 55 is a bottom view of the frame in accordance with the
embodiment of FIG. 49.
[0086] FIG. 56 is a perspective view of another illustrative frame
showing a base portion and three side portions in an unfolded
state.
[0087] FIG. 57 is a right side view of the frame in accordance with
the embodiment of FIG. 56.
[0088] FIG. 58 is a front view of the frame in accordance with the
embodiment of FIG. 56.
[0089] FIG. 59 is a left side view of the frame in accordance with
the embodiment of FIG. 56.
[0090] FIG. 60 is a rear view of the frame in accordance with the
embodiment of FIG. 56.
[0091] FIG. 61 is a top view of the frame in accordance with the
embodiment of FIG. 56.
[0092] FIG. 62 is a bottom view of the frame in accordance with the
embodiment of FIG. 56.
DETAILED DESCRIPTION
[0093] In describing the components of the frame and alternative
versions, or embodiments, of some of these components, the same
reference number can be used for elements that are the same as, or
similar to, elements described in other versions or
embodiments.
[0094] Referring now to FIGS. 1 to 4, a non-limiting example of a
frame according to the present disclosure is illustrated generally
at 10. The frame 10 comprises a first portion 12 (also referred to
as a base portion), at least one second portion (also referred to
as a side portion). In the illustrated embodiment, three second
portions (also referred to as flap portions) 14a-c are shown.
(Collectively, side portion 14, and generically, side portion 14.
This nomenclature is used elsewhere herein.) In some embodiments,
the luggage case can include more or less than three side portions
14. In the illustrative embodiment, the base portion 12 is
illustrated as what can be described conventionally as the "back"
of the luggage case, but it will be understood that the orientation
of the base portion 12 in this manner is to aid the reader's
understanding of the embodiments of the present disclosure, and not
intended to be a limitation. Accordingly, the base portion 12 can
be oriented towards one or more of any facet of the luggage case,
including those conventionally described as "top", "bottom" or
"side". It will also be appreciated that the shapes of the base
portion 12 and side portions 14 can be chosen to accommodate the
desired design of the luggage case.
[0095] The base portion 12 or side portions 14 can be solid or they
can contain apertures 30 that can be incorporated to reduce
material and weight of the frame 10 without significantly reducing
or sacrificing structural integrity. The base portion 12 and side
portions 14 can also be formed to include additional structural
features such as tube mounts 40 configured to accept typical down
tubes for extendable handles, tube protectors 42, an extendable
handle mount receptacle 44, fixed handle mounts 46, or various
forms of bracing 48 as illustrated in FIGS. 1 to 4. It is to be
appreciated, with the benefit of this description, that the
additional structural features are optional and that in other
embodiments, the frame 10 can be modified to include various
combinations of the additional features or omit these additional
features. The base portion 12 and side portions 14 can be
substantially planar, as illustrated by the side portions 14a and
14b in FIG. 1, or can be curved or contoured to achieve the desired
shape as illustrated by the side portion 14c in the same
figure.
[0096] The base portion 12 has a perimeter 20 to which the at least
one side portion 14 is hingeably affixed. The manner by which the
base portion 12 and the at least one side portion 14 are hingeably
affixed is not particularly limited. For example, the hinge
construction can involve using a living hinge. As another example,
the hinge construction can also include a barrel hinge.
[0097] Furthermore, although the present embodiment includes a
unitary frame, variations are contemplated. For example, in other
embodiments, the frame can be modified to be formed from separate
base and side portions. It is to be appreciated that when the side
portions are separate pieces, the side portions 14 can be connected
fixedly or hingeably to the base portion 12 upon assembly of the
luggage case. It is to be appreciated, with the benefit of this
description, that fixedly attaching the side portion 14 to the base
portion 12 provides further rigidity for the luggage case.
Alternatively, hingeably affixing the side portion 14 to the base
portion 12 can provide greater flexibility for both the assembled
case and the assembly process.
[0098] As illustrated in FIGS. 1 to 4, there are three side
portions 14a-c connected to the perimeter 20 of the base portion
12. In the present embodiment, the at least one side portion 14 is
hingeably affixed to the base portion 12, by living hinges 22, but
those skilled in the art will recognize that the side portions 14
can be rearranged, attached or connected by other mounting
methods.
[0099] Referring now to FIGS. 5 and 6, there is shown the frame 10
in varying states of assembly, showing one and then a second of the
illustrated three side portions 14 moved about their hinged
attachment to the perimeter 20 of the base portion 12 (ie. the
living hinges 22). FIG. 5 illustrates one side portion 14a in a
first position with respect to the base portion 12, and a side
portion 14b in a second position with respect to the base portion
12. FIG. 6 illustrates two side portions 14a and 14b in a second
position with respect to the base portion 12.
[0100] It is to be appreciated, with the benefit of this
description, that forming the frame 10 as a generally flat article,
as shown in FIGS. 1 to 4, allows easier stacking and shipping. This
reduces expense because the luggage structure and its volume is
created during final assembly by the rotation of the at least one
side portion 14 of the frame 10. When the frame 10 is assembled, it
forms a stable structure to support a soft sided luggage case.
[0101] Referring now to FIGS. 7 to 11 there is illustrated a frame
10 in accordance with the present disclosure in which the three
illustrated side portions 14a-c are in a second position. When the
three side portions 14 are so oriented, they engage with each other
to form a secure structure. In the illustrated embodiment, the side
portion 14c is hingeably affixed to the base portion 12, and is
rotated to engage with the side portions 14a and 14b. Referring to
FIG. 10, when the base portion 12 and side portions 14 are oriented
in this manner, a volume is defined, which can be utilized as the
cargo compartment of the luggage case.
[0102] FIGS. 12 to 16 illustrate a frame 10 in accordance with the
present disclosure in association with other components of a
typical wheeled soft sided luggage case. In particular, there is
shown a base 50 including a plurality of wheel assemblies 60, and
an extendable handle mount 70 that mates with the extendable handle
mount receptacle 44. It is to be re-emphasized that the base 50 is
not particularly limited and can include a wide variety of other
bases or can be omitted altogether in some embodiments. For
example, the frame 10 can be modified to have a fourth side portion
such that the base 50 would no longer be necessary. In addition,
the features of the base 50 such as the wheel assemblies 60 and the
extendible handle mount 70 can be modified or omitted in some
embodiments.
[0103] Referring to FIG. 17, there shown a detail of the connection
between the base 50 and the frame 10. In one illustrative
embodiment of the disclosure, the frame 10 is formed with tabs 80
for fixably engaging with the base 50. In the illustrative
embodiment, these tabs 80 are arranged on the perimeters of the
base portion 12, and two of the side portions 14 to mateably engage
with the base 50. It will be appreciated by those skilled in the
art that there are many methods for creating a secure engagement
between these elements, including but not limited to glue,
fasteners, clips or pins. In another embodiment, the base 50 can be
formed as an integral portion of the frame 10 and connected to the
base portion 12 along a portion of its perimeter 20 similar to the
side portions 14.
[0104] Referring to FIG. 18 there is illustrated a detail of a
living hinge 22. It is to be appreciated, with the benefit of this
description, that a living hinge can provide a simple and flexible
hinge mechanism. Furthermore, a deep living hinge can be used to
allow for small alterations in the relative positions of the base
portion 12 and side portions 14 to accommodate larger tolerances in
the manufacturing of the soft components of the soft sided luggage
while maintaining a fixed connection between the elements but
without compromising the structural integrity of the frame when in
its assembled form. This style of hinge also allows for a small
amount of flexibility so that the luggage case can resiliently
withstand shocks and accommodate the contents of case.
[0105] FIG. 19 illustrates another structure for the interface
between the side portions 14, in this case 14d and 14e, which can
include structural elements to enhance the engagement between these
elements to increase the structural integrity of the frame and
thereby transmit any "top loads" experienced by the soft sided
luggage case to the ground in a stable and efficient manner. It is
to be appreciated, with the benefit of this description, that the
side portions 14d and 14e are similar to the side portions 14a and
14c, respectively, as described above. However, in this
illustrative embodiment, the side portion 14d includes an L-shaped
side edge 90 along at least a portion of the perimeter of the side
portion 14d, and the side portion 14e includes a corresponding
L-shaped top edge 95 designed to cooperate with the L-shaped side
edge 90 when the frame 10 is assembled to form a structure and
define a volume. One will appreciate that there are other
alternative mating structures and attachment means that will secure
the side portions 14.
[0106] FIG. 20 partially illustrates a portion of a soft covering
98 covering the frame 10. The soft covering 98 can comprise denier
or other material typical of those used in the construction of soft
sided luggage. In the present embodiment, the soft covering 98
include fabric tabs 99 to engage with the frame 10. Apertures 30
can be specifically included in the frame 10 to permit convenient
attachment points for the fabric tabs 99.
[0107] In the present embodiment, the frame 10 is molded from a
single sheet of thermoplastic material. Thermoplastic, also known
as a thermosoftening plastic is a polymer that turns to a liquid
when heated and freezes to a rigid state when cooled sufficiently.
Most thermoplastics are generally high-molecular-weight polymers
whose chains associate through weak Van der Waals forces, stronger
dipole-dipole interactions and hydrogen bonding, or even stacking
of aromatic rings. Many thermoplastic materials are addition
polymers, for example, vinyl chain-growth polymers such as
polyethylene and polypropylene, or they can be productions of
condensation or other forms of polyaddition polymerisation, such as
the polyamides or polyester.
[0108] In the present embodiment, the frame 10 is molded using a
thermoforming process. Thermoforming is a manufacturing process
where typically a sheet of plastic is heated close to its melt
point so that it is rendered flaccid and pliable, and while in a
flaccid state it is molded to assume a desired shape. The stock
thermoplastic sheet is typically a planar sheet of material,
perhaps extruded, with marginal portions surrounding a central
portion. The central portion of the sheet is the bulk or majority
portion of the sheet that is molded to form the main part of the
frame 10. Thermoplastics typically used in the thermoforming
process can include polymers such as acrylonitrile butadiene
styrene (ABS), polyethylene (PE, high molecular weight polyethylene
(HMWPE), polystyrene, high-impact polystyrene (HIPS), polypropylene
(PP), thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), or
polyethylene terephthalate (PET).
[0109] The thermoplastic sheet formed in this process is then
introduced to a forming die, where vacuum pressure draws the soft
material against the detail on the form tool. The excess material
is them trimmed away to reveal the finished part. This trimming can
be accomplished by any of several conventionally understood means
such as computer controlled or die cut trimming. Thermoforming is a
method of forming the frame 10, but it will be understood by those
skilled in the art that several equivalent manufacturing processes
can be used to produce the same result. By forming the frame 10
from a single sheet of thermoplastic sheet stock, the resulting
frame is less complex and costly to design, manufacture and faster
to assemble, while remaining lightweight.
[0110] It is to be re-emphasized that the embodiments described
above are non-limiting embodiments. Notwithstanding the specific
examples, it is to be understood that the frame 10 is not
particularly limited to any size, shape or method of manufacture.
For example, the frame can be modified to include additional
features such as compartment walls, or customized recesses for
holding specific articles. Similarly, the frame 10 can be modified
to remove or omit features such as the apertures 30, the tube
mounts 42, the extendible handle mount receptacle 44, the fixed
handle mounts 46, or the various forms of bracing 48.
[0111] In general terms, the frame 10 is configured to provide a
stable structure to support a soft sided luggage case. It is to be
re-emphasized that the structures shown in FIGS. 1 to 20 are
non-limiting representations. Notwithstanding these specific
examples, it is to be understood that other mechanically equivalent
structures can be devised to perform a similar function as the
frame 10.
[0112] Referring to FIGS. 21 to 27, another embodiment of a frame
100 is shown. The frame 100 includes a base portion 112 and a
plurality of side portions 114a, 114b, and 114c. Each of the
plurality of side portions 114a, 114b, and 114c is connected to the
base portion with a hinge mechanism 122 and moveable between a
first position and a second position. In the present embodiment,
the frame 100 is configured to form a frame about 21 inches tall.
The width of the base portion 112 is about 13.9 inches. However, it
is to be understood that in other embodiments, the frame 100 can be
modified to have dimensions greater or less than in the present
non-limiting example dependent on a desired dimension of the
assembled luggage case.
[0113] In the present embodiment, the base portion 112 and the
plurality of side portions 114a, 114b, and 114c can collectively or
independently define a portion 130 for an aperture to reduce
material and weight of the frame 100 or to allow for openings in
the luggage case. Similar to the frame 10, the base portion 112 and
the plurality of side portions 114a, 114b, and 114c can also be
formed to include additional structural features such as tube
protectors 142, an extendable handle mount receptacle 144, fixed
handle mounts 146, or various forms of bracing 148.
[0114] Each of the side portions 114a and 114b includes an L-shaped
side edge 190 along at least a portion of the perimeter of the side
portions 114a and 114b. In addition, the side portion 114c includes
a corresponding L-shaped top edge 195 designed to cooperate with
the L-shaped side edge 190 when the frame 100 is assembled to form
a structure and define a volume. In the present embodiment, the
L-shaped side edge 190 further includes a flare 194. The flare 194
stretches the soft covering 98 placed over the frame 10 to reduce
any sagging or wrinkling of the soft covering 98. It is to be
appreciated, with the benefit of this description, that the
tightening of the fabric by the flare 194 further adds to the
rigidity of the luggage case.
[0115] The frame 100 is formed with a connection mechanism 180 for
fixably engaging with a base 150. It will be appreciated by those
skilled in the art that there are many methods for creating a
secure engagement between the frame 100 and the base 150 and that
the connection mechanism 180 can be modified. For example, other
connection mechanism can include but not limited to glue,
fasteners, clips or pins. In another embodiment, the base 150 can
be formed as an integral portion of the frame 100 and connected to
the base portion 112 along a portion of its perimeter 120 similar
to the plurality of side portions 114a, 114b, and 114c.
Furthermore, in the present embodiment, the frame 10 is formed with
round corners 192 as shown in FIGS. 21 to 31. It is to be
appreciated, with the benefit of the specification, that the use of
the rounded corners 192 helps to transfer vertical forces to
horizontal forces and vice versa.
[0116] In the present embodiment, the bracing 148 includes vertical
and horizontal ribs. In the present embodiment, the ribs are formed
during the thermoforming process at the same time as the other
structural features. It is to be appreciated that the exact
configuration of the bracing 148 is not particularly limited and
that several variations are contemplated. For example, other
embodiments can use diagonally oriented bracing 148. In further
embodiment, the bracing 148 can also be modified to be curved
instead of linear.
[0117] The manner by which the bracing 148 is disposed on the frame
100 is not particularly limited. For example, instead of forming
the bracing from thermoforming process, the bracing 148 can be
modified to be additional material attached to the frame after the
thermoforming process. It is to be appreciated that the additional
material is not limited and can include another type of material,
such as metal, or a similar plastic to the plastic from which the
frame 100 is formed. In another embodiment, the bracing 148 can be
modified to be a pattern disposed onto the sheet of plastic prior
to the thermoforming process. In another embodiment, the bracing
148 can be an inherently rigid portion of the frame 100 resulting
from the structural property of the original plastic sheet (not
shown), for example, caused by either a chemical reaction or
another type of treatment process capable of locally modifying the
properties of the frame 100 to create the bracing 148.
[0118] It is to be appreciated, with the benefit of this
description, that by using vertical and horizontal ribs, the
bracing 148 provides additional support in the horizontal and
vertical directions of the luggage case. Therefore, the structural
rigidity of the luggage case would be increased since most force
applied to the luggage case during use would generally be in the
horizontal or vertical directions as load is placed on top of the
luggage case. However, it is to be appreciated that in other
applications or situations where the luggage case is exposed to
various load forces, the bracing 148 can be modified
accordingly.
[0119] All directional references (e.g., vertical, horizontal, top,
bottom, above, below, and side) are used for identification
purposes to aid the reader's understanding of the embodiments of
the present invention, and do not create limitations, particularly
as to the position, orientation, or use of the invention unless
explicitly set forth in the claims. Connection references (e.g.,
attached, coupled, connected, joined, and the like) are to be
construed broadly and can include intermediate members between a
connection of elements and relative movement between elements.
[0120] It will be understood that the specification is illustrative
of the present invention and that other embodiments within the
spirit and scope of the invention will suggest themselves to those
skilled in the art. All references cited herein are incorporated by
reference. While the foregoing provides certain non-limiting
example embodiments, it should be understood that combinations,
subsets, and variations of the foregoing are contemplated. The
monopoly sought is defined by the claims.
[0121] An example of a variation can include modifying the frame
100 by cutting openings and trimming various portions of the frame
to reduce the weight of the frame. In addition, it is to be
appreciated that by trimming the connection mechanism 180 of the
frame 100, the connection mechanism can be modified to connect to
various bases. Referring to FIGS. 28 to 34, one such modification
to the frame 100 is shown as frame 100a. It is to be appreciated,
with the benefit of this description, that the manner by which the
frame 100 is modified to arrive at the frame 100a is not
particularly limited. For example, the frame 100 can be manually
cut or trimmed using a stamping press.
[0122] Referring to FIGS. 35 to 41, another embodiment of a frame
200 is shown. The frame 200 includes a base portion 212 and a
plurality of side portions 214a, 214b, and 214c. Each of the
plurality of side portions 214a, 214b, and 214c is connected to the
base portion with a hinge mechanism 222 and moveable between a
first position and a second position. In the present embodiment,
the frame 200 is configured to form a frame about 25 inches tall.
The width of the base portion 212 is about 16.8 inches. However, it
is to be understood that in other embodiments, the frame 200 can be
modified to have dimensions greater or less than in the present
non-limiting example dependent on a desired dimension of the
assembled luggage case.
[0123] Furthermore, like components of the frame 200 bear like
reference to their counterparts in the frame 100, except
incremented by 100. The frame 200 includes a portion 230 for an
aperture, tube protectors 242, an extendable handle mount
receptacle 244, fixed handle mounts 246, bracing 248, a connection
mechanism 280, L-shaped side edge 290, round corners 292, a flare
294, and a L-shaped top edge 295.
[0124] The frame 200 can also be modified by cutting openings and
trimming various portions of the frame to reduce the weight of the
frame. In addition, it is to be appreciated that by trimming the
connection mechanism 280 of the frame 200, the connection mechanism
can be modified to connect to various bases. Referring to FIGS. 42
to 48, this modification to the frame 200 is shown as frame 200a.
It is to be appreciated, with the benefit of this description, that
the manner by which the frame 200 is modified to arrive at the
frame 200a is not particularly limited. For example, the frame 200
can be manually cut or trimmed using a stamping press.
[0125] Referring to FIGS. 49 to 55, another embodiment of a frame
300 is shown. The frame 300 includes a base portion 312 and a
plurality of side portions 314a, 314b, and 314c. Each of the
plurality of side portions 314a, 314b, and 314c is connected to the
base portion with a hinge mechanism 322 and moveable between a
first position and a second position. In the present embodiment,
the frame 300 is configured to form a frame about 29 inches tall.
The width of the base portion 312 is about 19.3 inches. However, it
is to be understood that in other embodiments, the frame 300 can be
modified to have dimensions greater or less than in the present
non-limiting example dependent on a desired dimension of the
assembled luggage case.
[0126] Furthermore, like components of the frame 300 bear like
reference to their counterparts in the frame 100, except
incremented by 100. The frame 300 includes a portion 330 for an
aperture, tube protectors 342, an extendable handle mount
receptacle 344, fixed handle mounts 346, bracing 348, a connection
mechanism 380, L-shaped side edge 390, round corners 392, a flare
394, and a L-shaped top edge 395.
[0127] The frame 300 can also be modified by cutting openings and
trimming various portions of the frame to reduce the weight of the
frame. In addition, it is to be appreciated that by trimming the
connection mechanism 380 of the frame 300, the connection mechanism
can be modified to connect to various bases. Referring to FIGS. 56
to 62, this modification to the frame 300 is shown as frame 300a.
It is to be appreciated, with the benefit of this description, that
the manner by which the frame 300 is modified to arrive at the
frame 300a is not particularly limited. For example, the frame 300
can be manually cut or trimmed using a stamping press.
[0128] In some instances, components are described with reference
to "ends" or "edges" having a particular characteristic and/or
being connected with another part. However, those skilled in the
art will recognize that the present invention is not limited to
components which terminate immediately beyond their points of
connection with other parts. Thus, the term "end" or "edge" should
be interpreted broadly, in a manner that includes areas adjacent,
rearward, forward of, or otherwise near the terminus of a
particular element, link, component, part, member or the like. In
methodologies directly or indirectly set forth herein, various
steps and operations are described in one possible order of
operation, but those skilled in the art will recognize that steps
and operations can be rearranged, replaced, or eliminated without
necessarily departing from the spirit and scope of the present
invention. It is intended that matter contained in the above
description or shown in the accompanying drawings shall be
interpreted as illustrative and not limiting. Changes in detail or
structure can be made without departing from the spirit of the
invention as defined in the appended claims.
* * * * *