GB2509509A

GB2509509A - An article of luggage and method of manufacture thereof

Info

Publication number: GB2509509A
Application number: GB201300104A
Authority: GB
Inventors: Sedat Selvi
Original assignee: IT Luggage Ltd
Current assignee: IT Luggage Ltd
Priority date: 2013-01-04
Filing date: 2013-01-04
Publication date: 2014-07-09
Also published as: GB201300104D0

Abstract

Â A method of manufacture of an article of comprises the steps of providing a sheet (6, fig.1) of foamed plastics material, forming a surface pattern 20 upon or in the sheet (6, fig.1) of foamed plastics material, separating the patterned sheet of foamed plastics material into a plurality of panels 30, 32, 34, 36 of a desired shape and configuration and assembling and securing the panels together to form an article of luggage. A sheet of fabric (4, fig.1) may be bonded to the foamed plastics material before the surface pattern 20 is formed thereon. The formed article of luggage has a surface pattern 20 on a surface other than or in addition to the front or rear surfaces, and the method of manufacture enables the formed surface pattern 20 to be provided all over the article of luggage. For example, the pattern may be present on the sides or over a curved region without distorting the formed pattern while maintaining the self-supporting benefits of using a foamed plastic material.

Description

Improved Article of Luggage The present invention relates to an improved article of luggage for use by s travellers, and in particular to a soft case having a patterned surface and a method of manufacture of such a case.

Generally suitcases, or other articles of luggage, can be divided into hard' and soft' constructions. Broadly, hard cases are those in which the top, io bottom and sides cannot be pierced by a blade or needle (or at least substantially resist this) and those that are not of hard' construction are considered to be of soft' construction.

A hard case typically comprises upper and lower shells of rigid plastics is material that are releasably secured together by a zip fastening to allow opening of the case, and secured together by a hinge arrangement at one edge to allow pivoting of the shells when the zip fastening allows. It is known to manufacture the shells of hard cases by drawing the shell from a sheet of thermoplastics material.

It is known to produce soft cases from a foamed plastics material such as EVA (Ethylene-vinyl acetate) as described in EP1689263 by drawing sheets of the foamed plastics material into shells. This allows for a soft case to produced that is shape wise self supporting in the absence of an interior framework, that is the shape of the case is maintained by the moulded shells of foamed plastics material, the shells forming a base and a lid. However, it is necessary to prevent the forming of wrinkles during the moulding operation to provide corrugations at the corner regions of the rims.

In short, this method of manufacture limits the design of the case to s shapes that can be produced by the drawing process.

This process also produces wastage in materials that are cut from the edges of the shells after the moulding process.

to There is further wastage in that a single moulding machine is only able to produce shells for a suitcase of a single size. In addition the footprint of the moulding machine may occupy substantially more factory space than the cross section of case shell being produced causing economic inefficiency in the manufacturing process.

It is also known to provide foamed plastics material panels, for example of EVA, to provide a decorative moulding on the exterior panels of cases.

These are considered by consumers to provide a look of strength to a case.

It is known that consumers prefer to see externally patterned cases, as fashion considerations play a large part in the decision making process of the consumer. In the case of hard cases, such patterning may be provided by the use of decorative films.

when drawing a moulded sheet of foamed plastics material, such as EVA, into a shell, a moulded surface pattern will be distorted in part by the drawing process in certain regions. This produces an undesirable visual effect that is unappealing to consumers. Accordingly, the use of such S decorative motifs is limited in practice to those parts of the shell where such distortions will not occur (that is the front and back panels of a case).

It is desirable to overcome these difficulties in order to provide a case of a to foamed plastics material such as EVA while also producing a case having an all over non-distorted patterned motif.

According to a first aspect of the present invention a method of manufacture of an article of luggage bearing a surface pattern on a is surface other than or in addition to the front or rear surface of the article of luggage comprises the steps of a) providing a sheet of foamed plastics material; b) forming a surface pattern upon or in the sheet of foamed plastics material; c) separating the patterned sheet of foamed plastics material into a plurality of panels of a desired shape and configuration d) assembling and securing together the plurality of panels to form an article of luggage.

This has as an advantage that the formed surface pattern can be provided all over the article of luggage, for example on the sides or over a curved region of the article of luggage, without distorting the formed pattern while maintaining the self supporting shape wise benefit of utilising a foamed plastics material to produce a soft article of luggage.

s In addition, by producing large panels of the composite sheet bearing the pattern, panel shapes can be efficiently separated from the composite sheet to produce a minimum of wastage.

It is a further advantage that a patterned composite sheet is not restricted to to the manufacture an article of luggage of a single size (as would be a drawn sheet), instead by forming the composite sheet into panels of appropriate size a wide variety of different sizes and shapes of case are possible. Indeed, it will be apparent that a set of matching articles of luggage of different sizes having the same pattern can be manufactured is from patterned composite sheets produced from the same forming process.

Preferably a sheet of fabric is bonded to the sheet of foamed plastics material prior to step b). This has as an advantage that it provides a better aesthetic to the outer surface of the article of luggage which is an important consideration to a consumer. In addition the sheet of fabric adds to the strength of the article of luggage.

Preferably the foamed plastics material is EVA. This has as an advantage that it is a polymer that approaches elastomeric materials in softness and flexibility, yet can be processed like other thermoplastics. EVA also has good clarity and gloss, barrier properties, low-temperature toughness, stress-crack resistance, water proof properties, and resistance to UV radiation all of which are advantageous features for an article of luggage.

S Preferably the sheet of foamed plastics material is heated prior to step b).

Preferably in step b) the surface pattern is moulded or impressed into the sheet of foamed plastics material.

to Preferably, step d) includes the step of securing together the plurality of panels to form an article of luggage by stitching of each of the plurality of panels to at least one other of the plurality of panels.

Preferably, step d) includes the step of securing one or more of the is plurality of panels to other of the plurality of panels by way of zip fastenings.

Preferably, step d) further includes the step of securing carry straps or handles to the article of luggage, or providing attachment means for such carry straps or handles.

Preferably, step d) further includes the step of providing a towing handle assembly for the article of luggage.

Preferably, step d) further includes the step of providing a plurality of wheel assemblies for the article of luggage.

Preferably, the surface pattern is a raised surface pattern.

Preferably, the surface pattern is a repeating surface pattern.

According to a second aspect of the present invention, an article of luggage comprises a base section and a lid section each formed of a foamed plastics material, the base section and the lid section providing a rear surface and a front surface of the article of luggage, the article of to luggage bearing a surface pattern on a surface other than or in addition to the front or the rear surface of the article of luggage.

Preferably, the article of luggage comprises a plurality of panels bearing a surface pattern, in which at least one of the panels bears the surface is pattern over a curved portion or a side portion of the article of luggage.

More preferably, the panels comprise a foamed plastics material.

Preferably the foamed plastics material is EVA.

Preferably the surface pattern is moulded or impressed into the foamed plastics material.

Preferably, the surface pattern is a raised surface pattern.

Preferably, the surface pattern is a repeating surface pattern.

The invention will now be described, by way of example only, in relation to the attached Figures, in which Figure 1 shows a view of a composite sheet for use in the present invention; and Figure 2 shows a schematic side view of the composite sheet of Figure 1 introduced to a moulding machine; Figure 3 shows a schematic side view of the composite sheet of Figure 1 being moulded in the moulding machine; to Figure 4 shows a schematic side view of the composite sheet of Figure 1 removed from the moulding machine; Figure 5 shows an illustrative perspective view of the composite sheet bearing the moulding; Figure 6 shows an illustrative view of the moulded composite sheet of is Figure 5 formed into panel shapes; Figure 7a shows an exploded view of a plurality of formed panel shapes prior to assembly of an article of luggage; Figure 7b shows a perspective view of an article of luggage formed according to the present invention; and Figure 8 shows a perspective view of a finished article of luggage formed according to the present invention.

Referring first to Figure 1 there is shown a composite sheet 2 for use in the present invention. A sheet 6 of a foamed plastics material, for example EVA (Ethylene-vinyl acetate) is provided. A first surface of the sheet 6 of the foamed plastics material is provided with a fabric covering 4. Any suitable fabric may be used for the fabric covering 4, for example a nylon fabric. The fabric is adhered to the first surface of the sheet 6 of the foamed plastics material in any suitable manner, for example a glue sheet (not shown) is provided between the fabric and s foamed plastics material which bonds when heated. In this way the composite sheet 2 is produced. The fabric covering 4 may be omitted, but is preferred as it both adds to the strength of the article of luggage produced and also provides a better aesthetic to the outer surface of the article of luggage.

As may be seen with reference to Figure 2, a moulding machine 10 is provided. The moulding machine has a male mould 12 and a female mould 14. The dimensions of the male and female mould are such that the composite sheet 2 will be impressed across all or substantially all of its is surface area. This has as a further advantage that the economics of the process are enhanced since a footprint of the moulding machine 10 is more greatly reflected by a length and breadth of the composite sheet 2.

The composite sheet 2 is laid upon the lower mould. The upper and lower moulds are brought together to impart a pattern to the composite sheet (Figure 3). Conveniently the composite sheet is first heated to a suitable temperature to allow the foamed plastics material to soften and so be more readily shaped by the moulding machine 10.

It will be understood that the fabric covering 4 will be able to withstand the operation of the moulding machine 10, that is it will allow the foamed plastics material to deform in the moulding machine 10 without itself becoming split or damaged.

The upper and lower moulds are separated to allow the shaped composite s sheet 2, now bearing a surface pattern 20, to be withdrawn from the moulding machine 10 (Figure 4).

where the composite sheet 2 is laid such that the foamed plastics sheet 6 contacts the female mould 14 a raised surface pattern 20 will be produced to on the visible surface of the foamed plastics sheet 2. Conversely if the composite sheet 2 is laid such that the foamed plastics sheet 6 contacts the male mould 12 a raised surface pattern 20 will be produced on the visible surface of the fabric covering 4.

is The shaped composite sheet 2 may then be formed, for example by cutting or other suitable manner, into desired panel shapes 30,32,34,36 (Figure 6). In Figure 7a left and right hand side panels 30,32, first lid surround panel 36, second lid surround panel 38, first lid panel 40 and second lid panel 34 are shown. The side panels, first lid surround panel, and second lid surround panel can be secured to a panel forming a back or rear of the article of luggage. Similarly the first lid surround panel 36 is also secured to a panel forming one end of the article of luggage. As may be seen from Figure 8 the panel forming a back or rear of the article of luggage and the panel forming one end of the article of luggage may be provided as a single panel 42.

The various panels may be secured together in any suitable manner.

By way of illustration, the side panels 30,32, first lid surround panel 36, second lid surround panel 38 and the end panel (not shown) are each s secured to the single panel 42 along an edge by any suitable means, conveniently by stitching, to form a base section. The left and right hand side panels 30,32 are also secured at their edges to the first lid surround panel 36 and the second lid surround panel 38, by any suitable means, again conveniently by stitching. An opening is defined between the first to lid surround panel 36 and the second lid surround panel 38. The first lid panel 40 and second lid panel 34 are joined in a suitable manner to form a lid section.

The lid section is then connected to the base section to releasably cover is the opening in the base section and thereby form an article of luggage 60.

For example, in Figure 7b one end of the first lid panel 40 is secured to an edge of the first lid surround panel 36 such that the lid section is hingedly attached to the base section, with the remainder of a periphery of the lid section being releasably connected to the base section by way of first and second sides of a zip fastener 50. In the illustrated embodiment the first lid panel 40 is secured to an edge of the first lid surround panel 36 by stitching.

Piping 62 may additionally be used to secure the sides of the zip fastener 50 to the panels as desired. Piping 62 may also be used to strengthen or reinforce the stitching.

A second zip fastener 52 can be seen releasably securing one edge of first lid panel 40 to an edge of the second lid panel 34.

S To finish the construction of the article of luggage 60, wheel assemblies 70 and a towing handle assembly 72 are added to the article of luggage. In practice, in order to mount the wheel assemblies 70 openings are provided in the base of the article of luggage 60 to accept the wheel assemblies 70 for mounting. The openings can be incorporated to into the article of luggage 60 when assembled or introduced into a suitable panel prior to assembly of the article of luggage. Similarly openings are provided at an upper region of the article of luggage 60 for receiving an internal part of the towing handle assembly 72. The internal part of the towing handle assembly 72, including parallel hollow receiving is tubes is located within the article of luggage 60, with the receiving tubes extending through the openings provided. Depending limbs of an external portion of the towing handle assembly 72 are then introduced to and secured for sliding engagement in the receiving tubes.

As is conventional, the article of luggage may be further be provided with a carrying handle (not shown) on one or more of its side faces.

The presence of an undistorted surface pattern, in particular a repeated raised surface pattern 20, over the article of luggage 60 will create a distinctive impression upon consumers. In particular, the presence of an undistorted raised surface pattern 20 over curved sections such as the first lid surround panel 36 and the second lid surround panel 38, or single panel 42 as it transitions from the rear of the article of luggage into the end of the article of luggage, as well as on side surfaces of the article of luggage 60 such as those formed by the side panels 30,32 or the end of s the article of luggage would not be possible if the base section had been formed as a shell by drawing of a sheet of foamed plastics material.

Claims

CLAIMS1 A method of manufacture of an article of luggage bearing a surface pattern on a surface other than or in addition to the front or rear surface s of the article of luggage comprises the steps of a) providing a sheet of foamed plastics material; b) forming a surface pattern upon or in the sheet of foamed plastics material; c) separating the patterned sheet of foamed plastics material into a to plurality of panels of a desired shape and configuration d) assembling and securing together the plurality of panels to form an article of luggage.
2 A method of manufacture according to claim 1, in which a sheet of is fabric is bonded to the sheet of foamed plastics material prior to step b).
3 A method of manufacture according to claim 1 or claim 2, in which the foamed plastics material is EVA.
4 A method of manufacture according to any previous claim, in which the sheet of foamed plastics material is heated prior to step b).
A method of manufacture according to any previous claim, in which in step b) the surface pattern is moulded or impressed into the sheet of foamed plastics material.
6 A method of manufacture according to any previous claim, in which step d) includes the step of securing together the plurality of panels to form an article of luggage by stitching of each of the plurality of panels to at least one other of the plurality of panels.
7 A method of manufacture according to any previous claim, in which step d) includes the step of securing one or more of the plurality of panels to other of the plurality of panels by way of zip fastenings.o 8 A method of manufacture according to any previous claim, in which step d) further includes the step of securing carry straps or handles to the article of luggage, or providing attachment means for such carry straps or handles.is 9 A method of manufacture according to any previous claim, in which step d) further includes the step of providing a towing handle assembly for the article of luggage.A method of manufacture according to any previous claim, in which step d) further includes the step of providing a plurality of wheel assemblies for the article of luggage.11 A method of manufacture according to any previous claim, in which the surface pattern is a raised surface pattern.12 A method of manufacture according to any previous claim, in which the surface pattern is a repeating surface pattern.13 An article of luggage comprising a base section and a lid section s each formed of a foamed plastics material, the base section and the lid section providing a rear surface and a front surface of the article of luggage, the article of luggage bearing a surface pattern on a surface other than or in addition to the front or rear surface of the article of luggage.14 An article of luggage according to claim 13, in which the article of luggage comprises a plurality of panels bearing a surface pattern, in which at least one of the panels bears the surface pattern over a curved portion or a side portion of the article of luggage.An article of luggage according to claim 13, in which the panels comprise a foamed plastics material.16 An article of luggage according to any of claims 13 to 15, in which the foamed plastics material is EVA.17 An article of luggage according to any of claims 13 to claim 16, in which the surface pattern is moulded or impressed into the foamed plastics material.18 An article of luggage according to any of claims 13 to 17, in which the surface pattern is a raised surface pattern.19 An article of luggage according to any of claims 13 to 18, in which s the surface pattern is a repeating surface pattern.A method of manufacture of an article of luggage substantially as described herein with reference to the accompanying Figures.o 21 An article of luggage substantially as described herein with reference to Figure 7b and Figure 8 of the accompanying Figures.