WO2006021737A1

WO2006021737A1 - Moulded multi-panel frameless article of luggage

Info

Publication number: WO2006021737A1
Application number: PCT/GB2005/002674
Authority: WO
Inventors: Sedat Selvi
Original assignee: Landor & Hawa International Limited
Priority date: 2004-07-08
Filing date: 2005-07-06
Publication date: 2006-03-02
Also published as: GB0513806D0; GB0415325D0; GB2415892A; GB2415892B

Abstract

A method of making an article of luggage of side panel construction having a lid section (1) and a base section (2) by forming at least the base section of such multi-panel construction as to provide in the absence of means for reinforcing the perimeter of the base section a shape wise self supporting side panel construction and in which the base section is so formed by shaping/deforming a first panel (4) such that it that defines the base region (4) and opposite ends of the base section (31, 32) and two side panels (5, 6) that are secured to the side edges regions of the thus formed first panel (4).

Description

MOULDED MULTI-PANEL FRAMELESS ARTICLE OF LUGGAGE

This invention relates to the construction of luggage for use by travellers.

Inter alia the present invention is concerned with the construction of so called side panel construction.

Many constructions of such articles of luggage namely case for use by travellers are known. These known constructions are conveniently considered as comprising two major types of construction respectively commonly known as as 'soft' and 'hard' cases.

Such cases are of varied form and conventionally include in addition to carrying handle arrangements at least a pair of wheels/rolls for facilitating the movement of the case by a user.

When such wheels/rolls are provided the cases are conventionally provided with a towing handle structure which is moveable between an extended user case towing position and a retracted stowage position.

It is a convenient and a conventional manner in for example commercial usage to define a 'hard' case as being hard in the sense that the walls, top and bottom thereof cannot be readily pierced by a blade or needle whilst a 'soft' case can be regarded as one that could be readily pierced.. In practice these distinctions can be regarded as being based upon user experiences arising from attempts to gain unauthorised access to the content of a case.

Conventionally known 'hard' and 'soft' cases incorporate a metal or plastics framework extending around the internal perimeter of the case in such position as to provide structural strength to the walls of the case sufficient to ensure that the case retains its required shape during any carrying or other handling of the case.

Such frameworks can involve internal tongue and groove arrangements. In practice, in addition to such a framework, the known cases not infrequently incorporate additional reinforcements at the top, base and corner sections. Such reinforcements can be formed from plywood, or P. E. Board

Bearing in mind the extent of travel by air and the fact that airlines impose limits upon the weight of luggage that a passenger may carry before incurring overweight surcharging it is highly desirable that the empty weight of a case should be as low as possible whilst maintaining adequate strength of construction of a case

As is also well known, most cases comprises a base load container section and some form of lid section. In practice the base section is normally considerably deeper than the lid section.

In practice, the production of the base sections for side panel case constructions from 'hard' material involves a moulding operation which in relation to the overall dimensions of the conventional case, particularly those intended for air travel usage involves relatively deep mouldings to produce a four walled tray like formation. The production of such deep mouldings can involved manufacturing problems relating to the actual moulding processes and also the costs in the production of appropriate moulding apparatus.

It is an object of the present invention to provide a case construction that deals with both of the above mentioned matters of avoiding excessive case weight and deep moulding problems. Broadly, according t a first aspect of the invention there is provided a method of making an article of luggage of side panel construction having a lid section and a base section by forming at least the base section of such multi-panel construction as to provide in the absence of means for reinforcing the perimeter of the base section a shape wise wise self supporting side panel construction.

Preferably, the base section is so formed by shaping/deforming a first panel such that it that defines the base region and opposite ends of the base section and two side panels that are secured to the side edges regions of the thus formed first panel.

In accordance with a further aspect of the invention there is provided a method of making an article of luggage of side panel construction having a lid section and a base section by constructing, the base section from at least three panels in such manner as to be shape wise self supporting in the absence of means for reinforcing the perimeter of the base section

Conveniently the method includes the steps of forming from a first panel of self supporting material a base section of such form as to provide both the base and opposite ends of the base section, and from two further panels the opposite side walls of the base section, securing the further panels to the. side edge regions of the base and opposite ends of the first panel whereby the three panels provide in combination a tray like formation having a self supporting peripheral rim

Preferably, the panels comprise a material known as foamed or expanded EVA or PVC.

Preferably, at least the first panel is produced by deforming an initially flat panel.

According to a further aspect of the invention there is provided an article of luggage of side panel construction comprising a lid section and a base section wherein at least the base section is of such multi-panel construction as to be shape wise self supporting in the absence of means for reinforcing the perimeter of the base section

Preferably the base section is formed from a first panel that defines the base region and opposite ends of the base section and two side panels that are secured to the side edge regions of the base and opposite ends forming regions of the first panel.

Preferably a first panel of self supporting material is of such form as to provide/define both the base and opposite end regions of the base section, and wherein two further panels are of such form as to provide opposite side walls for the base section, said further panels being secured to the side edge regions of said base and opposite ends in such manner that the three panels provide in combination a tray like formation having a self supporting peripheral rim

In a preferred construction the article of luggage wherein the three panels panels are moulded from a plastics material such as foamed or expanded EVA or PVC.

Conveniently the sections are formed from initially flat panels.

According to a rurther aspect of the invention a case construction incorporates a moulded lid forming section formed from a panel of plastics material, and a moulded base forming section formed from a base and ends forming panel and two base section side forming panels, with all said panels being formed from a plastics material and so shaped and profiled as to be shape wise supporting when arranged to provide the article of luggage . A preferred construction the side regions of the base section are adapted to provide integral locations for accommodating handling wheels/rolls for the article of luggage

Preferably the two moulded case forming sections are connected together a hinging arrangement connected between the base section and the Zip fastener arrangement adapted to provide for the opening and closing of the article of luggage..

Conveniently, the lid section is formed from two or more panels in such manner that the lid section can accept patterns and/or pockets. _s

I o For a better understanding of the invention and to show how to carry the same into effect reference will now be made to the accompanying drawings in which:- i

Figure 1 illustrates a general oblique front view of a case incorporating the concepts of the invention;

Figure 2 illustrates a general oblique rear view of a the case illustrated in Figure 1 ;

15 Figure 3 is a schematic oblique outline drawing of the lid section of the case of Figures 1 and 2,

Figure 4, is a schematic front view outline drawing of the lid section of the case of Figures 1 and 2;

Figure 5, is a schematic side view outline drawing of the lid section of the case of Figures 1 and 2;

Figure 6, is a schematic outline section drawing on the line VI-VI of Figure 3; Figure 7 is a facing view of a back section forming panel;

Figure 8 is an internal view of the back section forming panel;

Figure 9 is an oblique view illustrating the interior and one side of a base section side panel;

Figure 10 is an oblique view illustrating the exterior of the panel of Figure 9;

Figure 11 is schematic side view line drawing of the panel of Figures 9 and 10;

Figure 12 is a schematic line drawing view of the other side of the panel of Figures 9 and 10; and

Figure 13 is a schematic line drawing of the panel as shown in Figure 11.

Referring to Figures 1 and 2 of the drawings. The case construction shown therein comprises a lid 1 formed from moulded plastics material panels and a base 2 formed from a moulded plastics material. These two sections are connectable one to the other in such fashion as to provide a case formation.

The lid section in the embodiment illustrated is formed from a single panel 3 of such shape and profile as to provide a shallow tray like formation.. The shape and form of this panel will be described in greater detail hereinafter.

The base section 2 of the embodiment illustrated is formed from three separate panels namely, a base back panel 4, and two side panels 5 and 6. These panels 4, 5 and 6 are of such shape and form that when they are connected one to the other by, for example, stitching they combine to produce a tray formation that is relatively deep, as compared with the depth of the Hd section tray formation. The shape and form of these panels 4 5, and 6 will be discussed in greater detail herein after.

The two tray formations are so shaped and dimensioned as to be positionable in face to face relationship as shown n the Figures.

The two sections are joined together by a hinging arrangement (not shown in the

Figures)

The opening and closing of the sections 1 and 2 of the case is effected by way of a Zip fastener arrangement 7. As shown in Figure 1 the Zip fastener arrangement 7 includes a main Zip fastener 8 connected with the base section 2 and extending substantially around the total perimeter of the base section and a second zip fastener section 9 extending substantially around the total perimeter of the lid and base sections.. The effective lengths of both the Zip fasteners 8 and 9 is such as to allow total closure of the Zip fastener arrangement for closing the case.

Preferably, the zip fastener arrangement 7 is such as to enable expansion of the available volume of the suitcase by providing a gusset between the main and secondary Zip fasteners and so arranging the zipping action as to enable selective use or non use of the volume expansion capability. Such zipping arrangements are known on case constructions. It is thus thought that a detailed description of the formation of such a zipping arrangement is not necessary.

The case shown in Figures 1 and 2, includes a retractable towing handle 10 projecting from an appropriate recess/mounting 11 provided in the base section 2. In practice ,the case would incorporate wheels (not shown) at the bottom corners of the base section. The locations of such wheels is schematically indicated by indentations 12 at the associated bottom corners. In practice also, the case would be provided with a carrying handle (not shown) at the end thereof adjacent to the towing handle. If desired the case can be provided with a second carrier handle (not shown) located along one of the sides of the bottom section 2.

The lid and base forming sections 1 and 2 are moulded from a foamed plastics material such as that known as EVA or other expanding plastic materials such as that known as PVC.

If desired, the case sections 1 and 2 could be externally covered by a fabric material shaped to conform closely to the external form of the lid and base sections.

Since cases based upon the concepts of the invention do not include strengthening/stiffening frames or the like around the peripheries of the top and/or bottom sections the shape and strength of the case is derived from the original shapes of the panels forming the base and lid sections and their subsequent deformation to obtain the requisite form/profiling of the base and Hd sections.

It therefore follows that the empty weight of the case as compared with that of a case incorporating strengthening frame structures is reduced by the weight of such frame structures and any associated mounting arrangements.

In the absence of the stiffening frame and any associated mounting arrangements the profiling of the lid and base sections involve predetermined interrelationships between the lengthways and transverse cross sections of the panels at various locations of the lid and base section forming panels leading to the associated tray like formation having a generally overall smoothly curved appearance. Referring now to Figures 3 to 6 as mentioned these are schematic linear representations of the shaped panel forming the lid section 1. As will be seen the general shape is rectangular with rounded corners.

In Figure 3 the line Xl to X2 schematically represents the form/shape of the section of the panel taken along a medial line 16 extending from top to bottom of the panel as shown in the Figures 3 and 5..

The medial line 16 can be regarded as lying lengthways of what may be regarded as the medial line of the main body of the lid section 1. Thus the line Xl - X2 can be regarded as a illustrating the cross section of the lid section panel along the medial line.

It will be noted that this line Xl- X2 is generally of a curvilinear convex shape which includes a main portion 13 thereof in the form of a gradual convex curve with the end regions 14 and 15 each having a greater curvature than that of the portion 13. In the Figures 3 to 5 the end region 14 is initially smoothly curved transition of one curvature leading from the main portion 13 and terminating in a short region of a greater curvature with the end of this shorter region being at the point Xl. The other end region 15 terminates in a shorter length of- greater curvature than the remainder of the medial line. This end region terminates at the point X2 of the line Xl -X2.

The shape of the lid section in a direction transverse to the aforesaid media line

12 takes the form illustrated in Figure 6 As will be seen from this Figure the transverse section includes a convex central portion extending to either side of the medial line 16 between the point 17 and the point 18. This transverse section extends outwards from the points 17 and 18 as flat regions 19 and 20 slightly angled downwards relative lid section region between the points 17 and 18. Each one of these regions 19 and 20 terminates in a edge region 21 that is generally transverse to the regions 19 and 20. In practice these edge regions 21 can be regarded as forming the side walls of the lid section.

In a similar manner the above mentioned end regions 14 and 15 can be regarded as forming the end walls to the Hd section.

As may be seen from Figure 6 the transition between the central section main portion 17 and the flat regions 19 and 20 lies on lines 22,23 passing through the points 17 and 18. . In practice the formation of these particular lines 22 and 23 produce distinctive ridge lines which as shown in the Figures 1,3,4 and 5 curve outwardly from a location intermediate the length of the main portion

In practice, the combinations of the various curvatures of the main body section and the side and end wall regions affords physical strength to the lid section so

that the resulting lid section has considerable physical strength that is able to withstand normal usage by the traveller and the handling of the case incorporating the lid section at locations such as airport luggage handling facilities.

j The construction of the base section 2 will now be considered in relation to Figures 7 to 13.

As has been mentioned the base section 2 is formed from three appropriately shaped panels including a base panel 4, and two side wall forming panels 5 and 6.

The form of the base panel 4 is specifically illustrated in Figures 7 to 13. As will be seen the panel 4 incorporates a main portion 27 having at one end (the upper end in the Figures 7 and 8) a case end wall forming part 28 extending substantially perpendicular to the main. As will be seen the transverse width of this end part is less than that of the main portion. As may also be seen from the Figiires 7 and 8 there is a smooth rounded transition from the main portion 27 and the end part 28. Similarly the change in the transverse width from the main portion to the end part 28 is a smooth curved formation as can be particularly seen from Figure 7 and additionally from Figure 2..

At the other end of the main portion 27 the end region is reduced in transverse width and is deformed relative to the plane of the main portion to form a second end wall part 29 to the case.

The side edges of the base panel 4 are turned to lie at right angles to the planes of the main portion 27 and two end parts 28 and 29 and to the main portion to provide narrow edge regions 30 extending lengthways of the two sides of the panel which facilitate the attachment of the base 4 to the associated side panels 5 and 6.

The free ends 31 and 32 of the two end wall forming parts 28 and 29 are utilised in the attachment of the aforesaid Zip arrangement 7. In practice the hinge arrangements for hinging the lid section to the base section is located at the free end region 32. This hinge arrangement (nor shown) can be of and convenient form such as invlving an appropriately sixed sheet of flexible material attached to the free end region 32 and to the aforesaid Zip arrangement.

As will be noted from the Figures the side panels are not as is conventional with many case constructions flat but are profiled so as to provide these side panels with sufficient strength as to avoid the need for side wall stiffening members.

In addition it will noted that the side panels 5 and 6 shown in Figures 9 and 10 by reason of the overall curved formation of the case may be regarded a forming a left hand side panel and a right side panel. The construction and shaping of the side panels 5 and 6 are the same except for the left and right handedness. Referring more particularly to Figures 9 to 13 (these Figures are concerned with the shape and profiling of the side panels of the case base section ) in conjunction with Figures 1 and 2. As has been mentioned the panels 5 and 6 are of the same construction, with the essential difference resulting from the need for left and right handed formations.

As may particularly be noted from Figures 2 and 9 the side panels 5 and 6 may be regarded as being generally of an overall L-shape including a main upright portion 33 which provides the actual side wall to the base section 2 and and a shorter portion 34 extending from the upright portion 33 to form the bottom corner 35 of the case base section. This housing wraps around the panel and increases rigidity and strength of the associated panel.

The upright portion 33 comprises a main portion that is slightly arched as is indicated in the Figure 9, 11 and 12, such arching being associated with the appearance of the case and for establishing structural strength. In practice, the shaping ( i.e., arching) is not restricted to that shown in the Figures but can take many forms as desired bearing in mind that structural strength needs to be retained..

The upper end of the portion 33 (as seen in the Figure ) curves inwards to provide a portion 36 which is dimensioned as to co-operate with the end part 28 of the lid section 1.

The other end 34 of the main portion 33 is likewise curved inwards to provide the base of the aforesaid corner portion 35.

The lengthways edge regions of the upright 33 are deformed to extend transverse to the main portion to provide a narrow wall parts or edge flanges 38 by which the edge side wall is secured able to the base section 2. With a view to increasing the stiffness of the wall panel a region 39 of the main portion 33 is raised relative to the remainder of the main portion. This raised location 39 is defined be curved ridge line extending length ways of the main portion.

In addition, in said raised region a curved concavity or depression 40 is formed in the region 39 such manner as to form a concavity in the side wall in such manner as to enhance the overall stiffness of the case side wall. As will be seen from the Figures this depression is localised (as seen in the Figures) the moulded recess 36 for the wheel or roll.

In practice, it has been found that the interrelationships between the various curved, raised and depression areas achieves a required appearance and strength and enhances the overall stability of the side walls of the bottom section 2.

Depending upon the intended mode of interconnection the side wall constructions to the base section, the end parts of the side walls are dimensioned and shaped to provide adequate material to allow folding and stitching of the side walls to the base panel.

It will be noted that the side panel case construction as so far described is formed from four panels appropriately shaped and profiled to form a hard case with the required strength and stiffness..

If desired one or more of the panels can be cut and stitched in such manner as to create/provide for aesthetic changes.

Also the front panel of the lid section can be split so as to accept patterns or pockets. A case formed by the proposals of the invention can take an appearance different from that illustrated in the figures provided that the proposal effectively to wrap around the sides and top and bottom sides of the case is retained. And additionally also to wrap around the base portion of the case to provide the recesses for the wheels/rolls

The lid section and the bases sections can be hinged together by any convenient means commonly used in the construction of cases..

It will be understood that the case would conventionally be provided with one or more carrying handles (not shown in the Figures)

If considered necessary the base section 2 can be reinforced in the immediate vicinity of any carrying handles and also in the immediate vicinity of the towing handle 10

It follows from the forgoing that the method of constructing a hard case as proposed by the invention avoids problems that frequently arise in relation to deep drawing moulding processes.

Claims

1. A method of making an article of luggage of side panel construction having a lid section and a base section characterised by forming at least the base section 9!1) of such multi-panel construction as to provide in the absence of means for reinforcing the perimeter of the base section a shape wise wise self supporting side panel construction.

2. A method of making an article of luggage as claimed in claim 1, characterised by forming the base section by shaping/deforming a first panel (4) such that it that defines the base region (1) and opposite ends (28,29) of the base section and two side panels (5,6) that are to be secured to the side edges regions (30) of the thus formed first panel.

3. A method of making an article of luggage of side panel construction having a lid section (1) and a base section (2) characterised by constructing the base section from at least three panels (4,5,6) in such manner as to be shape wise self supporting in the absence of means for reinforcing the perimeter of the base section

4. A method of making an article of luggage as claimed in claim 1 , 2 or 3, and characterised by the steps of forming from a first panel (4) of self supporting material a base section (1) of such form as to provide both the base and opposite ^■ ends of the base section, and from two further panels (5,6) the opposite side walls of the base section (1), securing the further panels to the side edge regions of the base (30) and opposite ends (28,29) of the first panel whereby the three panels (4,5, 6) provide in combination a tray like formation having a self supporting peripheral rim 5. A method of making an article of luggage as claimed in claim 4, characterised by moulding the panels (4,

5,6) from a material known as foamed or expanded EVA or PVC.

6. A method of making an article of luggage as claimed in claim 4, characterised by forming at least the first panel (4) is produced by deforming an initially flat panel.

7. A method of forming an article of luggage as claimed in any one of claims 2 to 6, and characterised by the step of securing the side panels (5,6) to the base panel (4) by a stitching operation.

8. A method of forming an article of luggage as claimed in claim any one of the preceding claims 2. to 7, and characterised by including the step of attaching the lid (1) to the base section (2) by way of a Zip fastener arrangement (7,8) .

9 .A method of forming an article of luggage as claimed in claim 5, characterised by securing the Zip fastener (7,8) to the lid and base sections (1 ,2) by stitching.

10. A method of forming an article of luggage as claimed in any one of the preceding claims, and characterised by the step of forming the lid section (1) from a panel (4) of mouldable material in such manner as to provide a tray like formation having a periphery complimentary to that of the base section, and connecting the lid section (1) to the base section (2) by the Zip fastener formation.

11. A method as claimed in any one of the preceding claim, characterised by adapted the side panels (5,6) as to accommodate mounting luggage user handling wheels.

12. An article of luggage of side panel construction characterised by a Hd section (1) and a base section (2) wherein at least the base section is of such multi-panel construction as to be shape wise self supporting in the absence of means for reinforcing the perimeter of the base section

13. An article of luggage as claimed in claim 12, chaacterised in that the base section (1) is formed from a first panel (4) that defines the base region and opposite ends (28,29) of the base section and two side panels (5,6) that are secured to the side edge regions (30) of the base and opposite ends forming regions (28,29) of the first panel.

14. An article of luggage as claimed in claim 12 or 13, and characterised in that a first panel (4) of self supporting material is of such form as to provide/define both the base and opposite end regions of the base section (1), and wherein two further panels (5,6) are of such form as to provide opposite side walls for the base section, said further panels (5,6) being secured to the side edge regions (30) of said base and opposite ends in such manner that the three panels (4,5 and 6) provide in combination a tray like formation having a self supporting peripheral rim

15. An article of, luggage as claimed in any one of claims 12, 13 and 14, and characterised in that the three panels (4,5 and 6) are moulded from a plastics material such as foamed or expanded EVA or PVC.

16. An article of luggage as claimed in claim 12,13,14 or 15, and characterised in that the two moulded luggage forming sections (1,2) are connected together a hinging arrangement connected between the base section and the Zip fastener arrangement (7,8) adapted to provide for the opening and closing of the article of luggage..