Luggage & method of manufacture

Abstract

Luggage includes a body formed by walls. At least one of the walls comprises at least in part a sheet of architectural laminate with an exterior decorative surface providing at least in part the exterior surface of a portion of the luggage.

Description

INCORPORATION BY REFERENCE

The inventor incorporates herein by reference any and all U.S. patents, U.S. patent applications, and other documents, hard copy or electronic, cited or referred to in this application.

Definitions

The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

The word luggage shall mean any container adapted to hold solid objects that may be lifted and carried by a single adult human being, and is intend to include, for example, attaché cases, brief cases, hand bags, suit cases, tote bags, etc.

The word “rectangular” includes square.

BACKGROUND OF INVENTION

Style and design are important factors that consumers consider when purchasing luggage. Strength and ruggedness is also important. Ideally, a line of luggage having unique style and design characteristics that also imparts strength and ruggedness to the luggage is highly desirable.

SUMMARY OF INVENTION

In accordance with this invention architectural laminates are employed as an exterior finish for luggage. Such architectural laminates impart both style and strength to the luggage and give a designer a vast number of decorative surfaces to choose from in designing fashionable luggage.

Architectural laminates, which are commonly used in the construction industry, comprise a substantially rigid sheet material that provides a decorative veneer. Such a laminate may simply be thin a sheet of a metal having an exterior surface shaped, finished, stamped, or otherwise treated to provide a decorative or aesthetic look to the exterior surface. Typically, such a laminate has a thickness that is no greater than 0.10 inch, for example, having a thickness substantially from 0.025 to 0.10 inch. Any form of art or graphic or pictorial treatment may be displayed as a decorative surface. Such laminates may also comprise multi-layers of sheet material or a paper impregnated with a resin such as, for example, described in U.S. Pat. No. 4,473,613. A common characteristic of architectural laminates is that the laminate sheet may be bent or otherwise formed into a desired shape and it will retain this shape after being so formed. For example, a flat, planar metal laminate sheet may be bent into a curved sheet, or a flat, planar resin impregnated laminate sheet may be heated so that it may be reshaped while at an elevated temperature, and upon cooling, remain in the reshaped configuration. Other architectural laminates are disclosed in U.S. Pat. Nos. 5,418,034 and 6,472,083.

This invention has one or more features as discussed subsequently herein. After reading the following section entitled “DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION,” one will understand how the features of this invention provide its benefits. The benefits of this invention include, but are not limited to: enabling a designer to use architectural laminates in new ways to improve both the appearance and ruggedness of luggage.

Without limiting the scope of this invention as expressed by the claims that follow, some, but not necessarily all, of its features are:

One, the luggage of this invention has a body formed by walls, at least one of which comprises at least in part a sheet of architectural laminate with an exterior decorative surface providing at least in part an exterior surface of a portion of the luggage.

Two, the architectural laminate may be fastened directly to a wall of the luggage, and a layer of backing material may be underneath the architectural laminate. For example, the backing material may comprise an open or closed cell foam plastic sheet, a polymer sheet of, for example, styrene or ABS, a woven/non-woven textile material, Neoprene rubber, etc.

Three, the walls of the luggage body form an interior adapted to hold objects and is accessible through an opening in the body. The opening may or may not be covered; it may or may not be closed by a zipper or other type of opening and closing device.

Four, the body may have a first wall segment comprising a pliable sheet material, and a second wall segment comprising an architectural laminate. The sheet of architectural laminate initially may be planar and at least a portion thereof may be formed into a predetermined non-planar shape that maintains this predetermined wall shape after being so formed or reshaped. This formed sheet of architectural laminate may be included in the body of the luggage.

Five, an edge portion of the pliable sheet material of the wall segment and an edge portion of the sheet of architectural laminate may be attached together. For example, the edge portions may be attached together by sewing or by an adhesive. The edge portions may have a piping therebetween.

These features are not listed in any rank order nor is this list intended to be exhaustive.

This invention also includes a method of manufacturing luggage. According to this method a luggage body is formed including at least one portion thereof comprising a pliable sheet and another portion thereof comprising a sheet of architectural laminate with an exterior decorative surface providing at least in part an exterior surface of said luggage. An edge portion of the wall comprising the pliable sheet material may be attached to an edge portion of the sheet of architectural laminate. The sheet of architectural laminate initially may be planar and at least a portion thereof may be reshaped into a predetermined non-planar shape that maintains this predetermined wall shape after being so reshaped and included in the luggage body. The edge portions may have a piping positioned therebetween.

The advantages of using architectural laminates have not been fully appreciated by the luggage industry. Luggage is manufactured from multiple parts and different processes that vary depending on the design of the finished product. These factors must be carefully considered in designing luggage, and often the finished product is the result of chosen compromises in structure, utility, and aesthetic appeal due to expenses associated with these factors. Using architectural laminates in manufacturing luggage avoids the many compromises previously necessary to offer luggage at a competitive price. This is achieved without sacrificing (1) structural integrity and strength imparted to luggage because of inherent weight to strength ratio of architectural laminates, (2) enhanced protection of objects contained within the luggage, and (3) a refinement of aesthetics unobtainable with other materials because of the multiple, decorative surface finishes available. Architectural laminates also provide cost savings by reducing the number of luggage parts and by reducing the labor costs in assembly due to fewer the number of parts and ease of fabrication.

Traditional methods of manufacturing may be used in the method of this invention, for example:

Sewing & stitching. Architectural laminates may be fastened this way by forming laminate panel or panels in a particular style of luggage and sewing and stitching a ‘pocket’ or ‘frame’ around a substrate carrying the to hold it in place. The laminate panel or panels can be fabricated with holes therein trough which a thread passes during sewing.

Chemical adhesives and/or tapes. Architectural laminates may be bonded with an adhesive or tape to a surface structure of luggage or edges of adjoining laminate pieces may be fastened together in this manner.

Mechanical fastening. Architectural laminates may be mechanically fastened by nut and bolt hardware, screws, nails, rivets, magnetism, trims and reveals, clips, and other mechanical fastening devices to a surface structure of luggage or edges of adjoining laminate pieces may be fastened together in this manner.

Stamping. Architectural laminates because they come in sheet form may be easily cut into different silhouettes by stamping or other means. This lends itself to facilitating low cost manufacture of luggage.

DESCRIPTION OF THE DRAWING

Some embodiments of this invention, illustrating all its features, will now be discussed in detail. These embodiments depict the novel and non-obvious luggage and method of this invention as shown in the accompanying drawing, which is for illustrative purposes only. This drawing includes the following figures (Figs.), with like numerals indicating like parts:

FIG. 1 is a perspective view of one embodiment of the luggage of this invention.

FIG. 2 is an exploded perspective view of the luggage shown in FIG. 1.

FIG. 2A is a cross-sectional view taken along line 2A-2A of FIG. 2.

FIG. 3 is a cross-sectional view of a wall of a conventional luggage piece.

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 1.

FIG. 5 is a cross-sectional view of a wall of a piece of conventional luggage.

FIG. 6 is a cross-sectional view of adjoining walls of luggage constructed in accordance with one embodiment of this invention.

FIG. 7 is a perspective view of another embodiment of the luggage of this invention.

FIG. 8 is a cross-sectional view of adjoining walls of luggage constructed in accordance with another embodiment of this invention.

FIG. 9 is a cross-sectional view of adjoining walls of luggage constructed in accordance with yet another embodiment of this invention.

FIG. 10 is a cross-sectional view of adjoining walls of luggage constructed in accordance with still another embodiment of this invention.

FIG. 11 is a cross-sectional view of adjoining walls of luggage constructed in accordance with one more embodiment of this invention.

FIG. 12 is a cross-sectional view of adjoining walls of luggage constructed in accordance with another embodiment of this invention.

FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. 7.

DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION

General

The luggage of this invention may have many different embodiments, and two embodiments are depicted in FIGS. 1 and 7, and respectively identified by the numerals 10 and 10a. Common to all the embodiments of this invention is the use of a sheet of architectural laminate with an exterior decorative surface that provides at least in part the exterior surface of a portion of the luggage. Suitable architectural laminates may be purchased under the trademark Formica, or from such companies as Formwwod Industries, Chemetal, Nevamar, Brookside Vaneer, Wilsonart, Pionite, Ridgewood, ABET Laminati, Braewood, ARPA USA, or Laminart. The architectural laminate in addition to enhancing the appearance of the luggage provides improved strength and ruggedness. Moreover, because architectural laminate sheets come in so many forms, and have so many different varieties of decorative surfaces, a luggage designer has a wide selection to choose from, allowing the designer to be more creative in designing and styling luggage. The architectural laminate sheet forms a portion of some, but not all, of the walls of the luggage. Other walls, or portions thereof, are formed from pliable sheet material such as, for example, leather, plastics, textile material such as fabrics, that have durability and are flexible, being capable of bending or folding, and are generally soft so they may be penetrated by a sharp object such as a knife. Compared to this pliable sheet material, architectural laminate sheet material is very rigid, inflexible, hard, and impenetrable.

The architectural laminate may be fastened directly to a wall of an existing piece of luggage, for example, by gluing it to the exterior of the luggage wall. Or, a wall of a piece of luggage may be made from one sheet of architectural laminate or multiple layers of sheet material with the architectural laminate being the outer sheet with its decorative surface exposed to view. A layer of backing material may or may not be positioned underneath the architectural laminate. Suitable backing sheet material may comprise, for example, an open or closed cell foam plastic sheet, a polymer sheet of, for example, styrene or ABS, a woven/non-woven textile material, Neoprene rubber, etc.

FIGS. 1 through 4

As illustrated in FIGS. 1 and 2, the luggage 10 is a brief case comprising a body 12 providing an interior 14 accessible through an opening 16 in the body. A pair of straps 18 with buckles 20 enable a manually moveable cover wall section 22 to be held in place in a closed position as shown in solid lines in FIG. 1 to cover the opening 16. By unbuckling the straps 18 and moving the cover wall section 22 to an open position shown in dotted lines in FIG. 1, a user may place objects in the interior 14 of the luggage 10.

One desirable feature of this invention is that the luggage body 12 may be constructed from one or more walls that are substantially rigid and inflexible because they include a sheet of architectural laminate. For example, the architectural laminate sheets 24a, 24b, and 24c are glued by an adhesive 26 to a foam backing sheet 28 that underlies each of the laminate sheets as depicted in FIG. 2A. This assembly of multiple layers of sheets is then attached, for example, typically by sewing or gluing the assembly to an exterior surface 22a (FIG. 2) of the cover wall section 22. The decorative surfaces S1 of these sheets 24a, 24b, and 24c are exposed to view. These surfaces may be the same or different, displaying any form of art or graphic or pictorial treatment.

Another desirable feature is that the luggage 10 may be constructed so some of the walls forming the body 12, or portions thereof, are made of a pliable sheet material and other walls, or portions thereof, include a sheet of architectural laminate. As illustrated best in FIGS. 3 and 4, a top wall 28 includes an internal support member 30 having a pliable sheet material 31 wrapped around the support member. The support member 30 may comprises cardboard, corrugated paper, an open or closed cell foam plastic sheet, a solid polymer sheet such as styrene or ABS, textile material, Neoprene rubber, leather, and adds some rigidity to the top wall. A handle 32 is mounted to the exterior of the top wall. The pliable sheet material 31 has an underside portion 31a abutting a portion of the cover wall section 22, which is a pliable sheet material. This is standard practice and provides the type of body construction shown in FIG. 3. In contrast, in this invention the architectural laminate sheet 24c is glued and/or sewn, or otherwise attached together, to the cover wall section 22 as illustrated in FIG. 4. Straight, or looped, conventional stitching 25 is used in the luggage 10 to attach an edge portion ED1 of the pliable sheet material of the top wall 28 and an edge portion ED2 of the substantially rigid architectural laminate sheet 24c.

Many types of architectural laminates that are substantially planar sheets may be reconfigured. Thus, an initially planar architectural laminate sheet, or at least a portion thereof, is reshaped into a predetermined non-planar shape that maintains this predetermined, non-planar wall shape after being reshaped. This reconfigured laminate sheet may be included in the body of the luggage. For example, the ends of the laminate sheets 24a, 24b, and 24c are reconfigured into a curved segment S2 that overlaps the cover wall section 22 where this section joins the top wall 28 as depicted in FIG. 4. When a thin metal laminate sheet is employed, simply bending the appropriate end forms the curved segment S2. When a multilayered, resin impregnated laminate sheet is employed, the sheet is heated to an elevated temperature, and while hot, formed into the desired shaped such as the curved segment S2. Then this reshaped sheet is allowed to cool. When cooled, the desired shaped is maintained; in this case the curved segment S2.

FIGS. 5 and 6

FIG. 5 depicts a conventional luggage piece having adjoining walls A and B attached by stitches 17. A stiffening member 11 is lodged between pliable sheets 13 and 15, forming the wall A to enhance the rigidity of this one wall A. As shown in FIG. 6, such a stiffening member 11 and the sheet 13 are eliminated when a planar architectural laminate sheet, for example, the sheet C is used. This sheet C may use a foam backing sheet 28 beneath the architectural laminate sheet C, which is bonded thereto by an adhesive 26.

FIGS. 7 and 13

The luggage 10a illustrated in FIG. 7 is a suitcase where substantially flat wall segments are covered with planar architectural laminate sheets 40 and 42. In the luggage 10a adjacent parallel walls 44 and 46 are, respectively, covered by or formed from the laminate sheets 40 and 42. As best depicted in FIG. 13, the wall 46 and a top wall 47 are connected along a junction J and these walls are substantially at a right angle with respect to each other. The top wall 47, which has a handle 49 attached thereto, comprises a pliable sheet, for example, a woven nylon fabric or leather or a vinyl plastic. The wall 44 is rectangular and it includes the rectangular, substantially planar sheet 40 with its decorative surface S3 exposed to view. The wall 46 provides a frame for the wall 44, and it includes the planar sheet 42 with its decorative surface S4 exposed to view. In this embodiment, the planar architectural laminate sheets 40 and 42 retain their planar configuration and are not reformed to alter their shape. The architectural laminate sheet 42 may be stamped from a sheet with the unused cutout central portion salvaged and used in another luggage piece.

As best illustrated in FIG. 13, a conventional piping 50 is sewn by stitches 52 along the rectangular edges ED3 and ED4 respectively of the laminate sheets 40 and 42. This piping 50 is positioned along the junction between the laminate sheets 40 or 42, as the case may be, and an adjacent pliable sheet, for example the top wall 47. A foam backing sheet 28 is beneath the laminate sheet 42, which is attached by an adhesive 26 to the foam backing sheet.

FIGS. 8 through 12

FIGS. 8 through 12 illustrate different ways to attach a pliable wall segment to a wall segment employing an architectural laminate sheet, whether or not reshaped. In FIG. 8, an edge portion ED5 of an architectural laminate sheet 60 is inserted into a pocket 62 formed in the end of a wall segment 64 comprising the pliable sheet material. Only the architectural laminate sheet 60 is used to form an adjoining wall segment, thereby eliminating any cost associated with the foam backing sheet 28. Some rigidity is imparted to the pliable wall segment 64 by an internal support member 30, which lies approximately in the same plane as the architectural laminate sheet 60. Stitches 52 and adhesive 26 hold the pliable wall segment 64 to the architectural laminate sheet 60. The wall construction shown in FIG. 9 is almost identical to that illustrated in FIG. 8, except a foam backing sheet 28 is bonded to the architectural laminate sheet 60 with the adhesive 26 and a pliable sheet 64a projects outward from the wall segment 64 to extend beneath the laminate sheet 60, providing a space 61 between the pliable sheet 64a and the foam backing sheet 28. The pliable sheet 64a may be a fabric lining for the interior of the luggage, for example, silk.

FIGS. 10 11, and 12 show slightly different connection systems than discussed above for attaching a pliable wall segment to a wall segment employing an architectural laminate sheet. FIG. 10 depicts a pliable wall segment 70 that includes overlying pliable sheets 70a and 70b with an internal support member 30 between these sheets. The sheet 70b extends under a laminate sheet 74 and forms a part of a wall segment 72. The portion P of the sheet 70b extending under the laminate sheet 74 has the laminate sheet 74 bonded to it as discussed above using an adhesive 26 and stitches 52. FIG. 11 shows essentially the same connection system as FIG. 10, except the internal support member 30 is eliminated.

The connection system illustrated in FIG. 12 is like that depicted in FIG. 13, except the wall segments E and F. The wall segment E (the segment including the architectural laminate sheet 24) and the wall segment F (the pliable wall segment) instead of being at a right angle with respect to each other are approximately in the same plane.

Scope of the Invention

The above presents a description of the best mode contemplated of carrying out the present invention, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this invention. This invention is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this invention to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the invention as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the invention:

Claims

1. Luggage comprising

a body providing an interior accessible through an opening in the body, said interior being adapted to hold objects,

said body having a first wall segment comprising a pliable sheet material, and a second wall segment comprising a substantially rigid sheet material having an exterior decorative surface.

2. The luggage of claim 1 where the substantially rigid sheet material is a sheet of architectural laminate.

3. The luggage of claim 2 where the sheet of architectural laminate initially is planar and at least a portion thereof is reshaped into a predetermined non-planar shape that maintains said predetermined wall shape after being reshaped and included in the body of the luggage.

4. The luggage of claim 1 where an edge portion of the pliable sheet material of the wall segment and an edge portion of the substantially rigid sheet material of the second wall segment are attached together.

5. The luggage of claim 4 where the edge portions are attached together by sewing.

6. The luggage of claim 4 where the edge portions are attached together by an adhesive.

7. The luggage of claim 4 where the edge portions have a piping therebetween.

8. Luggage comprising

a plurality of walls joined together to form a body providing an interior accessible through an opening in the body, said interior being adapted to hold objects,

a first wall comprising a pliable sheet material, and a second wall comprising a substantially rigid sheet of architectural laminate having an exterior decorative surface that provides at least a portion of an exterior surface of said second wall, and

where an edge portion of the pliable sheet material of the first wall and an edge portion of the sheet of architectural laminate of the second wall are attached together.

9. The luggage of claim 8 where the sheet of architectural laminate initially is planar and at least a portion thereof is reshaped into a predetermined non-planar shape that maintains said predetermined wall shape after being reshaped and included in the second wall.

10. The luggage of claim 8 where the edge portions are attached together by sewing.

11. The luggage of claim 8 where the edge portions are attached together by an adhesive.

12. The luggage of claim 8 where the edge portions have a piping therebetween.

13. Luggage comprising a body formed by walls, at least one of said walls comprising at least in part a sheet of architectural laminate with an exterior decorative surface providing at least in part an exterior surface of a portion of the luggage.

14. The luggage of claim 13 where the architectural laminate is fastened directly to a wall of the luggage.

15. The luggage of claim 13 including a layer of backing material underneath the architectural laminate.

16. The luggage of claim 15 where the backing material comprises cardboard, corrugated paper, an open or closed cell foam plastic sheet, a solid polymer sheet, textile material, Neoprene rubber, or leather.

17. A method of manufacturing luggage comprising

(a) forming a plurality of walls into a body of the luggage including an interior adapted to hold objects and accessible through an opening in the body, one of said walls comprising a pliable sheet material, and another of said walls comprising a substantially rigid sheet of architectural laminate having an exterior decorative surface that provides at least a portion of an exterior surface of the luggage, and

(b) attaching said walls together.

19. The method of claim 18 where an edge portion of the wall comprising the pliable sheet material is attached to an edge portion of the sheet of architectural laminate.

20. The method of claim 18 where the sheet of architectural laminate initially is planar and at least a portion thereof is reshaped into a predetermined non-planar shape that maintains said predetermined wall shape after being reshaped and included in the second wall.

21. The method of claim 18 where the edge portions have a piping therebetween.

22. A method of manufacturing luggage comprising forming a luggage body including at least one portion thereof comprising a pliable sheet and another portion thereof comprising a sheet of architectural laminate with an exterior decorative surface providing at least in part an exterior surface of said luggage.

24. The method of claim 22 where an edge portion of the wall comprising the pliable sheet material is attached to an edge portion of the sheet of architectural laminate.

25. The method of claim 22 where the sheet of architectural laminate initially is planar and at least a portion thereof is reshaped into a predetermined non-planar shape that maintains said predetermined wall shape after being reshaped and included in the luggage body.