AN ARTICLE OF LUGGAGE WITH EXTERIOR POCKETS IN A MOULDED PORTION

An article of luggage with exterior pockets in a moulded portion An article of luggage comprising: a body having an interior defining a body containment volume accessible through a body opening; a lid comprising a moulded concave shell having an interior defining a lid containment volume accessible through a lid opening extending in a lid opening plane; and a hinge between the body and the lid to enable movement of the lid relative to the body between: an open position in which the body and lid containment volumes are accessible through the body and lid openings; and a closed position in which the body and the lid openings cooperate such that the body and lid containment portions are enclosed. The moulded concave shell comprises: a lower protruded portion which protrudes from the lid opening plane via a lower stepped portion; an upper protruded portion which protrudes from the lid opening plane via an upper stepped portion that faces the lower stepped portion. The moulded concave shell further comprises a first aperture that provides access to a lower pocket within the lid containment volume behind the lower protruded portion; and a second aperture that provides access to an upper pocket within the lid containment volume behind the upper protruded portion, wherein the upper pocket is in part bounded by an interior surface of the upper stepped portion.

TECHNICAL FIELD

The disclosure relates to the field of luggage, such as suitcases, comprising at least one moulded shell.

BACKGROUND

One advantage of luggage that comprises at least one moulded shell is that the moulded shell provides more protection to contents of the luggage than a fabric alternative. Furthermore, by contrast with fabric, a moulded shell retains its shape without the need for other structure-defining elements.

In fabric luggage, fabric panels may be fastened together in order to achieve a three-dimensional form. Such fastening is generally straightforward, for example by stitching. By contrast, it is more complex to fasten single piece moulded portions to other elements and, in any case, it is not necessary to do so in order to obtain a three-dimensional form since the moulded portion itself provides the three-dimensional form.

GB 2580666, in common ownership with the present disclosure, discloses a moulded luggage shell with an exterior fabric panel. However, the protective advantages of the moulded shell do not provide protection to the contents of the pocket since the exterior surface of the pocket is fabric.

SUMMARY OF THE DISCLOSURE

Against this background there is provided an article of luggage comprising:a body having an interior defining a body containment volume accessible through a body opening;a lid comprising a moulded concave shell having an interior defining a lid containment volume accessible through a lid opening extending in a lid opening plane; anda hinge between the body and the lid to enable movement of the lid relative to the body between: an open position in which the body and lid containment volumes are accessible through the body and lid openings; and a closed position in which the body and the lid openings cooperate such that the body and lid containment portions are enclosed; wherein:wherein the moulded concave shell comprises:a lower protruded portion which protrudes from the lid opening plane via a lower stepped portion;an upper protruded portion which protrudes from the lid opening plane via an upper stepped portion that faces the lower stepped portion;a first aperture that provides access to a first pocket within the lid containment volume behind the lower protruded portion; anda second aperture that provides access to an upper pocket within the lid containment volume behind the upper protruded portion, wherein the upper pocket is in part bounded by an interior surface of the second stepped portion.

In this way, advantages of a moulded portion for protection of suitcase contents can be exploited in the context of pockets accessible from an exterior of the article of luggage without having to open the lid of the article of luggage. Furthermore, the interior surface of the second stepped portion provides a moulded surface at a lower edge of the upper pocket which enables use of the moulded lid shell for protection of contents at the lower edge of the upper pocket.

Optionally, the upper and lower stepped portions are substantially perpendicular to the lid opening plane. Optionally, the lower stepped portion may comprise the first aperture. In this way, the first aperture may be less obvious, less accessible for swift access by a third party, and more protected from damage.

The moulded concave shell may further comprise a first recessed portion between the upper and lower stepped portions and set back from the upper and lower protruded portions.

The concave moulded shell may further comprise a second recessed portion that is set back from the upper protruded portion and substantially perpendicular to the lid opening plane, and a top stepped portion on an opposite side of the upper protruded portion from the upper stepped portion, wherein the second aperture is located in the top stepped portion. In this way, the second aperture may be less obvious, less accessible for swift access by a third party, and more protected from damage.

The lower pocket may comprises a first fabric receptacle having a first receptacle opening, the first receptacle opening having a first side and a second side, wherein the first side of the first receptacle opening is fastened to the moulded shell on a first side of the first aperture and the second side of the first receptacle opening is fastened to the moulded shell on a second side of the first aperture. In this way, the fabric receptacle may prevent significant movement of contents of the pocket within the moulded shell.

The first receptacle opening may be closable by a first pocket zipper having a first zipper tape on the first side of the first receptacle opening and a second zipper tape on the second side of the first receptacle opening, such that both the first aperture and the fabric receptacle are openable and closable by the first pocket zipper.

The first zipper tape may be fastened to the moulded shell by stitching and the second zipper tape is fastened to the moulded shell by stitching. In this way, one zipper provides the functionality to close the aperture and the pocket.

The upper pocket may comprise a second fabric receptacle having a second receptacle opening, the second receptacle opening having a first side and a second side, wherein the first side of the second receptacle opening is fastened to the second moulded shell on a first side of the second aperture and the second side of the second receptacle opening is fastened to the second moulded shell on a second side of the second aperture.

The second receptacle opening may be closable by an upper pocket zipper having a primary zipper tape on the first side of the second receptacle opening and a secondary zipper tape on the second side of the second receptacle opening, such that both the second aperture and the second fabric receptacle are openable and closable by the second pocket zipper. In this way, one zipper provides the functionality to close the aperture and the pocket.

The article of luggage may further comprise a lid liner fastened to the second moulded portion within and proximate the lid opening such that the first fabric receptacle and, where present, the second receptacle are located between the lid liner and the moulded portion. In this way, further restriction of movement of pocket contents may be provided.

The article of luggage may further comprise a body liner fastened to the body within and proximate the body opening.

Optionally, in the closed position in which the body and the lid openings cooperate such that the body and lid containment portions are enclosed, cooperation is provided by a primary zipper comprising a first tape fastened to the first moulded portion proximate the base opening and a second tape fastened to the second moulded portion proximate the lid opening.

The article of luggage may further comprise a plurality of protruding wheel systems, each comprising at least one wheel, wherein each protruding wheel system is fastened to an exterior of the first moulded portion.

Each wheel system may comprise a connection element and a wheel unit, wherein the wheel unit is rotatable relative to the connection element about a generally vertical axis that sits outside a footprint of the base.

Optionally, the article of luggage may be is in the form of a suitcase.

In a further aspect of the disclosure there is provided a method of manufacturing an article of luggage, the article of luggage comprising:a body having an interior defining a body containment volume accessible through a body opening;a lid comprising a moulded concave shell having an interior defining a lid containment volume accessible through a lid opening extending in a lid opening plane;the method comprises:moulding the lid comprising a concave shell to include:a lower protruded portion which protrudes from the lid opening plane via a lower stepped portion;an upper protruded portion which protrudes from the lid opening plane via an upper stepped portion that faces the lower stepped portion;making an incision to provide a first aperture in the moulded concave shell that provides access to a lower pocket within the lid containment volume behind the lower protruded portion;making an incision to provide a second aperture in the moulded concave shell that provides access to an upper pocket within the lid containment volume behind the upper protruded portion, wherein the upper pocket is in part bounded by an interior surface of the upper stepped portion;fastening a hinge between the body and the lid to enable movement of the lid relative to the body between: an open position in which the body and lid containment volumes are accessible through the body and lid openings; and a closed position in which the body and the lid openings cooperate such that the body and lid containment portions are enclosed.

In this way, straightforward manufacture of an article of luggage comprising a moulded top with exterior accessible pockets may be provided.

The method may further comprise:providing a first fabric receptacle having a first receptacle opening the first receptacle opening having a first side and a second side;fastening the first side of the first receptacle to the moulded shell on a first side of the first aperture;fastening the second side of the first receptacle to the moulded shell on a second side of the first aperture.

The method may further comprise: fastening a first pocket zipper having a first zipper tape and a second zipper tape to the lid, wherein the first zipper tape is fastened on the first side of the first receptacle opening and the second zipper tape is fastened on the second side of the first receptacle opening, such that both the first aperture and the fabric receptacle are openable and closable by the first pocket zipper.

Optionally, any one or more of the fastening steps of the method comprises stitching.

DETAILED DESCRIPTION

FIG.1is a schematic diagram of an article of luggage, specifically a suitcase100, according to a first embodiment of the disclosure.

The suitcase100comprises a body110having an interior defining a body containment volume accessible through a body opening (extending in a body opening plane115, labelled inFIG.3). The suitcase100comprises a lid120having an interior defining a lid containment volume accessible through a lid opening extending in a lid opening plane (extending in a lid opening plane125).

The body110is hingedly attached to the lid120to enable movement of the lid120relative to the body110between an open position and a closed position.

In the closed position, the body opening meets the lid opening such that the body opening plane115and the lid opening plane125are parallel. A principal zipper130, located between the lid opening plane and the body opening plane, may be used to fasten the lid120proximate the lid opening to the body110proximate the body opening. The principal zipper130may comprise a first zipper tape fastened to the body110around the body opening and a second zipper tape fastened to the lid120around the lid opening.

The lid120comprises a first moulded shell. The first moulded shell provides for a three-dimensional structure without the need for separate shape defining elements.

In a first option, the body110may comprise a second moulded shell. The second moulded shell provides a three-dimensional structure without the need for separate shape defining elements. The moulded shell may be of a hard material which does not substantially yield under pressure or of a soft material which yields to some degree under pressure.

In a second option, the body110may comprise a fabric exterior with an interior shape defining skeleton.

With reference toFIG.1, the body110comprises a side handle112, a top handle114and a retractable handle assembly116. The body110further comprises a first wheel assembly191, a second wheel assembly192, a third wheel assembly193and a fourth wheel assembly194(not visible inFIG.1). Each of the first, second, third and fourth wheel assemblies191,192,193,194is located in one of four corners of a lower surface of the body110. Each wheel assembly191,192,193,194comprises: an arm that extends between its corner of the lower surface of the body110to a location outside a footprint of the body110. This leads to increased stability relative to wheel assemblies that are solely located within the footprint of the body110. Each wheel assembly191,192,193,194further comprises a pair of wheels, one on each side of the arm. The pair of wheels together is configured to rotate around a vertical axis provided by a rotatable stem that projects beneath the arm. Each wheel of the pair of wheels is also configured to rotate around a horizontal axis that extends through the rotatable stem. In this way, the suitcase is highly maneuverable.

With reference toFIG.3, the lid120comprises a lower protruded portion150that extends substantially out from the lid opening plane125and an upper protruded portion170that also extends substantially out from the lid opening plane125. The lower protruded portion150comprises a lower edge155via which the lower protruded portion150projects from the lid opening plane125at a lower end of the lower protruded portion150. The lid120comprises a first recessed portion165between the lower protruded portion150and the upper protruded portion170, wherein the first recessed portion165extends out from the lid opening plane125to a lesser degree than the lower protruded portion150and the upper protruded portion170. The lid120also comprises a lower stepped portion160that extends between the lower protruded portion150and the first recessed portion165and that is substantially perpendicular to the lid opening plane125. The lid120also comprises an upper stepped portion175that extends between the upper protruded portion170and the first recessed portion165and that is substantially perpendicular to the lid opening plane125. In this way, the first recessed portion165is located between the upper and lower stepped portions175,160and set back from the upper and lower protruded portions170,150.

With reference toFIG.6, a first aperture161is located in the lower stepped portion160. The first aperture161provides access to a lower pocket162that is located within the lid containment volume behind the lower protruded portion150.

The lower pocket162comprises a first fabric receptacle having a first receptacle opening, the first receptacle opening having a first side and a second side. The first side is fastened to the moulded shell on a first side of the first aperture towards a front of the first recessed portion165and the second side of the first receptacle opening is fastened to the moulded shell on a second side of the first aperture towards a rear of the first recessed portion165.

The first receptacle opening is closable by a first pocket zipper having a first zipper tape on the first side of the first receptacle opening and a second zipper tape on the second side of the first receptacle opening, such that both the first aperture161and the first fabric receptacle are openable and closable by the first pocket zipper.

The first zipper tape may be fastened to the moulded shell by stitching and the second zipper tape may be fastened to the moulded shell by stitching.

In this way the stitching of the first zipper tape and the second zipper tape to the moulded shell not only provides the functionality of opening and closing the lower pocket162via the first pocket zipper but also provides the functionality of retaining the first fabric receptacle in position.

It may be that the first fabric receptacle is not otherwise fastened to the first moulded shell. This reduces manufacturing steps and costs.

The lid containment volume may be provided with a fabric lining such that the first fabric receptacle may be located between the moulded lid and the fabric lining so as to provide some restriction of movement of the first fabric receptacle beyond the stitching around the zipper tapes.

By providing the first aperture161in the lower stepped portion160, it more discrete than would be the case if it were in the front face and also the stitching and zipper is less vulnerable to damage from handling such as in airport luggage handling areas. Furthermore, the lower pocket162lends itself well to receiving and accommodating the kinds of items, like laptop computers and tablets, that travelers like to be accessible in an exterior pocket rather than in the main body of the luggage.

The body containment volume may also be provided with a fabric lining to complement the fabric lining of the lid containment volume.

The lid120comprises a second recessed portion185between the upper protruded portion170and a top edge of the lid120. The lid120also comprises a top stepped portion180that is substantially perpendicular to the lid opening plane125. The second recessed portion185extends out from the lid opening plane125to a lesser degree than the lower protruded portion150and the upper protruded portion170.

A second aperture181is located in the top stepped portion180. With reference toFIG.6, the second aperture181provides access to an upper pocket182that is located within the lid containment volume behind the upper protruded portion170. A lower portion of the upper pocket182is in part bounded by an interior surface of the upper stepped portion175. In this way, items at the bottom of the upper pocket182benefit from protection provided by the moulded material of the upper stepped portion175of the moulded shell of the lid120.

The upper pocket182comprises a second fabric receptacle having a second receptacle opening, the second receptacle opening having a first side and a second side. The first side is fastened to the moulded shell on a first side of the second aperture181towards a front of the second recessed portion185and the second side of the second receptacle opening is fastened to the moulded shell on a second side of the second aperture181towards a rear of the second recessed portion185.

The second receptacle opening is closable by a second pocket zipper having a primary zipper tape on the first side of the second receptacle opening and a secondary zipper tape on the second side of the second receptacle opening, such that both the second aperture and the second fabric receptacle are openable and closable by the second pocket zipper.

The primary zipper tape may be fastened to the moulded shell by stitching and the secondary zipper tape may be fastened to the moulded shell by stitching.

In this way the stitching of the primary zipper tape and the secondary zipper tape to the moulded shell not only provides the functionality of opening and closing the upper pocket via the second pocket zipper but also provides the functionality of retaining the second fabric receptacle in position.

The second fabric receptacle may be not otherwise fastened to the first moulded shell. This reduces manufacturing steps and costs. If the lid containment volume is provided with a fabric lining then the second fabric receptacle may be located between the moulded lid and the fabric lining so as to provide some restriction of movement of the second fabric receptacle beyond the stitching around the zipper tapes.

By providing the second aperture181in the top stepped portion180, it more discrete than would be the case if it were in the front face and also the stitching and zipper is less vulnerable to damage from handling such as in airport luggage handling areas.

Furthermore, the upper pocket182lends itself well to receiving and accommodating the kinds of items, like laptop computers and tablets, that travelers like to be accessible in an exterior pocket rather than in the main body of the luggage.

The lid120may further comprise a plurality of strengthening ribs121,122,123in the form of shallow linear indentations in a front surface of the lid. In the first embodiment of the suitcase100according to the disclosure, the strengthening ribs121,122, and123are all perpendicular to the sides of the suitcase.

In alternative arrangements, the first aperture161and/or the second aperture181are located elsewhere on the moulded lid portion.

In alternative arrangements, closure of the lower pocket162and the upper pocket182may be provided other than by zippers. For example, closure may be provided by one or more of the following: a magnetic clasp, a button tab, a snap fastener, or any other suitable closure.

FIGS.8and9are schematic diagrams of an article of luggage, specifically a suitcase200, according to a second embodiment of the disclosure.

The suitcase200of the second embodiment differs from the suitcase100of the first embodiment in a number of ways. The description that follow focuses on the differences relative to the suitcase100of the first embodiment.

The suitcase200comprises a first protruded portion250and a second protruded portion270both of which extend substantially out from the lid opening plane. Whereas for the suitcase100of the first embodiment the first aperture161is located on the lower stepped portion160, in the suitcase200of the second embodiment the first aperture261is located on a front face of the first protruded portion250. Similarly, the second aperture281of the suitcase200is located on a front face of the second protruded portion270rather than on the top stepped portion180.

Secondly, the lower stepped portion260, the upper stepped portion275and the top stepped portion280protrude from the lid opening plane at a gentle acute angle, whereas the equivalent stepped portions in the suitcase100project at an angle that is approximately perpendicular to the lid opening plane.

Furthermore, there is no distinct change in radius between the lower stepped portion260and a front face of the first protruded portion250. Rather, the radius is fairly continuous. Similarly, there is no distinct change in radius between the upper stepped portion275and the front face of the second protruded portion270or between the top stepped portion280and the front face of the second protruded portion270.

Also, relative to the suitcase100of the first embodiment, there is a larger radius between the lower edge255of the first protruded portion250and the front face of the first protruded portion250.

In this way, the overall profile of the font face when viewed from the side avoids the appearance of corners between the first protruded portion250, the first recess265and the second protruded portion270.

Finally, the suitcase200comprises a larger number of strengthening ribs222than the suitcase100of the first embodiment. Moreover, the strengthening ribs222are curved. In addition, the first aperture261and the second aperture281are parallel to the curves of the strengthening ribs222.

Alternative strengthening rib configurations and aperture configurations fall within the scope of the disclosure. For example, the apertures and/or the strengthening ribs may be inverted relative to what is shown inFIGS.8and9. The apertures may or may not be parallel to the ribs. Furthermore different aperture shapes are possible, including n-shaped, and u-shaped.

Also falling within the scope of the disclosure are embodiments having more than two protruded portions thus providing more than two pockets.

In addition, the moulded concave shell may comprise embossing for either or both of structural and aesthetic reasons.

In a further aspect of the disclosure there is provided a method of manufacturing an article of luggage in accordance with the disclosure.

The method comprises moulding the lid120comprising a concave shell to include a lower protruded portion150which protrudes from the lid opening plane125via a lower stepped portion160and an upper protruded portion170which protrudes from the lid opening plane125via an upper stepped portion175that faces the lower stepped portion160.

The method further comprises making an incision to provide a first aperture in the moulded concave shell that provides access to the lower pocket within the lid containment volume behind the lower protruded portion. The method further comprises making an incision to provide a second aperture in the moulded concave shell that provides access to an upper pocket within the lid containment volume behind the upper protruded portion, wherein the upper pocket is in part bounded by an interior surface of the upper stepped portion.

The method further comprises fastening a hinge between the body and the lid to enable movement of the lid relative to the body between: an open position in which the body and lid containment volumes are accessible through the body and lid openings; and a closed position in which the body and the lid openings cooperate such that the body and lid containment portions are enclosed.

In some embodiments, the upper and lower stepped portions are substantially perpendicular to the lid opening plane.

In some embodiments, the moulded concave shell further comprises a first recessed portion between the upper and lower stepped portions and set back from the upper and lower protruded portions.

In some embodiments, the concave moulded shell further comprises a second recessed portion that is set back from the upper protruded portion and substantially perpendicular to the lid opening plane, and a top stepped portion on an opposite side of the upper protruded portion from the upper stepped portion, wherein the second aperture is located in the top stepped portion.

In some embodiments, the method also comprises providing a first fabric receptacle having a first receptacle opening the first receptacle opening having a first side and a second side, then fastening the first side of the first receptacle to the moulded shell on a first side of the first aperture and fastening the second side of the first receptacle to the moulded shell on a second side of the first aperture.

The method may further comprise: fastening a first pocket zipper having a first zipper tape and a second zipper tape to the lid. In particular, the first zipper tape may be fastened on the first side of the first receptacle opening and the second zipper tape may be fastened on the second side of the first receptacle opening, such that both the first aperture and the fabric receptacle are openable and closable by the first pocket zipper.

In some embodiments, any one or more of the fastening steps may comprise stitching.