A system and method for a moldable wallet. A moldable wallet has a clam shell shape with a top shell coupled to a bottom shell by a shell hinge. The wallet comprises a sealed side located at the shell hinge, and a clamped top side, right side, and bottom side. The top shell and the bottom shell have a moldable material, which can be a thermoplastic material or other bendable or moldable metal. The wallet can further include a money clip which can be integral with the wallet or a separate piece.

BACKGROUND OF THE INVENTION

Technical Field

The present invention relates to a system and method for manufacturing a wallet.

Description of Related Art

Wallets are used for storing money, credit cards, etc. Typically, wallets are manufactured from leather or other similar material. Such material easily wears, stretches, and scoffs. Consequently, there is a need for an improved wallet.

DETAILED DESCRIPTION

Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

FIG. 1is a top perspective view of a wallet in one embodiment. In one embodiment the wallet comprises any moldable material. A moldable material is any material which is moldable and which, when set, comprises a hard and rigid material which retains the set shape. In one embodiment the moldable material is water resistant. In one embodiment the wallet comprises any bendable metal or thermoplastic material. The wallet can include, but is not limited to, carbon-fiber, titanium, aluminum, bendable metals, and thermoplastic materials. A thermoplastic material is a polymer which becomes moldable above a specific temperature and which returns to a solid state upon cooling. Virtually any thermoplastic material, including acrylics, polyvinyl chlorides, and others can be utilized. In one embodiment Kydex® manufactured by Kydex LLC of Bloomsburg, Pa. is utilized. Kydex is a thermoplastic acrylic-polyvinyl chloride which is often used in the airline industry.

As used herein, a wallet refers to an object which is used to store money, credit cards, identification cards, etc. In one embodiment, discussed herein, the wallet100comprises a clam shell with a top shell101and a bottom shell102.FIG. 2is a bottom perspective view of a wallet in one embodiment. The bottom shell102is better viewed inFIG. 2.

The top shell101and the bottom shell102meet at a shell hinge107. The shell hinge107is best seen inFIG. 3, which is a back perspective view of a wallet in one embodiment. The shell hinge107couples the top shell101and the bottom shell102. The shell hinge107is the pivot point at which the top101and bottom shells102meet and can be separated. Thus, if a user applies an upward force onto the top shell101, keeping the bottom shell102immobile, the top shell101will pull away relative to the bottom shell102, pivoting at the back hinge107.

The back hinge107can comprise virtually any hinge known in the art which will allow the top shell101to pivot relative to the bottom shell102, and vice versa. In one embodiment, the top shell101, the bottom shell102, and the shell hinge107are integrally made from a single piece of moldable material. In such embodiments the shell hinge107couples the top shell101to the bottom shell102and the thermoplastic properties of the shell hinge107allow it to operate as a hinge. In one embodiment, the shell hinge107also acts as a sealed rear side of the wallet. Returning toFIG. 1, it can be seen that the wallet comprises three clamped sides, the top side, the front side on the right, and the bottom side. The shell hinge107comprises a sealed rear side on the left ofFIG. 1. A clamped side refers to a side through which contents can be inserted or retrieved. Conversely, a sealed side refers to a side through which contents cannot be inserted or retrieved. A sealed side is permanently sealed during traditional usage whereas a clamped seal can be opened during traditional usage. It can be seen that a card, for example, can be inserted or retrieved from the right front side of the wallet by spreading the top shell101from the bottom shell102. However, the top shell101cannot be spread from the bottom shell102at the closed back side. Consequently, the wallet100depicted inFIG. 1comprises three clamped sides and one sealed side. While the shell hinge107is depicted on being located on the rear side on the left ofFIG. 1, this is for illustrative purposes and should not be deemed limiting. The shell hinge107can be located on any side of the wallet100. For example, the shell hinge107can be located on the top side, the bottom side, the left side, or the right side.

As seen inFIG. 1, in one embodiment the top shell101comprises a window104. A window, as used herein, is an area through which the wallet's contents can be viewed, and/or gripped. The window104can be located on the top shell101, the bottom shell102, or both. In one embodiment, and as depicted, the window104is located on the upper right corner of the top shell101. Such a placement allows the wallet's100contents, such as cards, to be viewed and retrieved as will be discussed in more detail below.

The window104can comprise a dissimilar transparent material, or, as depicted, the window104comprises a void or absence of material. Thus, as depicted, the window104comprises a cut-away portion in the top shell101located on the upper right corner of the top shell101.

As seen inFIGS. 1 and 2, the wallet100depicted further comprises a money clip103. As depicted the money clip103comprises the same material as the top shell101and bottom shell102. Thus, in one embodiment the top shell101, the bottom shell102, the shell hinge107, and the money clip103comprise one integral piece formed from the same sheet of material, discussed in more detail below. A money clip103allows money, cards, or other items to be stored on the external surface of the wallet100. In one embodiment, for example, cards such as credit cards or driver's license are stored within the internal compartment of the wallet100between the top shell101and the bottom shell102whereas money is stored on the external surface of the wallet100underneath the money clip103. The money clip103maintains its contents by friction and the force induced to the moldable material as it attempts to retain its shape. When the money clip103is stretched open to insert, for example, money, the money clip103urges forward to retain its set-shape adjacent to the bottom shell102. The memory, or set-shape, of the money clip103provides the friction and force necessary to retain the money beneath the money clip103. The same memory or set-shape also helps the shell hinge107attempt to retain its shape.

In one embodiment, however, the money clip103is not integrally made with the top101and bottom shells102. Instead, in other embodiments the money clip103is a separate piece which is added to the wallet100. The separate piece can comprise a wire, polymer, or virtually any material which can be coupled to the wallet100and function as a money clip103. The separate piece can comprise any material discussed above. In one embodiment the separate material comprises the same material as the wallet, whereas in other embodiments the separate piece comprises a dissimilar material as the wallet. In one embodiment the separate piece comprises titanium or tensile steel. Having a removable money clip103, in one embodiment, is an advantage in that users can customize their wallet to fit their needs. If they do not utilize a money clip103, they can remove the money clip103, resulting in a slightly thinner wallet.

Returning back toFIG. 1,FIG. 1shows a recess106. A recess106in an indention in the top shell101, the bottom shell102, or combinations thereof, which provide storage for the wallet100. A deeper recess106provides for more storage in the wallet100. In one embodiment the recess106has a shape substantially similar to a standard credit card. The thickness of the recess106can vary and ranges from about 1/16 of an inch to about 1/32 of an inch for a total void of between about ⅛ of an inch to about 1/16 of an inch. In one embodiment both the top shell101and the bottom shell102comprise a recess106which mates to form the storage compartment. The respective recesses of the top101and bottom shells102can comprise the same or different thicknesses.

The wallet100thickness is a sum of the thickness of the material of the top101and bottom shells102, the recess106, and the thickness of any optional money clip103. Accordingly, each of these variables can be adjusted to control the overall thickness of the wallet.

A recess106offers several advantages. If the shells101,102were simply flat with no recess, they would simply be two flat pieces pressed together. Such an embodiment cannot securely hold the wallet's contents, much of which is often valuable, confidential, and important. The recess106provides for a secure storage compartment in which to store these valuable items.

In one embodiment the wallet100is taller and wider than a common credit card. In one embodiment the wallet has a width of between about 2 and 2.5 inches. In one embodiment the height ranges between about 3.5 and 4.5 inches. The extra length and width allows the wallet to completely surround and encase its contents, increasing the security. In one embodiment, and as depicted, the bottom shell102, for example, extends upward and outward from the recess. As can be seen inFIG. 1, the bottom shell102extends outward at between about a 30-60° angle relative to the flat planar portion of the recess106. The angle can be adjusted depending on the desired thickness of the wallet100and the thickness of the recess106. As depicted, both the top101and bottom shells102comprise an angle such that the edges where they meet offer a thinner thickness. This thinner edge allows the wallet100to be more easily directed into a user's pocket, for example. Further, the thinner edge offers a sleeker, more aesthetically pleasing appearance. Finally, because of the angled wall portion of the shells101,102, the shells fully encase the wallet's content.

FIG. 4is a top perspective view of a wallet with cards in one embodiment. As can be seen, the contents of the wallet100can be spread out in a fan-like shape. This allows the user to view several different cards and choose the desired card. In traditional wallets the user had to retrieve all of the cards from the wallet, sort through them, and decide which card to use. Often a user has a business card, a personal card, a debit card, a driver's license, etc. Having to remove all of the cards and sort through them is inefficient and undesirable as this provides an opportunity to lose contents. The fanned embodiment inFIG. 4illustrates that several cards or items can be viewed at one time, allowing the user to select only the desired card. In one embodiment, to achieve the fanned embodiment, the user presses upon the card through the window104and swipes in the direction of the fan. The pressure causes the other cards to spread out as depicted. The user can then select the desired card, and swipe in the opposite direction to return the contents into the wallet.

The shell hinge107provides sufficient pressure upon the contents to allow the contents to be fanned out yet remain under the control of the wallet100. The pressure of the shell hinge107allows the wallet's contents, such as cards, to be pivoted at the lower left corner. This provides the unexpected advantage of allowing the user to visualize and select his or her cards without having to remove all of the cards. Another advantage is that because the cards are under constant pressure, the cards do not fall from the wallet. Compared to removing all of the cards and sorting all cards by hand, the wallet discussed increases security of the cards or contents within the wallet.

As noted, the shell hinge107and the set-shape of the wallet100ensure that the top shell101tries to keep its shape adjacent to the bottom shell102. In some embodiments the top shell101is touching the bottom shell102at the clamped edges, whereas in other embodiments they are not physically touching but are very close to one another. This ensures the contents of the wallet is encased within the wallet. In one embodiment, all four side-edges of the contents are secured by either a sealed edge or a clamped edge. For example, if a credit card is inserted into the recess, the shell hinge107acts a sealed edge secures the left side-edge, the top clamped edge at the intersection of the top shell101and the bottom shell102covers the top side-edge of the card, the bottom clamped edge at the intersection of the top shell101and the bottom shell102covers the bottom side-edge of the card, and the right clamped edge at the intersection of the top shell101and the bottom shell102covers the right side-edge of the card. Thus, all four sides of the card are secured. This is contracted to a traditional money-clip wallet wherein the top, for example, is open. An open side is a side which is not either clamped or sealed. In wallets with an open top, for example, the wallet expands and stretches to accommodate additional cards. When cards are removed for cleaning the wallet, for example, the wallet has undesirably permanently stretched. When such a wallet is turned upside down, the cards can then fall through the open top end. In one embodiment comprising four secure sides, sealed or clamped, this problem is eliminated or reduced because there are no open sides. Thus, in one embodiment, the wallet100does not comprise an open side.

Returning toFIG. 1, the top shell101and the bottom shell102each comprise an exposed edge105a,b, as depicted. The top shell101has three sides of exposed edges105a: a top side, a right side, and a bottom side. The top shell101does not have an exposed edge on the left side because of the location of the shell hinge107. The bottom shell102, as depicted, also has exposed edges105bon the top side, bottom side, and portions of the right side, but does not have an exposed edge on the left side because of the location of the shell hinge107. In one embodiment the every exposed edge105a, bis polished. As can be seen, and as previously discussed, the exposed edge105aof the top shell101is adjacent to the exposed edge105bof the bottom shell102. As discussed, in some embodiments these edges are touching, whereas in other embodiments they are separated by a small distance.

In one embodiment the exposed edges105a,bare polished. Polishing these edges105a,bresults in a smooth, and in one embodiment, shiny surface. A smooth surface prevents the wallet from becoming snagged on clothing, for example. Further, because a wallet is often worn close to the user's body, a smooth polished edge prevents injury such as scratching. Finally, a polished edge105a,bis aesthetically pleasing and demonstrates a high level of craftsmanship.

The wallet discussed herein has several benefits. First, in one embodiment, the wallet is water proof or water resistant. As such, in one embodiment, the wallet will not retainer moisture. Instead, when immersed in water, the wallet's material stays dry. This is contrasted to, for example, leather wallets which retain moisture and remain wet when coming into contact with water. The user will have a soggy wallet for hours after getting wet. Further, the leather wallet will expand and contract in response to the moisture, causing the contents to spill from the wallet. However, a wallet comprising water proof or water resistant materials, such as Kydex, the wallet will not remain wet. Further, because the wallet material, in one embodiment, does not expand or contract with moisture, the contents remain secure within the wallet. A surfer, for example, can surf with the wallet in his or her pocket, and the wallet's contents will remain secure within the wallet. Further, when the surfer gets out of the water, any water will drain away from the wallet.

Second, a wallet comprising moldable material, such as a thermoplastic material is far more durable compared to standard leather wallets, for example. Many materials, such as Kydex, are very tough and are difficult to scuff or scratch. A wallet comprising thermoplastic material can be stored next to metallic objects such as tools, and will not easily scratch or wear.

Third, because of the memory shape properties of the moldable material, such as a thermoplastic material, the material maintains its set shape far better than leather or other similar materials. As discussed above, when additional contents are placed in a leather wallet, for example, the leather stretches to accommodate the contents. When some contents are removed, the leather remains stretched resulting in the contents falling from the wallet. Because a thermoplastic material better maintains its shape, this problem is eliminated or reduced.

Fourth, as described above, in certain embodiments the wallet comprises a window. The window allows some of the wallet's contents to be viewed from the outside of the wallet. Additionally, the window allows the wallet's contents to be manipulated.

Fifth, in certain embodiments the wallet allows a fanned shape embodiment wherein several cards are spread out in a fan like shape while still being controlled under the pressure of the wallet. This allows a user to see and select a desired card from many cards. Further, such an embodiment reduces the likelihood that a card or other content will become lost while the user sorts through a pile of contents.

While a wallet has been described, one method of making the wallet will also be described.FIG. 5is a flow chart of the method of manufacturing the wallet in one embodiment.FIG. 5begins with the step of obtaining material. As discussed above, the material can comprise any thermoplastic material. In one embodiment the material comprises sheets of material. In one embodiment the sheets measure about 4 feet by 8 feet in size. The thickness of the sheet can vary depending upon the desired thickness of the wallet. In one embodiment the sheets comprise a thickness of about 0.080 inches. In another embodiment the sheets have a thickness of about 0.093 inches.

Next, the sheets are cut into sizes suitable for handling. The specific size is dependent upon the desired size of the wallet. In one embodiment the sizes ranges from about 6 inches to about 12 inches in length and from about 3 inches to about 8 inches wide. In one embodiment the size is about 9 inches long by about 5 inches wide. Virtually any method can be used for cutting. In one embodiment the sheets are scored with a razor knife. Once scored, the sheets can be snapped into the specified sizes.

Next, the material heated. Heating a moldable material, such as a thermoplastic material makes the material bendable and moldable. The specific temperature required for heating a specific moldable material will depend upon the moldable material. In one embodiment using Kydex, the Kydex is heated between about 305° F. to about 350° F., whereas in other embodiments it is heated between about 330° F. to about 350° F. For Kydex, a higher temperature results in crisper, better defined lines. However, a lower temperature results in higher throughput.

The heating can be accomplished on virtually any tool used to heat a material. These include ovens, pizza ovens, t-shirt presses, irons, and virtually any device which supplies heat. In one embodiment, a t-shirt press is utilized. With such a tool, the material is placed within the press, and when the top is closed, the material is sandwiched within the press. The heating time is dependent upon material type, material thickness, and desired temperature. In one embodiment utilizing Kydex a temperature of 350° F. can be reached in 55 seconds. A pizza oven typically requires about 6 minutes from room temperature.

After the heating step, the heated material is molded. In one embodiment the material is wrapped around a mold comprising the shape of the recess. In one embodiment, the mold comprises angled ends which provide the angled edges.

In one embodiment the mold is coated with a non-stick surface to keep the wallet material from adhering to the mold. In one embodiment the mold comprises Formica, although any rigid material, including but not limited to particle board, aluminum and other metals, etc., can be used.

The wallet is placed around the mold. Thereafter, the molded wallet is allowed to sit for a period of time. The sitting time is dependent upon the moldable material, but in one embodiment comprising Kydex the mold is allowed to sit for between about 3 to 6 minutes. In one embodiment the wallet is clamped to the mold. The wallet material, including Kydex in one embodiment, expands and contracts in response to heat. Thus, the clamping resists this expansion or retraction and maintains the desired shape. Virtually any type of clamps can be used. In one embodiment the material is clamped to 600 pounds force.

In one embodiment an air cooled press is utilized. An air cooled press decreases the time necessary to cool and set the molded wallet. In one embodiment an air cooled press reduces the cooling time from about 6 minutes to about 2.5 to 3 minutes. Such a reduction in time allows additional throughput.

After sitting for the desired time, the mold is removed. In one embodiment the mold is removed by separating the top shell101from the bottom shell102.

After removing the mold, any excess material is cut and removed. Thus, if an undesirable flap extended from the top shell101, this is cut and removed. Likewise, in one embodiment material is removed to form a window104. The material can be cut using any method discussed herein. In one embodiment a band saw or a scroll saw is used to cut the excess. In one embodiment, cutting the excess comprises using a saw to cut beyond the desired final lines. Thereafter, a grinder is used to form the desired line.

After cutting the excess material, in one embodiment, the wallet is polished in a polishing step516. Virtually any method of polishing can be utilized.FIG. 6is a flow chart of the polishing step in one embodiment. As depicted, in one embodiment the first step of polishing is utilizing a cecil wheel602. A cecil wheel602offers a finer grinding surface. In this step, the cecil wheel602prepares a smooth surface on the outer edges of the wallet.

After the cecil wheel602, in one embodiment is a rouge step604. Virtually any rouge can be utilized. In one embodiment a polishing rouge called Emory is utilized. A rouge micro-emulsifizes the surface of the material and disperses the heat evenly. In so doing, the rouge helps prevent clumping, creating a smooth surface.

The rouge can be applied with virtually any applicator known in the art. In one embodiment, the rouge is applied with a denim wheel.

After the roughing step604, in one embodiment, is the cotton wheel step606. A cotton wheel takes off the rouge, polishes the material, and makes the material shiny. The cotton wheel step606acts as the buffing step.

Referring back toFIG. 5, in one embodiment the polishing step516takes place prior to heating and folding the money clip518. The reason for this is the money clip is still jetting away from the body of the wallet. As such, the edges of the money clip are more readily accessible for the polishing step than if the money clip had already been folded. The money clip is folded by applying localized heat via any device known in the art. In one embodiment a commercial heating gun is used to apply localized heat. The money clip, depending upon the material utilized, in one embodiment is heated to a temperature of between about 200-250° F. Thereafter, the money clip is folded to its desired shape and location.

In one embodiment the wallet further comprises radio frequency identification (“RFID”) protection. Many modern credit cards have RFID chips, making them susceptible to being hacked and stolen from afar. Hackers can send signals to read the RFID credit cards, stealing the information, even when the credit cards are in the user's wallet. RFID protection offers a protective coating which shields the credit cards from hackers. Accordingly, in one embodiment, the wallet comprises RFID protection. In one embodiment, the wallet comprises RFID paper located on either the exterior or interior walls. The RFID paper can be installed with any method known in the art. As but one limiting example, in one embodiment RFID paper is secured to the inner, card-side, face of the wallet. In one example, a sandwiched layer of double sided tape located atop a layer of foil, located atop a layer of double sided tape, located atop a layer of RFID paper is utilized. The top layer of double sided tape is adhered to the interior surface of the wallet such that the RFID paper is adjacent the wallet's contents, such as credit cards. This is but one example of an RFID installation.

ADDITIONAL DESCRIPTION

The following clauses are offered as further description of the disclosed invention.Clause 1. A wallet comprising:a clam shell shape with a top shell coupled to a bottom shell by a shell hinge;wherein the wallet comprises a sealed side located at the shell hinge, and a clamped top side, right side, and bottom side;wherein said top shell and said bottom shell comprises a moldable material.Clause 2. The wallet of any proceeding or preceding clause wherein the top shell comprises edges, wherein the bottom shell comprises edges, and wherein the edges are polished.Clause 3. The wallet of any proceeding or preceding clause wherein said moldable material comprises a thermoplastic material.Clause 4. The wallet of any proceeding or preceding clause wherein said top shell comprises a window.Clause 5. The wallet of any proceeding or preceding clause wherein said top shell, said bottom shell, and said shell hinge comprise one integral piece.Clause 6. The wallet of any proceeding or preceding clause further comprising a money clip, wherein said money clip is coupled to said bottom shell.Clause 7. The wallet of any proceeding or preceding clause wherein said money clip is integrally made with the top shell and the bottom shell.Clause 8. The wallet of any proceeding or preceding clause wherein the bottom shell and the top shell each comprise a recess.Clause 9. The wallet of any proceeding or preceding clause wherein the top shell comprises a flat planar surface, a top angled side, a right angled side, and a bottom angled side.Clause 10. The wallet of any proceeding or preceding clause wherein the bottom shell comprises a flat planar surface, a top angled side, a right angled side, and a bottom angled side.Clause 11. The wallet of any proceeding or preceding clause wherein said wallet does not comprise an open side.Clause 12. The wallet of any proceeding or preceding clause wherein said moldable material comprises Kydex.Clause 13. The wallet of any proceeding or preceding clause further comprising RFID protection.Clause 14. A method of making a wallet, said wallet comprising:a clam shell shape with a top shell coupled to a bottom shell by a shell hinge;wherein the wallet comprises a sealed side located at the shell hinge, and a clamped top side, right side, and bottom side;wherein said top shell and said bottom shell comprise a moldable material;wherein the method comprises the steps of:a) obtaining a sheet of moldable material;b) heating the sheet of material to form a heated material;c) molding the heated material into a desired shape to form a molded piece;d) cutting excess material from the molded piece;e) polishing the molded piece to form a wallet.Clause 15. The method of any proceeding or preceding clause wherein said heating comprises heating between about 330° F. to about 350° F.Clause 16. The method of any proceeding or preceding clause wherein said moldable material comprises a thermoplastic material.Clause 17. The method of any proceeding or preceding clause wherein said molding further comprises allowing the heated material to set for a period between about 3 and 6 minutes.Clause 18. The method of any proceeding or preceding clause further comprising the step of removing the mold.Clause 19. The method of any proceeding or preceding clause wherein said step of cutting excess material comprises creating a window in the top shell.Clause 20. The method of any proceeding or preceding clause further comprising the step of heating and folding a strip on said bottom shell to form a money clip.Clause 21. The method of any proceeding or preceding clause further wherein said polishing of step e) comprises using a cecil wheel, followed by a rouge step, followed by a cotton wheel.