# Patent

## Title
Expandable luggage with locking expansion mechanism

## Abstract

An item of expandable luggage is provided with a muiltipositional locking expansion mechanism that includes a lock release actuator for unlocking the expansion plates that is located near or on a handle on the sliding plate situated towards the upper portion of the expandable body for easy accessibility, thereby permitting the user to adjust the inner volume of the luggage storage space when the compartment is fully packed. The extendable gusset is provided with one or more resilient members that retract the gusset into the interior of the luggage when it is not extended.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/456,171, filed on Jun. 5, 2003, now U.S. Pat. No. 7,093,700, which is a continuation of application Ser. No. 10/092,764, filed on Mar. 6, 2002, now U.S. Pat. No. 6,575,272, the disclosures of which are incorporated herein by reference and made a part of this application.


FIELD OF THE INVENTION
The present invention relates generally to expandable luggage, and particularly to expandable luggage having a zipperless expansion gusset with an easily accessible adjustable locking expansion mechanism.
BACKGROUND OF THE INVENTION
The needs of travelers for luggage space can vary considerably depending on the duration of a trip, types of clothing and other gear required, and the climate of the destination, to name a few. One way travelers accommodate these needs is by using expandable luggage that have heretofore been provided. Expandable luggage also offers the traveler a possible cost savings by avoiding the need to purchase more than one piece of luggage. Moreover, the capability of expanding a piece of luggage permits the traveler to change the carrying capacity throughout the course of a trip.
Expandable luggage of varying construction and designs are well known in the art.
Examples of existing expandable luggage include U.S. Pat. Nos. 6,220,411; 6,059,078; and 6,021,874, wherein '078 and '874 are commonly assigned to the present assignee. However, these designs have some disadvantages. For example, each of the luggage pieces disclosed therein contain an expandable portion or gusset requiring a zipper that must be manipulated into an open or closed position in order to expand or retract the expandable portion respectively. Zippers can become stuck and/or damaged due to wear and tear a typical piece of luggage encounters, or simply due to use over an extended period of time.
Another disadvantage pertains to the location of the various locking mechanisms for maintaining the luggage an expanded state. For example, in '411, the locking mechanism is located near the lower portion of the bridge plate at the bottom of the luggage, making the locking mechanism difficult to reach and operate when the luggage is packed and the user needs to increase the volume of the luggage to accommodate the storage of additional items. Similarly, the location of the hook and loop fastening mechanism in '078 and '874 used in adjusting the volume of the luggage disclosed therein is located near the bottom of the luggage, making the fastening mechanism difficult to reach and operate when the luggage is packed and the user needs to increase the volume of the luggage to accommodate the storage of additional items. There is therefore a need for an improved expandable luggage having zipperless expandable portion which overcomes these and other disadvantages associated with existing expandable luggage. As used herein “luggage” is intended to include all manner of containers, for example, but without limitation, briefcases.
SUMMARY OF THE INVENTION
In general, it is an object of the present invention to provide an expandable item of luggage, suitcase, bag or the like having an intermediately located zipperless expandable portion or gusset with a multipositional locking expansion mechanism. The interior storage volume of the item of luggage is easily adjusted, and directly corresponds to the retracted, various intermediate, and completely expanded states of the zipperless gusset.
The item of luggage preferably comprises a main body portion, an expandable body portion and an access panel. The main body has first (lower) and second (upper) support frame elements, inner and outer surfaces, a bottom wall, and a pair of opposing sidewalls. The expandable body portion is adjustably coupled to the main body by a multipositional locking expansion mechanism, and includes a support frame, a pair of opposing sidewalls and a zipperless expandable gusset. The zipperless expandable gusset is intermediately located between, and adjustably coupled to, the upper support frame element and the expandable body support frame.
The locking expansion mechanism preferably includes a locking element, a lock release element, a first expansion plate fastened to the upper and lower support frames of the main body, and a sliding second expansion plate fastened to the support frame of the expandable body portion. The first expansion plate includes a locking lug, preferably a pair of lugs, slidably coupled to a lug receiving slot, preferably a pair of slots, located on the second expansion plate. The locking expansion plates are slidably engageable and lockable to permit expansion and retraction of the zipperless gusset by adjustments in the height of the expandable body. The locking element is capable of engaging the locking lug in order to control the sliding and locking of the second expansion plate with respect to the first expansion plate. The lock release element for unlocking the expansion plates is easily operated and conveniently located near or on the sliding plate handle situated by the top region of the expanding body to provide for easy accessibility, thereby permitting the user to adjust the interior storage volume of the item of luggage without having to unpack in order to gain access to the unlocking mechanism, as is commonly the problem with expandable cases in the prior art. In a preferred embodiment, the item of luggage comprises a pair of locking expansion mechanisms located on opposing sidewalls.
The access panel is preferably attached to the expandable body portion by a zipper and hinged element. Additionally, one or more handles, straps or the like are preferably mounted on the outside of the luggage body for easy lifting and carrying, and wheels or the like are preferably mounted on the luggage for easy transport.
Another object of the invention is to provide an item of luggage further including a web of resilient plastic material or the like attached to the interior side of gusset between the gusset and the inner adjacent side walls of the main body and the expandable body. The web preferably extends between the respective opposing peripheral upper and extendable frame elements such that when the luggage is collapsed the gusset is drawn towards the interior region of the luggage, thereby allowing the opposing frame elements to come into contact without the user having to manually retract the gusset to the desired interior position. The web of resilient plastic material is preferably attached to the interior side of the gusset by an appropriate fastening means including, but not limited to an adhesive or the like.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cutaway view of an item of luggage fully expanded according to one embodiment of the invention;
FIG. 2 is an exploded view of the item of luggage in FIG. 1;
FIG. 3 is a cutaway view of the multipositional locking expansion mechanism according to one embodiment of the invention;
FIG. 3A is a cross-sectional view taken along line 3A-3A of FIG. 3 showing the mechanism in the locked position;
FIG. 3B is the cross-sectional view of FIG. 3A showing the mechanism in the released position;
FIG. 4 is an exploded view of the locking expansion mechanism in FIG. 3;
FIG. 5A is an interior plan view of the item of luggage and locking expansion mechanism in the fully retracted state;
FIG. 5B is an exterior plan view of the item of luggage and locking expansion mechanism in FIG. 5A;
FIG. 6 is an interior plan view of the item of luggage and locking expansion mechanism in FIG. 5A in an intermediate position between the fully extended and retracted positions;
FIG. 7A is an interior plan view of the item of luggage and locking expansion mechanism in FIG. 5A in the fully extended position;
FIG. 7B is an exterior plan view of the item of luggage and locking expansion mechanism in FIG. 7A; and
FIG. 7C is an interior perspective view of the item of luggage and locking mechanism plates shown in FIG. 7A.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings FIGS. 1-7. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. An exemplary embodiment of an item of luggage, suitcase, bag or the like of the present invention is shown in FIG. 1, and is designated generally throughout by reference numeral 10.
Referring to FIGS. 1-7, there is depicted an item of luggage 10 including a multipositional locking expansion mechanism 20 for supporting the expansion and retraction of an expandable zipperless portion or gusset 54 in accordance with the invention. Item of luggage 10 includes a cover or skin 80 made of a suitable material, such as ballistic nylon, a main body 14, an expandable body portion 50, and an access panel 24. The access panel 24 is preferably attached to main body 14 by a zipper 38 as shown in FIG. 1 and a hinged element 36 as shown in FIG. 2. Main body 14 is supported by bottom wall 16, lower (first) support frame element 26, upper (second) support frame 28, and opposed outer side walls (18a, 18b, 18c, 18d) as shown in FIG. 1. Expandable member 50 includes an expandable member support frame 52, a pair of opposing sidewalls, and an expandable zipperless gusset 54. Gusset 54 is intermediately located between and coupled to upper support frame 28 and expandable member support frame 52.
Multipositional expansion and locking mechanism 20, best shown in FIGS. 1, 3-7C, preferably includes a locking element 110, a lock release element 120, a substantially rectangular first stationary expansion plate 40, a substantially rectangular sliding second expansion plate 60 and a cover plate 75 that is removably attached to sliding plate 60. First expansion plate 40 is attached by appropriate fasteners 78 (e.g., bolts, screws) passing through reinforced openings 55 to upper 28 and lower 26 support frame members of main body 14, and sliding second expansion plate 60 is attached by appropriate fasteners 78 (e.g., bolts, screws) to expandable body support frame 52.
As shown in FIG. 4, first plate 40 preferably includes a pair of parallel spaced-apart locking lugs 42 slidably coupled to a pair of corresponding parallel spaced-apart elongated lug receiving slots 68 positioned between legs 30 located on second plate 60. Expansion plates (40,60) are slidably engageable and lockable by positioning locking element 110 in any pair of opposing locking apertures 45 in order to permit expansion and retraction of zipperless gusset 56 by adjustments in the height of expandable body 50.
As depicted in FIG. 3, lock element 110, preferably engaged for release by a spring-biased rotating crank (130,140) activated mechanism, is capable of engaging lower and upper locking apertures 45 located on either side of stationary plate 40 to thereby provide at least two locking positions for sliding expansion plate 60 with respect to first expansion plate 40. Lock release element 120, preferably includes a push button 88 activating mechanism to rotate cranks 130 and 140, thereby disengaging lock element 110 from apertures 45, is capable of unlocking expansion plates (40,60) when activated, permitting locking lugs 42 to slide within receiving slots 68.
In a preferred embodiment, the release mechanism actuator 120 is easily operated and conveniently located near or on a sliding plate handle or grip 72 situated towards the top region of expandable body 50 to provide for easy accessibility. The user is thus able to adjust the interior storage volume of the item of luggage 10 without having to unpack in order to gain access to the unlocking mechanism 120. In a preferred embodiment, the item of luggage 10 comprises a pair of locking expansion mechanisms 20 located on opposing sidewalls.
In another embodiment of the invention depicted in FIG. 2, an item of luggage 10 further includes gusset retracting means, which in the embodiment shown comprises a web 76 of resilient plastic material or the like attached to the interior side 84 of gusset 54, situated between outer gusset wall and inner adjacent side walls of main body 14 and the expandable body 50. Resilient web 76 extends between the respective opposing peripheral region of upper frame 28 and extendable frame 52, so that when expanded luggage item 10 is collapsed, gusset 54 is drawn towards the interior region of the luggage, thereby allowing the opposing frame elements (28,52) to come into contact with each other, without the user having to manually retract gusset 54 to the desired interior position and away from interfering with the retraction of luggage 10. The web of resilient plastic material 76 is preferably attached to the interior side 84 of gusset 54 by an appropriate fastening means including, but not limited to, an adhesive, mechanical fasteners, stitching, or the like.
Alternatively, the resilient web 76, or individual resilient elements in the form of flexible stays (not shown), can be sewn to the gusset 54, or alternatively, in a sleeve or pockets provided for this purpose.
Support frame members (26, 28, 52) are preferably made of a substantially rigid material to provide strength and rigidity to top, bottom and side walls of main body 14 and expanding body assembly 50. Support frame members (26, 28, 52) each optionally have the shape of an endless loop-like rectangular member and extend around the outer perimeter of main body 14 and expanding body assembly 50, between an inner lining 22 and outer skin 80.
Expansion plate 40, cover plate 75 and sliding expansion plate 60 are each made from any suitable rigid material, such as plastic, or from any suitable metal, such as steel or aluminum. Fasteners 78 can be of any suitable type, such as conventional rivets or screws.
Although luggage 10 has been shown with two locking expansion mechanisms 20 on opposing side walls, it should be appreciated that an item of luggage having more or less than two locking expansion mechanisms 20 is within the scope of the present invention. As will be understood by one of ordinary skill in the art seen, a variety of alternative embodiments can be provided within the scope of the present invention.
As shown in FIG. 2, a wheeled framework and wheels 48 are preferably mounted on the rear of bottom wall of main body 14 and are each made from any suitable material such as plastic and are secured together by any suitable fastening means such as rivets (not shown). The wheels are preferably made from rubber, plastic or any other suitable material, and are rotatably mounted in spaced apart positions along the rear lower edge of main body 14 for rotation about an axle. In an alternative embodiment, luggage 10 of the present invention can be provided without wheeled framework and wheels 48 so as to be suitable only for carrying by a handle, shoulder strap or both. The framed case can also be other than in the shape of a right parallel piped as depicted in FIGS. 1-7.
A first handle means or strap handle 46 is optionally secured in the middle of top wall to permit carrying of suitcase 10 in an upright position. A second handle means or strap handle 44 is optionally secured in the middle of outside wall (see FIG. 2) to permit carrying of suitcase 10 on its side.
A zipper 38 extends around the edge of access panel 24 and top edge of expandable body 50. Panel 24 preferably pivots at 36 from a top wall of the expandable body to open and thus permit access to the main storage cavity for the storage and or transport of items, including, but not limited to, clothing and other travel accessories. One or more secondary zippers (not shown) optionally extending across the outside of door 24 to permit access to front pockets (not shown) provided in panel 24 can also be provided.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention that come within the scope of the appended claims and their equivalents.

## Claims

1. an item of luggage having an interior region of adjustable interior volume, which comprises:
a) a first frame element;
b) a second frame element positioned adjacent said first frame element and configured substantially similarly to said first frame element, said second frame element being moveable between a first position in close adjacent relation to said first frame element and a second position relatively spaced from said first frame element, yet in general dimensional and configurational alignment therewith;
c) an expandable gusset connecting said first and second frame elements, said gusset being foldable to a first folded configuration when said second frame element is in said first position in close relation with said first frame element to reduce the interior volume, and expandable to a second extended configuration when said second frame element is in said second position in relative spaced relation with said first frame element, to increase the interior volume; and
d) gusset retracting means comprising a web of material attached to the interior side of said gusset and arranged such that when said second frame element is moved toward said first position, said gusset is drawn towards the interior region by force provided by said gusset retracting means, thereby allowing said first and second frame elements to come into close adjacent relation with each other, without the user having to manually retract said gusset to a desired interior position and away from interfering with the retraction of said second frame element.

2. The item of luggage of claim 1, wherein said web of material is resilient.

3. The item of luggage of claim 2, wherein said resilient material is plastic.

4. The item of luggage of claim 1, wherein said web of material is attached to said interior side of said gusset by at least one of adhesive, mechanical fasteners and stitching.

5. An item of luggage having an interior region of adjustable interior volume, which comprises:
a) a first frame element;
b) a second frame element positioned adjacent said first frame element and configured substantially similarly to said first frame element, said second frame element being moveable between a first position in close adjacent relation to said first frame element and a second position relatively spaced from said first frame element, yet in general dimensional and configurational alignment therewith;
c) an expandable gusset connecting said first and second frame elements, said gusset being foldable to a first folded configuration when said second frame element is moved toward said first position in close relation with said first frame element to reduce the interior volume, and expandable to a second extended configuration when said second frame element is in said second position in relative spaced relation with said first frame element, to increase the interior volume; and
d) gusset retracting means comprising a web of resilient material attached to the interior side of said gusset and arranged such that when said second frame element is moved toward said first position, said gusset is drawn towards the interior region by inward force provided directly to said gusset by said web of resilient material, thereby allowing the opposing frame elements to come into close adjacent relation with each other, without the user having to manually retract said gusset to a desired interior position and away from interfering with the retracting of said second frame element.

6. The item of luggage of claim 5, wherein said web of resilient material is attached to said interior side of said gusset by at least one of adhesive, mechanical fasteners and stitching.

7. An item of luggage having an interior region of adjustable interior volume, which comprises:
a) a first frame element;
b) a second frame element positioned adjacent said first frame element and configured substantially similarly to said first frame element, said second frame element being moveable between a first position in close adjacent relation to said first frame element and a second position relatively spaced from said first frame element, yet in general dimensional and configurational alignment therewith;
c) an expandable gusset connecting said first and second frame elements, said gusset being foldable to a first folded configuration when said second frame element is in said first position in close relation with said first frame element to reduce the interior volume, said gusset being expandable to a second extended configuration when said second frame element is in said second position in relative spaced relation with said first frame element, to increase the interior volume, and
d) a web of resilient plastic material attached to the interior side of said gusset and arranged such that when said second frame element is moved toward said first position, said gusset is drawn towards the interior region by inwardly directed force provided directly to the interior side of said gusset by said web of resilient plastic material, thereby allowing the opposing frame elements to come into close adjacent relation with each other, without the user having to manually retract said gusset to a desired interior position and away from interfering with the retraction of said second frame element.

8. The item of luggage of claim 7, wherein said web of resilient plastic material is attached to said interior side of said gusset by at least one of adhesive, mechanical fasteners and stitching.