Abstract:
A luggage case ( 10 ) has a molded, relatively hard or rigid back portion affixed to the relatively soft fabric constructed front portion ( 12 ). A connector form ( 25 ) constructed of an extruded, flexible shape extends around the peripheral rim ( 19 ) of the back portion, and has a first free end ( 30 ) which is attached by sewing to a gusset ( 21 ) that extends around the front portion ( 11 ). The connector form ( 25 ) has an upper portion that has one and preferably two channels on an outer portion, one of which contains a stiffening wire ( 36 ). The upper portion is fastened by stitching to the rim ( 19 ) of the back portion. The upper portion includes at least a pair of protruding pockets ( 22 ), which define a gap or channel ( 23 ) there between. A strap ( 39 ) attached to opposite sides of the back portion by triangular-shaped anchors, passes through this gap or channel ( 23 ) and had a lifting handle ( 38 ) attached thereto. A shoulder harness has ends that can be attached to an end of the back portion and to the lifting handle ( 38 ) at a shoulder yolk can be used to carry the luggage case ( 10 ) on one&#39;s back.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to constructing luggage cases from various materials, and in particular luggage constructions that use molded plastic parts and fabric parts. More particularly, such luggage cases are assembled using industrial sewing operations. Where a major portion of the outside envelope of the luggage case has large molded portions and large fabric portions, this type of luggage construction is generally called hybrid, referring to the fact that the molded portion is generally made like hard shelled luggage cases, but he the fabric portion has many esthetic and technical similarities to so-called soft side luggage cases.  
         BACKGROUND ART  
         [0002]    Generally, hybrid luggage cases conceptually are similar to a type of molded bottom wheeled duffle bag popular in the 1960&#39;s and 1970&#39;s. U.S. Pat. No. 5,588,569 shows this type of construction applied to the now popular upright case. Later, Samsonite Corporation popularized a line of luggage that incorporated hybrid construction techniques. This luggage case is shown in U.S. Pat. No. D427,434.  
         DISCLOSURE OF INVENTION 
     
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0003]    [0003]FIG. 1 is a front isometric view of one embodiment of the luggage case fully packed.  
         [0004]    [0004]FIG. 2 is a front isometric view of one embodiment of the luggage case empty with the top surface unzipped.  
         [0005]    [0005]FIG. 3 is a front isometric view of one embodiment of the luggage case empty and closed.  
         [0006]    [0006]FIG. 4 is a close-up exploded view of the connection form and the top and rear portion  11  s of one embodiment of the luggage case joined by the form.  
         [0007]    [0007]FIG. 5 is a section view taken along line  5 - 5  of FIG. 1 illustrating the connection form, top portion, and rear portion  11  of one embodiment of the luggage case in a joined position.  
         [0008]    [0008]FIG. 6 is a top isometric view of one embodiment of the flap handle.  
         [0009]    [0009]FIG. 7 is a profile view taken along line  7 - 7  of FIG. 6 illustrating the low profile of one embodiment the flap handle.  
         [0010]    [0010]FIG. 8 is a section view taken along line  8 - 8  of FIG. 6 illustrating both the low profile and the preferred connection means of one embodiment of the flap handle.  
         [0011]    [0011]FIG. 9 is a close-up exploded view of the strap anchor  51  and the portions of one embodiment of the luggage case to which it attaches.  
         [0012]    [0012]FIG. 10 is a section view taken along line  10 - 10  of FIG. 2 illustrating the connection means of one embodiment of the strap anchor  51 .  
         [0013]    [0013]FIG. 11 illustrates a user carrying one embodiment of the luggage case in the backpack configuration.  
         [0014]    [0014]FIG. 12 is a front isometric view of one embodiment of the luggage case with the backpack carry strap attached.  
         [0015]    [0015]FIG. 13A is a close-up exploded view of the female clasp connected to the carry strap and the male clasp connected to the front portion  12  of one embodiment of the luggage case prior to connecting.  
         [0016]    [0016]FIG. 13B is atop view of one embodiment of the carry strap.  
         [0017]    [0017]FIG. 14 is a close-up view of one embodiment of the carry strap and conversion clasp in the backpack configuration. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0018]    Best Mode for Carrying out the Invention  
         [0019]    A luggage case incorporating the features of the present invention is shown in FIG. 1. The luggage case  10  includes a rear portion  11  that is vacuum formed from a sheet of flexible thermoplastic, similar to that used in a typical hard luggage shell construction, a front portion  12  attached to the rear portion  11 , the front portion  12  being made of a soft-sided luggage construction of fabric shapes and panels, a carry handle  13  attached at a central location along one of the sides of the luggage case  10 , two strap systems  14  used to compress and stabilize the load inside the case, and an optional back pack carry strap  15  (see FIGS.  11 - 14 ). The rear shell portion of the luggage case  10  has a rear-facing surface  16 , opposing top and bottom surfaces  17 , and opposing side surfaces  18 . The edge of the opposing side surfaces and the opposing top and bottom surfaces forms a perimeter rim  19  to which is attached the front portion  12  of the luggage case  10 . The rear portion  11  of the luggage case  10  can include an extendable handle  20 , which fits in a collapsed position in the back surface of the luggage case  10 , and extends from that collapsed position to an extended position as desired by the user. In conjunction with the extendable handle  20 , at least a pair of wheels (not shown) can be attached to the rear portion  11  adjacent the intersection of the back surface with the bottom surface as is conventional for this upright style of luggage case for convenience in moving the luggage case  10  along a support surface.  
         [0020]    Referring still to FIG. 1, and to FIGS. 2 and 3, the front portion  12  of the luggage case  10  includes a gusset or collar  21  forming a rim around and extending rearwardly from the front surface of the luggage case  10 . The front surface of the front portion  12  of the luggage case  10  includes a variety of pockets, and as disclosed herein, includes a series of three pockets  22  extending horizontally and spaced vertically from one another on the front surface of the front portion  12  of the luggage case  10 . The three front pockets  22  form two channels  23  there between for receiving the strap systems  14 , which are described in greater detail below. The gusset  21  attached to the front surface of the front portion  12  of the luggage case  10  defines a perimeter which is attached to the perimeter rim  19  of the rear portion  11  of the luggage case  10 . The perimeter of the gusset  21  is attached to the perimeter rim  19  of the rear portion  11  of the luggage case  10  by a connector form designed specifically to integrate and connect these two pieces together in a strong, convenient and durable manner.  
         [0021]    The rear and front portion  12   s , when attached together, define an inner cavity  24  for receiving articles for packing. The volume of the luggage case  10  in the rear portion  11  is relatively fixed due to the formed hard-sided structure, while the volume of the front portion  12  is variable given its soft-sided construction. The strap system  14  assists in stabilizing the load when the luggage case  10  is not filled to capacity, as is described in greater detail below. The gusset  21  allows the luggage case  10  to expand or contract, by the front surface moving toward or away from the rear portion  11 , depending on the desired load. The attachment of the gusset  21  to the rear portion  11  of the luggage case  10  facilitates either large or small loads easily, and in further combination with the support strap system  14  facilitates in securing any variety of sizes of loads in the luggage case  10 .  
         [0022]    The connector form  25  for attaching the rear portion  11  to the front portion  12  of the luggage case  10  is shown in FIGS. 4 and 5. The preferably flexible connector form  25  is made of plastic or rubber and is formed by an extrusion process for continuous application around the entire perimeter rim  19  of the hard shell as well as the entire perimeter of the soft-sided gusset  21 . The connector form  25  attaches to the front portion  12  preferably by a sewing stitch  26 , which connects the form, the gusset  21 , and a liner  28  together. The connector form  25  also attaches to the rear portion  11  and gusset  21  preferably by a sewing stitch  27 .  
         [0023]    The cross-sectional shape of the connector form  25  is best shown in FIGS. 4 and 5, and includes a generally straight, downwardly depending (as oriented in FIGS. 4 and 5) inner wall  29 . The bottom end of the inner wall  29  is a free end  30  and the top end of the inner wall  29  is attached integrally to the top wall  31  of the connector form  25 . An outer wall  32  of the connector form  25  attaches integrally at its top end with the top wall  31  of the connector form  25 . The outer wall  32  includes two distinct inwardly directed channels: a top channel  33  and a bottom channel  34 . The two channels are separated by an indentation forming an outwardly directed slot  35 . The outer wall  32  of the connector form  25  thus generally has a W-shape in cross-section. The outer wall  32  does not extend as far downwardly as the inner wall  29 , which allows the inner wall  29 , to which the liner  28  and gusset  21  are attached by stitch  26 , to permit free access to properly place the stitch  27  around the perimeter of the rear portion  11 .  
         [0024]    An interior space is formed in the connector form  25  by the combination of the inner, top and outer walls, and is continuous along the length of the connector form  25 . As mentioned above, the connector form  25  facilitates the attachment of the front portion  12  to the rear portion  11  of the luggage case  10 . This is again best shown in FIGS. 4 and 5. Referring still to FIG. 4, a portion of the gusset  21 , zipper, top surface of the soft-sided portion of the luggage case  10 , the liner  28  for the rear portion  11  of the luggage case  10 , the sidewall defining the rim  19  of the rear portion  11  of the luggage case  10 , as well as a stiffening member, such as a tempered steel wire  36 , that assists in holding the shape of the rear portion  11  and for strengthening the interface of all these pieces, are shown in an exploded view. Note that the perimeter rim  19  of the rear portion  11  of the luggage case  10  has an outwardly flaring flange  37  around substantially the entire length of the perimeter rim  19 . Preferably, this flange  37  is formed by trimming off the excess thermoplastic material after vacuum forming the back portion.  
         [0025]    When attached together, as shown in FIG. 5, the bottom portion of the gusset  21  and the top portion of the liner  28  are attached to the bottom free end  30  of the inner wall  29  of the connector form  25 . The sewing attachment  26  is performed before the connector form  25  is placed on the perimeter rim of the hard-sided rear portion  11 . Once the gusset  21  and the liner  28  are attached to the bottom end of the inner wall  29 , the connector form  25  is then positioned on the rim of the of the luggage case  10 . In doing this, the perimeter rim  19  of the rear portion  11  is received in the recess such that the outward flange  37  at the top of the rim  19  of the rear portion  11  is received in the top channel  33 . The inside surface of the inner wall  29  of the connector form  25  engages the inside surface of the rim  19 , with the flange  37  in the inside surface of the rim  19  in relatively continuous contact with the inside surface of the inner wall  29 , as shown in FIG. 5.  
         [0026]    The stiffening member is positioned under the flange  37  of the perimeter rim and extends continuously around the rim  19 . The stiffening member is positioned in the top recess channel when the connector form  25  is placed on the rim  19  of the rear portion  11 . The wire  36  helps stiffen the rim  19  structure for stability and durability during use. The connector form  25  is then attached to the hard-sided luggage portion and the gusset  21  by placing a sewing stitch line  27  continuously around the rim  19  of the hard-sided portion in the indentation  35  formed on the outer wall  32  of the connector form  25 . The sewing extends through the outer wall  32  of the connector form  25 , through the wall of the rear portion  11 , and finally through the inside wall of the connector form  25 . Optionally for firmer attachment, this sewing stitch could also pass through and thus attach the gusset  21  as well. Preferably however, the fabric portions of the front portion  12  are stuffed into the cavity  24  of the bottom portion during this final sewing operation, well out of the way of the sewing machine arm and guide dogs used to place the stitch line  27 . This permits the sewing machine operator to concentrate on manipulating the cumbersome luggage case  10 , repositioning it to feed the assembled connector form  25 , stiffening member, and the front and back portions during sewing. The lower channel of the outer wall  32  of the connector form  25  is not further attached to the hard-sided rear portion  11 .  
         [0027]    The use of the connector form  25  to attach the soft-sided front portion  12  to the hard-sided rear portion  11  allows for a simple yet strong attachment structure. By not attaching the lower free end  30  of the inner wall  29  of the connector form  25  to the rear portion  11 , the liner and the lower portion of the inside wall can flex away from the hard-sided portion as needed, which alleviates stress on that connection point. Attaching the connector form  25  to the hard-sided portion through all four layers as described above at a location between the top and bottom channels securely positions the top rim  19  of the hard-sided portion securely in the top channel  33 , as well as keeps the wire  36  stabilizing member in proper position.  
         [0028]    As mentioned above and shown in FIGS.  1 - 3 , in a preferred embodiment of the present invention, a carry handle  13  is attached at a central location along one of the sides  17  or  18  of the luggage case  10 . In an alternative embodiment of the present invention, a low-profile flap handle  40  replaces the carry handle  13  illustrated in FIGS.  1 - 3 . As shown in FIGS.  6 - 8 , the flap handle  40  is generally attached in approximately the same location as the preferred embodiment carry handle  13 . The flap handle  40  serves the same function as the carry handle with the additional feature of being low-profile with respect to the side surface of the luggage case  10  (see FIG. 7).  
         [0029]    As shown in FIGS.  6 - 8 , at one end of the flap handle  40  is a base portion  41  having connection apertures through which connection rivets are inserted to attach the flap handle  40  to the side of the luggage case  10 . The base portion  41  can run substantially along the width of the luggage case  10 , if shorter, can be centrally located. A matching base cap  42  that also includes connection apertures covers the base portion  41 . A central portion  43  is formed adjacent the base portion  41  and includes at least one groove  44  running across the width of the flap handle  40 . The groove  44  serves to form an integral hinge portion. A semi-circular carry handle portion  45  is formed adjacent the central portion. The carry handle portion  45  includes a central handle aperture  46  bordered along the top by a ribbed handle portion  47 . Preferably, the handle aperture  46  is sized to allow a typical user to grasp the flap handle  40 . In addition, the ribbed handle portion is configured to increase the comfort and grip of the user. The ribbed handle portion  47  also serves to give the user a portion of the handle to grasp when pulling the handle upward away from the side surface  17  of the luggage case  10 .  
         [0030]    In a preferred embodiment, the flap handle  40  is made of a resilient, substantially flexible material. Preferably, the flexible nature of the material in conjunction with the groove or grooves will provide an integral hinged portion that allows the carry handle portion of the flap handle  40  to be pulled upward, away from the side surface of the luggage case  10  to act as a carry handle for the luggage case  10 .  
         [0031]    As mentioned above and illustrated in FIG. 7, when the flap handle  40  is not being used, it lays substantially flat along the surface of the luggage case  10  thereby creating a low-profile handle with respect to the surface of the luggage case  10 .  
         [0032]    In FIG. 8 is a section view illustrating the low profile of the flap handle  40  and a preferred means of connecting the flap handle  40  to the side  17  of the luggage case  10 . The flap handle  40  is connected to the side of the luggage case  10  via fasteners, such as rivets, that are inserted through the connection apertures in the flap handle  40  and through the molded shell of the luggage case  10 .  
         [0033]    As mentioned above and illustrated in FIGS.  1 - 3 , the luggage case  10  includes two strap systems in the channels  23  formed between the pockets  22  on the front portion  12  of the luggage case  10 . Each carry strap system  14  includes a central carry handle  38 , an adjustable strap  39  running through and extending from both sides of the carry handle  38 , a connection clasp  50  including male portions attached to both ends of the adjustable strap  39 , and female portions pivotally attached to the ends of generally triangularly shaped wrap-around strap anchors  51 . The adjustable strap  39  is attached to the front surface of the front portion  12  by rivets, sewing or other means.  
         [0034]    As mentioned above, the strap system  14  assists in stabilizing the load, when the luggage case  10  is not filled to capacity. The user may either increase or decrease the length of the strap depending on the size of the load. When the luggage case  10  is not filled to capacity, the user will want to decrease the length of the strap thereby compacting the soft side front portion  12  into the hard side rear portion  11  of the luggage case  10 . In the opposite case, the user will want to increase the length of the strap to allow the soft side top portion of the luggage case  10  to expand thereby creating more volume to accommodate a larger load.  
         [0035]    The support strap system strap anchors  51  are configured to extend from the molded rear portion  11  and wrap around a portion of the soft side front portion  12 . By wrapping around or partially over the soft side front portion  12  of the luggage case  10 , the strap anchors  51  serve to support and protect the soft side portion of the luggage case  10  and protect the luggage case  10  from side impact forces.  
         [0036]    As illustrated in FIG. 9, each strap anchor  51  includes two pieces: a first piece having a base portion  52 , an intermediate hinged portion  54 , and a generally triangular, apertured top portion  55 ; and a second bottom face plate piece  53  that covers the base portion  52 . Both the bottom face plate and the base portion  52  include aligned connection apertures for receiving a rivet or screw. Both the bottom face plate  53  and the base portion  52  are generally rectangular and are substantially similar in shape. Both the bottom face plate  53  and the base portion  52  have generally wedge-shaped cross-sections to minimize the overall profile of the strap anchor  51  when connected to the luggage case  10 , and to enhance its strength. A space (FIG. 10) formed between the apertured top portion  55  and the intermediate hinged portion  54  on the inner surface of the strap anchors  51  receives the connector form  25  and allows the anchor to lie flush on the luggage case  10 .  
         [0037]    The integral hinged portion located intermediate to the strap anchor  51  increases the flexibility of the strap anchor  51  thereby allowing the support strap system  14  to give-and-take with the shifting of loads. The pivot point attachment portion at the top of the strap anchor  51  provides additional flexibility. One end of the female connection clasp  50  is pivotally connected via a small length of webbing to the pivot point attachment portion thereby providing the female connection and thus the entire support strap system  14  additional flexibility. It is contemplated that the attachment mechanisms on the end of the straps could be reversed, or could be some other mechanism.  
         [0038]    As illustrated in FIG. 10, the strap anchors  51  are generally riveted or screwed to the side of the hard side rear portion  11  of the luggage case  10  through the connection apertures.  
         [0039]    An optional backpack carry strap  15  is available to enable the user to carry the luggage case  10  as a backpack. In the backpack configuration as illustrated in FIG. 11, the user can carry the luggage case  10  by slipping the respective side of the carry strap  15  over the left and right shoulders, as appropriate, of the user. FIGS.  11 - 14  illustrate the use of the luggage case  10  in the backpack configuration.  
         [0040]    The carry strap  15  is an elongated webbing material  61  with clasps  62  attached at each end to engage D-loops  63  located on the bottom corners of the rear portion  1 .  
         [0041]    Centrally located along the strap is a cushion pad  64  that helps comfort the user when using the strap. The cushion pad  64  has a curved yoke shape, with a central portion and two extending arms. The yoke portion is generally formed from an extendable or elastic material such as neoprene. The webbing  61  can be attached to the ends of the arms, or could extend continuously through the cushion. The central portion is generally wider than the extending arms. As shown in FIG. 1  3 A, a female clasp  65  is centrally connected to the carry strap  15  and directly on the central portion of the cushion. When used in the back pack configuration, the female clasp  65  connects the carry strap  15  to the male clasp  66  affixed to the front portion  12  of the luggage case  10  (see FIG. 3), preferably in the channel formed between the top and middle pockets. It can be near the carry handle  38 . The ends of the strap are attached to the D-loops  63  mounted at, near, or adjacent to the bottom corners of the rear portion  11 .  
         [0042]    [0042]FIG. 13A illustrates the female clasp  65  and male clasp  66  in an unconnected position. In FIG. 13A, a keyhole shaped aperture  67  is clearly shown, and is formed by generally connecting circles, one of which has a smaller radius. A large open area is formed that opens on a smaller open area. A plate having a cylindrical protrusion  68  extending therefrom forms the male clasp. A larger diameter, generally disk-shaped cap is centered on end of the protrusion. The cap is small enough to fit through the larger opening in the female clasp  65 , but is larger than the smaller opening in the female clasp. When the female clasp and male clasp are connected to form a conversion clasp, the cylindrical protrusion portion of the male clasp is received in the smaller portion of the keyhole-like aperture in the female clasp.  
         [0043]    Preferably, the cylindrical protrusion fits in the smaller opening with a snap-fit so the clasps do not disengage from one another.  
         [0044]    [0044]FIG. 13B illustrates an alternative embodiment of the carry strap  15 . In FIG. 13B, the carry strap  15  includes a centrally located, extendable, elastic-like yoke portion. As shown in FIG. 13B, when in an unstretched position, the yoke portion of the carry strap  15  is slightly curved. At the apex of the curved yoke portion is a female clasp insert. The clasp insert is integral to the yoke portion. In other embodiments, the clasp insert could be a male clasp or any other similarly functioning connection means. In the embodiment illustrated in FIG. 13B, the female clasp insert is similar to the female clasp described above. It includes a clasp aperture  67  that is keyhole-like in shape with a larger circular aperture joined to a smaller circular aperture.  
         [0045]    The yoke portion is preferably constructed of materials that are extendable, expandable, and/or elastic-like. In the embodiment in FIG. 13B, the yoke portion is constructed of neoprene. In addition, in a preferred embodiment, the yoke portion is perforated. Perforating the yoke portion can increase the flexibility and extendability of the carry strap  15 . In addition, perforations  69  increase the number of edges that contact the user thereby increasing the overall grip of the carry strap  15  when used either as a shoulder strap or a backpack strap. Also, perforating the yoke portion of the carry strap  15  increases the airflow between the strap and the user thereby helping to cool the contact areas between the yoke portion and the user.  
         [0046]    The elastic-like yoke portion of the carry strap  15  embodiment illustrated in FIG. 13B stretches from an unstretched first position (solid lines) to a stretched second position (dashed lines) when suspending a loaded luggage case  10 , whether used as a shoulder strap or a backpack strap. The elastic-like yoke portion returns to the unstretched first position when not suspending a load. The elastic quality of the yoke material serves as a shock-absorbing device by absorbing forces generated from the backpack load thereby supporting the backpack load while maintaining the comfort of the user.  
         [0047]    Preferably, whether being used in an over-the-shoulder mode or in a backpack mode, the primary portion of the carry strap  15  to contact the user is the elastic-like yoke portion. By utilizing the strap in this manner, the user will receive the most benefit from the comfort features described above. Therefore, in a preferred embodiment the overall length and adjustability of the carry strap  15  and the length of the yoke portion are sized to ensure that when in use primarily the yoke portion of the carry strap  15  contacts the user, regardless of the user&#39;s size.  
         [0048]    In other embodiments of the carry strap  15 , the yoke portion can be constructed of a combination of materials exhibiting a combination of characteristics. Some materials may be stretchy or elastic-like and some may not. Factors to be considered in selection of materials include but are not limited to the cost of materials, the types and weights of loads supported by the carry strap  15 , and the compatibility and ease of connecting adjoining materials. For example, in one embodiment, the yoke portion of the carry strap  15  may only include elastic-like materials on the portions of the yoke that extend over a user&#39;s shoulder. The portion of the yoke that remains behind a user&#39;s neck may be constructed of a non-elastic material.  
         [0049]    [0049]FIG. 14 provides a close-up view of the carry strap  15  and conversion clasp illustrated in FIG. 12. In the preferred embodiment shown in FIGS. 12 and 14, the male clasp is attached to the top front portion  12  of the luggage case  10  in the space  23  between protruding pockets  22 , and the female clasp is fixed to the carry strap  15 . In alternative embodiments, the female clasp could be attached to the luggage case  10  and the male clasp could be attached to the carry strap  15 . In addition, in still further embodiments, other attachment means including snaps, buttons, loops, and related attachment means could be used to attach the convertible carry strap  15  from a shoulder to a backpack strap.  
         [0050]    While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.