Patent Publication Number: US-6220412-B1

Title: Travel bag construction

Description:
BACKGROUND OF THE INVENTION 
     Soft-sided hand luggage such as rolling travel bags and the like generally include a rigid frame forming a hard sidewall boundary for a transportable clothing compartment with a flexible fabric enclosure attached to the rigid frame. Such travel bags are usually equipped with wheels and a retractable handle. Hangers may be supported within the compartment of the travel bag so that suits, dresses and the like may be folded, suspended and transported within the bag. 
     Conventional rolling travel bags usually employ steel or heavily reinforced plastic for the rigid frame. However, the heavy frame structure of conventional travel bags adds substantially to the overall size and weight of the bag while reducing its internal storage capacity. Accordingly, there is a continuing interest in providing rigid frame travel bags equipped with wheels and retractable pull handles which exhibit strength and durability without sacrificing storage volume or increasing the net weight of the bag. 
     SUMMARY OF THE INVENTION 
     The present invention provides light-weight rigid frame travel bags which include a soft-sided enclosure. Such bags may include a set of wheels and a retractable pull handle. Travel bags employing the light-weight rigid frame structure of the invention are particularly suitable for handling business suits and dresses as well as small clothing items without significant wrinkling while retaining or exceeding the capacity, compact size and durability characteristics of conventional soft-sided travel bags. The compact bag provided by the invention also accommodates a significant number of soft garments in auxiliary pockets yet remains small enough to fit within overhead carry-on bin compartments of commercial passenger aircraft. 
     In accordance with the invention, travel bags are made which employ a rigid plastic frame formed by interconnecting a front panel, a rear panel and a C-shaped bottom panel to form a rigid frame which defines the boundaries of a transportable compartment. The C-shaped bottom panel includes first and second end panel portions joined to a substantially flat intermediate panel portion. The plastic frame members are preferably formed by extruding plastic material such as acrylonitrile-butadiene-styrene copolymer (ABS) or polyvinylchloride (PVC) in a form which defines closely spaced flat side panels, sheets or plates joined together by multiple transverse web linking portions. The web linking portions or ribs are separated by cell passages extending longitudinally along the length of the rigid panel. This light-weight, multi-cellular panel construction provides relatively high burst strength and easily withstands the impacts and rough handling normally encountered during travel. However, it is very light and extremely rigid. 
     In the preferred embodiment of the invention, the bottom panel of the rigid frame is generally channel-shaped or C-shaped in side profile. The front panel and rear panel are captured within the end portions and attached to the bottom panel by suitable connecting means such as integrally formed connecting flanges which overlap the inside surface of an end panel. The opposite ends of the front and rear panels may be attached to the opposite end panel by overlapping interior and exterior support plates of left and right wheel assemblies. The end panels preferably define curved panel portions forming opposite endwall boundaries of the transportable compartment and one end panel is intersected by a handle receptacle notch. The end portion is stiffened and stabilized relative to the bottom panel by a retractable pull handle assembly mounted in the receptacle notch. The pull handle assembly is mounted on the end panel portion by interior and exterior receptacle plates which are curved for conforming, overlapping engagement against the inside and outside surfaces of the end panel portion. The front and rear panels are attached to the bottom panel and to the end panel portions and are structurally stabilized with respect to each other by interior and exterior wheel housing plates which are curved for conforming, flush engagement against the end panel portion. 
    
    
     The structure disclosed is easily formed into rigid frame travel bags which are lighter, sturdier and more durable than prior art bags of comparable size. Various other advantages and features of the invention will become readily understood from the following detailed description taken in connection with the appended claims and attached drawing in which: 
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a front perspective view of a travel bag including wheels and a retractable pull handle constructed in accordance with the present invention; 
     FIG. 2 is a top perspective view of the bag of FIG. 1 with the top closure in the open position; 
     FIG. 3 is an exploded perspective view illustrating the relative arrangement of the rigid frame members; 
     FIG. 4 is a sectional view taken along line  4 — 4  of FIG. 3 showing the multi-cellular construction of the bottom panel; 
     FIG. 5 is a sectional view taken along line  5 — 5  of FIG. 3 showing the multi-cellular extruded construction of the front panel; 
     FIG. 6 is a top perspective view, partially broken away, of the transportable storage compartment showing the left and right wheel housing support plates mounted on curved inside surfaces of the rigid frame members; and 
     FIG. 7 is a rear perspective view of the travel bag of FIG. 1 showing the attachment of wheel assemblies and a retractable pull handle assembly onto a curved portion of a wrap-around end panel. 
    
    
     The drawing incorporated herein forms a part of the specification to illustrate presently preferred embodiments of the invention. Throughout the drawing, like reference numerals designate corresponding elements. This drawing, together with the description, is for illustrating how the invention can best be made and used. The drawing should not be construed as limiting the invention to the illustrated and described embodiments. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The drawing illustrates a rigid frame travel bag referred to generally by the reference numeral  10 . FIG. 1 shows the top and front of the travel bag in its upright, rolling orientation. FIG. 2 shows the bag  10  open. Most of the description herein is with reference to the orientation of the open travel bag  10  as shown in FIG.  2 . 
     As shown in FIGS. 1 and 2, the travel bag  10  includes generally parallel front and rear panels  12 ,  14  which are mounted along opposite sides of a generally C-shaped shell  16  having a channel-shaped side profile. The C-shaped shell includes a substantially flat intermediate bottom panel portion  18  connected on opposite ends to left and right wrap-around end portions  20 ,  22 . 
     Panels  12 ,  14  include edge portions  12 A,  14 A and end portions  20 ,  22  include edge portions  20 A,  22 A (see FIG. 2 ), which form the perimeter of a generally rectangular access opening  24  to a transportable storage compartment  26 . A soft top closure member  28  is moveably coupled by a cloth hinge  30  or the like to the rear panel  14  for movement between a closed position (in which the access opening  24  is covered) and an open position (in which the access opening and the storage compartment are exposed). 
     The front panel  12  and the rear panel  14  are captured in flush engagement within the wrap-around end portions  20 ,  22 . The front and rear panels are attached to the shell  16  by connecting flanges  32 ,  34  and by wheel assemblies  36 ,  38  (see FIGS.  2  and  6 ). While only two (2) flanges  32 ,  34  are illustrated, it will be recognized that additional or other flanges or the like may be used at other locations to attach the front and rear panels  12 ,  14  to the shell  16  and/or the end portions  20 ,  22 . Various means, such as spade fasteners, bolts, glue and the like may be used to interconnect the frame components. As illustrated, the front and rear panels  12 ,  14  are attached to the shell  16  by integrally formed connecting flanges  32 ,  34  which overlap the inside surface of the wrap-around end portion  20  and are secured to the wrap-around end portion  20  by fasteners  40 . Fasteners  40  also attach a lift handle  42  to the outside surface of the wrap-around end portion  20  as shown in FIG.  7 . Another lift handle  43  is similarly attached to the front panel  12 . In this arrangement the front panel  12  and rear panel  14  are dimensioned and conformed for flush engagement along the inside surface of the flat bottom panel  18  and the wrap-around end portions  20 ,  22 . The front and rear panels are captured within the C-shaped shell by inwardly turned retainer flanges  44 ,  46  formed on the wrap-around end portions  20 ,  22 , respectively. As shown in FIG. 3, the wrap-around end portions  20 ,  22  are integrally formed with the flat bottom panel  18 . The wrap-around end portions  20 ,  22  project generally at right angles with respect to the flat bottom panel  18  and are connected thereto by curved panel portions  48 ,  50  which form smooth transition surfaces. 
     As illustrated in FIGS. 2,  3  and  6  the front panel  12  and rear panel  14  are attached to the end portion  22  by wheel assemblies  36 ,  38 . The front panel  12  and the rear panel  14  are intersected by wheel housing notches  12 C,  14 C for accommodating curved wheel cups  36 C,  38 C, respectively (see FIG.  6 ). Likewise, the side edges of the curved portion  50  joining end portion  22  and bottom panel portion  18  of the C-shaped shell  16  are intersected by side notches  50 A,  50 B aligned with the wheel housing notches  12 C,  14 C, respectively. The wheel assemblies  36 ,  38  include outside support plates  36 A,  38 A and inside support plates  36 B,  38 B, respectively. The outside and inside support plates each include a wheel cup and are dimensioned for nesting engagement one within the other. 
     The outside and inside support plates include curved flange portions  36 F,  38 F which engage the curved outside surface and the curved inside surface of the wrap-around end portion  22 . Each wheel assembly also includes a side flange  36 G,  38 G integrally formed with the curved flange portions  36 F,  38 F, respectively, and projecting normally therefrom. In this arrangement, the front panel  12 , bottom panel  18  and wrap-around end portion  22  are sandwiched between the inside and outside support plates  36 A,  36 B. A rigid union is established and maintained by fasteners  40  which penetrate through the nested flanges and sandwiched panel portions. Attachment of wheel assembly  38  is identical, with the result that the panels forming the left frame of the travel bag  10  are stabilized and provide rigid support for a set of roller wheels  52 ,  54 . The roller wheels  52 ,  54  are preferably polyurethane ball-bearing in-line skate wheels or the like. 
     In FIGS. 2,  3  and  7  a retractable pull handle assembly  56  is shown which includes a handle receiver  58  mounted in a receptacle notch  60  which intersects the curved panel portion  48 , the wrap-around end portion  20  and the flat bottom panel  18 . The wrap-around end portion  20  is stiffened and stabilized relative to the bottom panel  18  by an external receptacle plate  62  and an internal receptacle plate  64 . The receptacle plates are curved for conforming, overlapping engagement against the curved inside and outside surfaces of the curved, wrap-around end portion  20 . 
     The retractable pull handle assembly  56  includes a pull handle  66  attached to parallel extension rods  68 ,  70 . The extension rods are extendable and retractable through parallel guide tubes  72 ,  74 , respectively. The guide tubes  72 ,  74  are firmly attached to the internal receptacle plate  64  and also are secured to the flat bottom panel  18  near the wrap-around end portion  22  by an anchor bracket  76 . The parallel guide tubes further strengthen the bottom panel  18 , thereby opposing buckling and collapse caused by compression and bending forces. 
     In the preferred embodiment the above-described rigid frame structure is constructed from light-weight high strength plastic panels formed by extruding plastic material such as acrylonitrile-butadiene-styrene copolymer (ABS) or polyvinylchloride (PVC) to form multi-cellular panels as shown in FIGS. 4 and 5. In the sectional view of the flat bottom panel  18  shown in FIG. 4, the extruded panel comprises first and second flat sheets or plates  18 A,  18 B spaced apart and joined together by multiple transverse web linking portions or ribs  18 C. The web linking portions are laterally spaced with respect to each other, thereby forming multiple parallel cells  78  which separate adjacent ribs  18 C and extend longitudinally along the length of the rigid panel member. The front and rear panels  12 ,  14  may have the same multi-cellular construction. As illustrated in FIG. 5 front panel  12  (shown in cross-section) is extruded in the form of first and second flat sheets or plates  121 A,  121 B spaced apart and joined by transverse web liking portions or ribs  121 C which also define multiple parallel channels or cells  78 . 
     Multi-cellular rigid frame members  12 ,  14 ,  18  provide increased strength and reduced weight without compromising the internal storage volume capacity of the travel bag  10 . Typically, the extruded panel members have a thickness dimension of ¼ inch and the linking web members have a thickness of about {fraction (1/64)} inch with lateral spacing between the web linking portions approximately {fraction (3/16)} inch. 
     The overall dimensions of travel bag  10  are typically about seventeen (17) inches by twenty-four (24) inches by seven (7) inches, making the bag sufficiently small to fit within the overhead bins of commercial airliners. The bag  10  ordinarily includes padding and covering (not illustrated) of conventional heavy fabrics, as such DuPont 1050D ballistic nylon and the like, commonly used for soft-sided luggage. 
     An assembly of soft auxiliary compartments  80 ,  82  and  84  may be attached to the outside of the closure member  28  as shown in FIG.  1 . Access to the various compartments is provided by heavy-duty self-repairing nylon zippers Z or the like. 
     In the preferred embodiment the pull handle  66  is covered by a rubberized comfort grip and the extension rods are constructed of industrial strength aluminum rated at about five hundred (500) pounds bending strength. The lift handles  42 ,  43  are also preferably rated at a pull strength of about five hundred (500) pounds. The additional handle  42  is placed near the retractable handle assembly  56  to allow lifting with two hands when required. 
     The various panels and components of the invention may be prefabricated using light-weight durable material such as PVC, ABS or the like and may be assembled using only a simple tools such as screwdrivers and nut drivers. ABS and PVC are described herein as preferred construction materials because they are currently considered to be the best materials for constructing the high strength light-weight panels described. However, the panels may be formed of other engineered materials such as polyester or other sheet or molded materials having suitable dimensional stability and sufficient structural strength to provide a novel compact travel bag which is highly durable and impact resistant. 
     Although the foregoing description refers to a wheeled carry-on travel bag, the invention is not so limited. The construction principles described may be readily applied to larger or smaller travel cases which do not employ wheels or pull handles or which employ wheels, skids or the like positioned at other locations on the frame of the travel bag. For example, the bag may be made with larger dimensions and/or utilize four (4) or more casters secured to the outside surface of bottom panel  18 , front panel  12 , back panel  14  or either of the end portions  20 ,  22 . 
     In the embodiment described in detail, the end portions  20 ,  22  are joined to bottom panel  18  through curved transitions and include inwardly projecting flanges  44 ,  46  to form smoothly curved wrap-around end portions. It will be readily recognized, however, that such curved construction and inwardly projecting flanges are illustrations of the preferred embodiment and may be eliminated or modified as desired. The C-shaped shell need only have a substantially flat bottom panel  18  supporting oppositely disposed end panels  20 ,  22  which project from the back panel  18  to produce the novel structure of the invention. Use of a C-shaped shell to which front and back panels are joined to form the frame permits extremely simple and rapid assembly, avoiding many of the bracing structures, etc., used in previous travel bag frames. This structure also permits formation of a travel bag which is much lighter and more sturdy than prior travel bags or cases of similar volume. 
     Although the invention has been described with reference to exemplary embodiments constructed with certain preferred materials, various changes, substitutions and modifications can be made without departing from the spirit and scope of the invention as defined by the appended claims.