Patent Publication Number: US-6662944-B2

Title: Firearm carrying case

Description:
FIELD OF THE INVENTION 
     The invention relates generally to protective firearm carrying cases and more particularly to a dual utility firearm carrying case having a rigid outer housing and a removable flexible inner shell. 
     BACKGROUND OF THE INVENTION 
     Conventional firearm carrying cases which are utilized to carry, transport or ship firearms and other items are generally constructed in two different forms. One has rigid housing which has the same structure and function as a conventional suitcase. The other has a soft-walled, deformable shell formed generally around an outline of the firearm. Each case is used for a separate specific purpose. The rigid case is ideal for shipping and long-term storage, while the deformable case is ideal for portable in-field transportation. As a result, a hunter is forced to incur the expense of owning both cases and having to choose one over the other for certain activities when neither may be individually suitable for the activity separately. 
     The rigid cases are generally formed from a metallic or plastic material having a base and lid connected by an elongated piano hinge. The interior is usually filled with a padding material conforming to the interior dimensions to provide cushioning and for securing the firearm against movement within the case. This style of case provides increased protection at the expense of size and portability. However, there are several other disadvantages. Rigid cases are heavy and non-deformable. As a result, these cases have limited utility, and are best suited for shipping by commercial carrier or long-term storage. These rigid cases are cumbersome to carry in the field, such as when a hunter must backpack or use an all-terrain vehicle (“ATV”) through rough or wooded terrain. Further, it is known that the weak piano hinge is subject to damage when improperly handled during the loading, storage or unloading of the cases on either private or commercial carriers. The protective capability of this rigid case is compromised when the hinge is damaged. 
     Other rigid cases are so-called rear load gun cases that have also long been known. See, e.g., U.S. Pat. Nos. 290,208; 784,901 and 3,744,687. More recently, the rear load rigid cases have grown in popularity along with the popularity of ATVs. Brackets have been specifically designed to attach the rear-load cases to the ATV&#39;s. See, e.g., U.S. Pat. Nos. 5,706,990 and 6,021,936. The rigid rear-load cases have the interior surfaces lined with a synthetic fur-like material or other material suitable for cushioning purposes. See, e.g., U.S. Pat. Nos. 3,744,687; Des. 421,179 and Des. 309,675. 
     The soft-walled cases are well known and commonly formed of a layered composite, for example, a fabric, canvas, leather or leather-like exterior material and a foam or woolen-type of interior. These cases are lightweight and flexible. It is known to configure a case to the general profile (side view) of the firearm. Accordingly, the soft-walled cases may be easily carried by a hunter in the field. The disadvantage of these soft-walled cases is that they do not provide adequate security and protection for the firearm during private or commercial shipping of the shell. Further, for obvious reasons, the soft-walled cases are not suitable for mounting by bracket top an ATV. 
     As a result of the prior art designs, a hunter may need to use both cases for an activity in the field. This is not only costly, but cumbersome and time consuming. Therefore, a need exists to provide a firearm case system having multiple capabilities. 
     One prior art dual utility firearm carrying case is described U.S. Pat. No. 5,669,495 issued to West. The case includes a rigid outer housing having a plurality of sidewalls to define an interior storage chamber. In the preferred embodiment, one of the ends of the housing is sealed. An opposite open end is selectively closable by a lid which is pivotally secured to one of the elongated sidewalls of the housing. The latching mechanism is provided for securing the lid in close relationship with respect to the housing. The case also includes an inner housing which is sized to fit snugly within the storage chamber of the rigid outer housing. The inner housing includes an outer cover having upper and lower portions which are integrally formed and selectively joined along their outer edges by a closure fastener which, in the preferred environment, is a waterproof zipper. Fitted within the upper and lower cover portions are a pair of oppositely-oriented article-conforming support elements, which are formed of a closed cell foam material which is lightweight and substantially rigid so that an article contained within formed pockets in each of the supports is supported and secured when stored within the inner housing. 
     One major disadvantage of the case of the &#39;495 patent is that the inner housing must be completely removed from the rigid housing in order to access the contents. In order to place a firearm or other item within the article-conforming supports formed in the closed cell foam material, the inner housing must be opened in a clamshell fashion. The recess formed in the article-conforming support member is accessible only when the inner case has been entirely removed from the rigid housing and opened to its fullest extent, such that the top and bottom portions of the flexible case are disposed substantially co-planar. 
     Another disadvantage of the case of the &#39;495 patent is that the inner housing is sized to fit snugly within the storage chamber of the outer rigid housing. This design makes insertion and removal of the inner housing difficult. During removal, the snug fit causes a vacuum to form between the inner housing and the rigid outer housing, tending to pull the inner housing back into the storage chamber. During insertion of the inner housing, the snug fit creates an air pocket which resists further insertion of the inner housing into the storage chamber. The snug-fitting feature is necessary to achieve the desired objective of supporting the firearm in the article-conforming recesses of the inner case, such that the firearm is immovable therein as taught in the &#39;495 patent. The inner case of the &#39;495 patent functions the same as its rigid housing save for the soft sides. As a result, the inner housing still retains all of the disadvantages of other prior art cases. 
     Yet another disadvantage of the &#39;495 patent, is that when the inner case is sized to fit snugly within the rigid housing, the inner case must have the same configuration as the rigid outer housing. As a result, the case is still bulky and difficult to transport in the field. 
     Accordingly, a need exists for our improved dual utility cases for carrying firearms which advantageously combines a rigid firearm case with a soft-walled case to provide a wide versatility of usage, namely, ability to remove the firearm from both the rigid case and soft-walled case without prior removal of the soft-walled case from the rigid case, and ability to remove the soft-walled case from the rigid case either with or without the firearm disposed within the soft-walled case. 
     SUMMARY OF THE INVENTION 
     In one principal aspect of the present invention, the dual utility firearm carrying case includes a rigid outer housing, a flexible inner shell and pockets defined between the flexible inner shell and the outer housing. The rigid outer housing includes a body and an end cap. The body includes a first contoured wall defining a first engagement portion, a first chamber, and a first open end. The first open end is defined by a free edge of the first contoured wall formed in a first plane. The end cap includes a second contoured wall defining a second engagement portion, a second chamber, and a second open end. The second open end is defined by a free edge of the second contoured wall formed in a second plane, such that when the body and the end cap are interconnected an interior cavity is defined. When the first and second engagement portions are connected a line of separation is cooperatively defined oblique to a longitudinal axis of the case such that the end cap may be easily disconnected from the body. The flexible inner shell includes a soft wall defining an opening and an interior cavity for receiving a firearm. The flexible inner shell is configured to be selectively, cooperatively and glidingly received within the first and second chamber. The firearm may be selectively disposed within the flexible inner shell when the flexible inner shell is disposed within the body and carried independently of the rigid outer housing and in cooperation therewith. 
     In another aspect of the present invention, the dual utility firearm carrying case includes a rigid outer housing and a flexible inner shell. The outer housing includes a body and an end cap. The body includes a first contoured wall defining a first chamber and a first open end. The end cap includes a second contoured wall defining a second chamber and a second open end. The body and the end cap are interconnected to define an interior cavity. The flexible inner case includes a soft wall defining an opening having a closure fastener and an interior cavity for receiving a firearm. The inner case is complementarily configured to be selectively, cooperatively and slidingly received within the cavity and disposed partially within the first chamber and partially within the second chamber, such that removal of the end cap exposes the closure fastener. The firearm may be inserted and removed from the inner case while the inner case is disposed within the rigid outer housing. The firearm may be carried by selective disposition within the flexible inner shell independently of the rigid housing and in cooperation therewith. 
     Prior firearm cases are bulky, cumbersome and/or unprotective. They are not suitable for common carrier transportation and use by a hunter in the field. For example, conventional firearm cases are suitable for securely transporting, but are bulky and problematic in the field. Further, prior dual utility cases are difficult to separate and reassemble, and remain cumbersome when separated. Consequently, there exists a need for an improved firearm carrying case. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of a firearm carrying case in accordance with an embodiment of the present invention. 
     FIG. 2 is a top perspective view of the firearm carrying case of the invention. 
     FIG. 3 is a bottom perspective view of the firearm carrying case of the present invention. 
     FIG. 4 is a side elevation view of the firearm carrying case of the present invention. 
     FIG. 5 is a cross-sectional view of the firearm carrying case of the present invention depicted in FIG. 4 taken along line  5 — 5 . 
     FIG. 6 is a broken away partial cross-sectional view of the firearm carrying case of the present invention depicted in FIG. 4 taken along line  6 — 6 . 
     FIG. 7 depicts the inner shell opened while remaining disposed within the outer housing for removal or insertion of the firearm in the direction of the arrow. 
    
    
     Shilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention. 
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION 
     With reference to the drawings a dual utility firearm carrying case  10  incorporating the principles of the present invention is shown in FIG.  1 . The case includes an outer housing  12  and an interiorly disposed flexible inner shell  14 . The case  10  facilitates the safe and convenient transportation and/or storage of a long firearm  11  (FIGS.  5  and  7 ). It will be recognized that the dimensions of this case may be adjusted as per the dimension or configuration of the firearm. For example, the case may be configured for a long firearm, a pistol or any other suitable configuration. Preferably, the case  10  provides protection not only during transportation in a private or commercial carrier such as an auto, truck, train or airplane, but also when attached via a bracket to ATV. Use of the case in this manner, permits maximum protection for the firearm deep into the woods. When the ATV cannot proceed any further, the flexible inner shell housing the firearm may be removed from the outer housing  12  in order to proceed deeper into the woods with a certain amount of protection for the firearm. 
     As shown in FIGS. 1-3, the outer housing  12  includes a main body portion  16  and an end cap  18 . Preferably the outer housing  12  is formed of a suitable plastic material. For example, the outer housing  12  may be preferably formed from different plastics such a acryloritrile butadiene styrene, polypropylene, polyethylene or any other suitable material. The body portion  16  and end cap  18  are preferably formed in any suitable process. For example, the body portion  16  and end cap  18  may be formed by a suitable manufacturing process, such as a blow molding, injection molding, thermo molding, thermo forming, rotational molding, rotational forming or any other suitable process. This body portion  16  includes a first contoured wall  20  defining a first engagement portion  38 , a first chamber  30  and a first open end  26 . The first contoured wall  20  has a predetermined thickness with an outer surface  22  and an inner surface  24 . It will be recognized that the predetermined thickness of the wall  20  is suitable to provide protection against impact and abrasion forces. For example, the predetermined thickness in this embodiment may be preferably 0.120″-0.170″ and may range from 0.80″-0.200″ or any other suitable dimension. The outer surface  22  may have a generally rough texture for an improved grasping surface or any other suitable surface texture. The first contoured wall  20  in this embodiment generally follows an outline of the long firearm which has a larger dimension at the first open end  26  of the longitudinal axis L and has a smaller dimension at a first closed end  28  of the longitudinal axis L. 
     The first open end  26  is defined by a free edge  32  of the first contoured wall  20 . The free edge  32  is formed in a first plane which is disposed oblique to the longitudinal axis L in this embodiment as depicted by angle α. It will be recognized that the first plane may be disposed at any suitable angle to achieve the following advantages. The free edge  32  defines one opening  34  for the first chamber  30 . 
     The first engagement portion  38  is formed in the first contoured wall  20  adjacent the first open end  26  for engaging the end cap  18 . In this embodiment, the first engagement portion  38  is formed at the first open end  26  as an offset sleeve  40  separated from the remainder of the main body portion  16  by a shoulder  42  (see also FIG.  6 ). As shown in FIG. 6, a width dimension D 1  of the sleeve  40  is less than a width dimension D 2  of the main body portion  16  adjacent the shoulder  42 . A plurality of first interconnection elements  44  are formed in the first engagement portion  38  for retaining the end cap  18  attached to the main body portion  16 . In this embodiment, the first interconnection elements  44  are formed as alternating ribs  46  and channels  48  with at least one rib  46  and channel  48 . It will be recognized that the alternating ribs  46  and channels  48  may be formed with any suitable number. For example, there may be an odd number of interconnection elements in total or individually, or any other suitable configuration. As shown in FIG. 7, the ribs  46  in this embodiment extend substantially continuously about the circumference of the sleeve  40 . However, it will be recognized that the ribs  46  may be formed in any suitable configuration. For example, the ribs may be segmented along their length around the sleeve  40  or any other suitable configuration. 
     As shown in FIGS. 1-4, the end cap  18  includes a second contoured wall  68  defining a second engagement portion  86 , a second chamber  74 , and a second open end  78 . The second contoured wall  68  has a predetermined thickness with an outer surface  70  and an inner surface  72  (FIG.  6 ). It will be recognized that the predetermined thickness of the wall  68  is suitable to provide protection against impact and abrasion forces. For example, the predetermined thickness in this embodiment may be preferably 0.120″-0.170″ and may range from 0.080″-0.200″ or any other suitable dimension. The outer surface  70  may have a generally rough texture for an improved grasping surface or any other suitable surface texture. The second contoured wall  68  includes a second open end  78  and a second closed end  76  defining a second chamber  74  therein. The second open end  78  is defined by a second free edge  80  of the second contoured wall  68  which defines an opening  82  for the second chamber  74 . The second free edge  80  is formed in a second plane which is preferably disposed oblique to the longitudinal axis L and substantially parallel to the first plane  36 , as depicted by angle α. 
     As shown in FIG. 6, a second engagement portion  86  is formed in the second contoured wall  68  at the second open end for complementary engagement with the first engagement portion  38 . In this embodiment, the second engagement portion  86  is defined in an annular area, coplanar with the remainder of the second contoured wall  68 . A plurality of second interconnection elements  88  are formed in the second engagement portion  86  to engage the first interconnection elements  44  of the main body  16  such that the main body  16  and end cap  18  are retained in an interconnection configuration. In this embodiment, the second interconnection elements  88  include a series of spaced projections  90  which extend form the inner surface  72  toward oppositely disposed second interconnection elements  88 . It will be recognized that projections  90  may be formed in any suitable configuration. For example, there may be at least one projection, an odd number of projections or any other suitable configuration. As shown in FIGS. 1-4, the projections  90  are segmented about the circumference of the second end  78 . However, it will be recognized that the projections  90  may be formed continuously about the end cap  18  if so desired. The number and type of projections  90  and ribs  46  may be varied in accordance with the desired retention force. 
     In this embodiment, as shown in FIGS. 1-3 and  5 , alignment contours  54  are formed on opposing sides of the main body portion  16  extending from the first end  26  for a desired extent. It will be recognized that the alignment contours  54  may have any suitable configuration. For example, the alignment contours  54  may be formed as a rounded shape, having a number of specific sides and edges or any other suitable configuration. Alignment receptacles  55  are formed on the end cap  18  complementary to the alignment contours  54  for operative connection therebetween. The at least one alignment contour  54  and alignment receptacle  55  are disposed on the case  10  such that the main body  16  and end cap  18  may interengage unidirectionally. 
     As shown in FIGS. 5 and 6, an interior cavity  92  is defined by the cooperative association of the main body  16  and the end cap  18 . A line of separation LS (FIGS. 4 and 6) is defined by the second free edge  80  and the shoulder  42  which is oblique to the longitudinal axis L in this embodiment. As a result of the oblique orientation, the end cap  18  is easily disconnected from the main body  16 . Further, as shown in FIG. 6, it will be recognized that the first contoured wall and the second contoured wall are substantially coplanar about the line of separation. 
     The flexible inner shell  14 , as shown in FIGS.  1  and  5 - 7 , is configured to be received within the interior cavity  92  defined by the first chamber  30  and the second chamber  74  when the main body  16  and end cap  18  are cooperatively associated (FIG.  6 ). The inner shell  14  includes a soft wall and, in this embodiment, is formed from any suitable material or combination of materials. For example, a heavy duty fabric or natural material, such as leather or other suitable material may form an outer covering  94  of the inner shell  14 , and a layer of foam  96  or other suitable material may be disposed on the interior surface of the outer covering  94  to provide impact resistance. The foam layer  96  may be either an open-celled or closed-celled foam or any other suitable material. An inner cover  98  is disposed on the opposite surface of the foam layer  96  which may be formed from any suitable material which is soft and will not damage the surfaces of the firearm. 
     The inner shell  14  in this embodiment, FIGS.  1  and  5 - 7 , is formed as a unitary element which is folded in half along a fold line defining a bottom edge  100  of the inner shell  14 . It will be recognized that the inner shell  14  may be formed in any other suitable configuration. For example, the inner shell  14  may formed of several separate pieces connected together, or any other suitable configuration. The inner shell  14  defines an opening  108  and a shell interior cavity  110  for receiving the firearm  11 . A closure fastener  106  is associated with the opening  108  and is preferably disposed on a back edge  104  and a portion of a top edge  102 . The remainder of the top edge  102  is joined together along the remaining length in a conventional manner such as sewing, adhesive or fusing. The inner shell  14  is configured to be selectively, cooperatively and slidingly received and disposed within the interior cavity  92 . Pockets  112  are defined between the inner shell  14  and the outer housing  12  when the inner shell  14  is disposed within the outer housing  12  so that the inner shell  14  may be easily inserted and removed. It will be recognized that the loose fitting inner shell  14  is advantageous in that the hunter does not have to overcome the pressure within the case created by insertion of a snug form-fitting inner element nor the vacuum created by removing such a snug form fitting inner element. A pair of handles  114  (FIG. 1) are also attached to the inner shell  14  for transportation purposes. 
     As shown in FIGS. 1-5, the firearm carrying case  10  also includes a handle  52 , lock mechanism  56 , sling mounts  58 , and balance pads  60 . The handle  52  is integrally formed on the top of the main body portion  16  near the center of gravity of the case when loaded with the firearm. The lock mechanism  56  includes a rib  57 A formed as an extension of the handle  52  adjacent the first open end  26 , and a housing  57 B formed on the end cap  18 . A first aperture  62  is formed in the rib  57 A and a second aperture  63  is formed in each side of the housing  57 B such that when the main body  16  and end cap  18  are interconnected all of the apertures  62 ,  63  are in registry. In this embodiment, a locking element in the form of a hasp latch  62  may be inserted through the apertures  62 ,  63  to securing the end cap  18  to the main body  16 . It will be recognized that any other suitable locking element may be used. For example, a padlock or any other suitable locking element. The sling mounts  58  formed on the bottom of the main body  16  have longitudinally extending apertures  66 . A sling (not shown) may be attached in a suitable manner so that the case  10  may be carried. The balance pads  60  are formed on the bottom of the main body  16  at the second end  28  and adjacent the shoulder  42  near the first open end  26 . The sling mounts  58  are disposed between the balance pads  60 . The balance pads  60  provide stability for the case  10  when it is disposed in an upright orientation on a surface. 
     In operation, as partially shown in FIG. 7, the firearm  11  may be selectively disposed with the shell interior cavity  110  of the flexible inner shell  14  when the inner shell  14  is disposed within the body  16 . The closure fastener  106  may then be closed. If the inner shell  14  is not disposed within the body  16 , the end cap  18  may be removed from the body  16  by rotating the end cap  18  in a direction away from the handle  52 . The flexible inner shell  14  may then be slidingly received within the first chamber  30  of the body  16 . A portion of the inner shell  14  remains disposed outside the first chamber  30  so that the closure fastener  106  may be moved to an open position in order to remove the firearm  11  while the inner case  14  remains disposed within the first chamber  30 . Transportation of the firearm may be independent of the outer housing  12  or in cooperation therewith. If transportation within the outer housing  12  is desired, the end cap  18  is aligned with the main body  16  such that the portion of the inner case  14  disposed outside the first chamber  30  is received within the second chamber  74  of the end cap  18 . The end cap  18  is then fully installed such that the first and second interconnection elements  44 ,  88  engage and the second free edge  80  is disposed adjacent to the shoulder  42 . The flexible inner shell  14  is then securely disposed within the interior cavity  92 . The lock mechanism  56  may then be attached. When the hunter is in the field, the lock mechanism  56  in the end cap  18  are removed and the user may then remove the flexible inner shell  14  for independent transportation of the firearm. 
     Furthermore, while the particular preferred embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the teaching of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.