Patent Publication Number: US-9894972-B2

Title: Luggage items with expandability

Description:
RELATED APPLICATIONS 
     This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/721,361, filed Nov. 1, 2012, the contents of which are hereby incorporated by reference as if recited in full herein for all purposes. 
    
    
     BACKGROUND 
     The inventive subject matter is generally directed to items of luggage, including suitcases, backpacks, travel packs, carry-ons, duffel bags, brief cases, travel cases, and gear bags. More particularly, the inventive subject matter is directed to luggage items with an expandable section to selectively increase the volume of the item and hence the carrying capacity. In some embodiments, the inventive subject matter is directed to a modular luggage system where one item of luggage removably couples to a main item of luggage with the expandable section. 
     One patent of interest, U.S. Pat. No. 7,594,569 in the name of The North Face, shows a small backpack that is zippered to the face of a larger backpack. When the small backpack is detached, a set of pockets is exposed on the supporting face of the larger backpack. The face of the larger backpack includes a stowable cover that can be pulled out to cover the pockets and the area that was occupied by the detached backpack. 
     Other such modular systems show detachable backpacks or similar carriers on the face of an item of luggage or expandable sections in an item of luggage. 
     In present day travel, many travelers prefer to avoid the hassles and extra costs associated with traveling with multiple items of luggage. Travelers also prefer not to travel with unnecessarily bulky luggage items. At the same time, travelers may acquire items during the course of trip or may reduce the number of items they initially started with. Accordingly, a significant need exists for luggage items and systems that adaptably adjust capacity to the needs of a traveler. 
     SUMMARY 
     The inventive subject matter in its various embodiments overcomes the aforementioned disadvantages in the prior art by providing a novel expandable luggage system. The system allows for modularity, as well as expandability. 
     In certain general embodiments, the inventive subject matter is directed to an item of luggage, comprising: a plurality of sides sufficient to define a first volumetric space, an expandable section disposed within the space between first and second opposing sides, wherein at least the first opposing side defines a boundary for the volumetric space and provides an exterior surface for the item of luggage; and 
     the expandable section having a first configuration wherein it is stored within the space and has an expandable side that is adjacent to the first opposing side, and a second configuration wherein the expandable side extends a predetermined distance from the first opposing side to define a boundary for a second volumetric space that is the same as or different from the first volumetric space. 
     In any of the embodiments contemplated herein, the second opposing side may be removable and the expandable side may be extendable to provide the corresponding exterior side of the item of luggage and to define a generally planar boundary for the second volumetric space. 
     In any of the embodiments contemplated herein, the expandable section may be configured to expand beyond the boundary of the second opposing side so as to define a second volumetric space that is greater than the first volumetric space. 
     In any of the embodiments contemplated herein, the luggage item may consist of a modular set of luggage items comprising a main item and a removable item, and the second opposing side may consist of a side of a removable item of luggage. 
     In any of the embodiments contemplated herein, the removable item of luggage may be the smaller of the items and includes at least one shoulder strap. 
     In any of the embodiments contemplated herein, the removable item includes two backpack straps. 
     In any of the embodiments contemplated herein, the expandable section may be made of a flexible material. 
     In any of the embodiments contemplated herein, the luggage item may include a stay system, or other support mechanisms, that supports the expandable section in a desired form. 
     In any of the embodiments contemplated herein, the stay system may extend into the second volumetric space and supports the expandable section in an intended configuration defining the second volumetric space. 
     In any of the embodiments contemplated herein, the second volumetric space may be from about 25% to about 200% or greater that than the first volumetric space. 
     In any of the embodiments contemplated herein, the removable pack may attach to the main item via a zipper, or other inter-engaging parts. 
     In any of the embodiments contemplated herein, the volumetric space may be defined by two or more sides of the main luggage item and a surface of the second opposing side. 
     In any of the embodiments contemplated herein, the luggage item may consist of a modular set of luggage items comprising a main item and a removable item, and the first opposing side is a side of the main item and the second opposing side comprises a side of a removable item of luggage. 
     In any of the embodiments contemplated herein, the first opposing side and at least one other side of the main item may define a volumetric space for the main item, and the surface of the second opposing side is partly or fully recessed into the volumetric space for the main item. 
     In any of the embodiments contemplated herein, the surface of the second opposing side may be disposed above the compartment of the main luggage item so as to provide a total volumetric space for the combined main item and removable item that is greater than the volumetric space of the main luggage item. 
     The inventive subject matter is also directed to a method of making a luggage item according to any of claims comprising providing a main luggage item with an expandable section that is stored in a compartment of the main luggage item. 
     These and other embodiments are described in more detail in the following detailed descriptions and the Figures. 
     The foregoing is not intended to be an exhaustive list of embodiments and features of the inventive subject matter. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings. 
     The following is a description of various inventive lines under the inventive subject matter. The appended claims, as originally filed in this document and the above-referenced provisional patent application, or as subsequently amended, are hereby incorporated into this Summary section as if written directly in. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying Figures show representative embodiments according to the inventive subject matter, unless noted as showing prior art. 
         FIG. 1  shows front, left perspective views of a modular assembly of a main luggage item and a removable item coupled to the main luggage item, with the top arrow pointing to the removable item after being decoupled from the main item and the lower arrows indicating possible configurations of the main item following the decoupling of the main item. 
         FIG. 2  shows a back side view of the general assembly of  FIG. 1 . 
         FIG. 3  shows a left side view of the general assembly of  FIG. 1 . 
         FIG. 4  shows a right side view of the general assembly of  FIG. 1 . 
         FIG. 5  shows a top view of the general assembly of  FIG. 1 . 
         FIG. 6  shows a bottom view of the general assembly of  FIG. 1 . 
         FIG. 7A  shows configuration of the general main item in the assembly of  FIG. 1  following decoupling from the removable item, with the arrow indicating the configuration of the main item following deployment of an expandable section stored in a compartment of the main item. 
         FIG. 7B  is a perspective view of the bottom of the general main item of luggage from 
         FIG. 7B  showing the volumetric configuration of the deployed expandable section. 
         FIG. 8A  shows a left side view of the general main luggage item of  FIGS. 7A-7B  with an optional supporting stay system associated with the main item and its expandable section, the stay being used to support the expanded section in a desired configuration. 
         FIG. 8B  shows details of a receiver associated with the general main luggage item of  FIGS. 7A-7B  for coupling to one end of a supporting stay, with the left side showing a removable stay decoupled from the receiver and the right side showing the stay coupled to the receiver. 
         FIG. 8C  shows further details of a stay system according to  FIGS. 8A-8B . 
         FIG. 9  shows a bottom view of the general main luggage item according to  FIGS. 7A-7B  with an alternative stay system associated with a bottom side of a deployed expandable section. 
         FIG. 10  shows details of an openable front side of the expandable section of the general main luggage item of  FIGS. 7A-7B . 
         FIG. 11A  shows a top view of the general main luggage item according to  FIGS. 7A-7B , with the deployed expandable section. 
         FIG. 11B  shows a bottom view of the general main luggage item according to  FIGS. 7A-7B , with the deployed expandable section. 
         FIG. 12A  shows a left side view of the general main luggage item according to  FIGS. 7A-7B , with the deployed expandable section. 
         FIG. 12B  shows a front side view of the general main luggage item according to  FIGS. 7A-7B , with the deployed expandable section. 
         FIG. 12C  shows a right side view of the general main luggage item according to  FIGS. 7A-7B , with the deployed expandable section. 
         FIG. 13  shows the main luggage item with the arrow indicating a configuration for an associated coupling system for coupling the main luggage item to the removable item. 
         FIGS. 14A-B  show the general modular assembly of luggage items of  FIG. 1  with stowable shoulder straps on the removable item. 
         FIGS. 15A-15B  show another example of an assembly of a main item of luggage in the form of a duffel bag with a removable item attached at one end, namely a shoulder bag, with  FIG. 15A  showing the items coupled together and  FIG. 15B  showing the items decoupled from one another. 
     
    
    
     DETAILED DESCRIPTION 
     Representative embodiments according to the inventive subject matter are shown in  FIGS. 1-15  (the “Figures”), wherein the same or generally similar features share common reference numerals. 
     In some embodiments, the inventive subject matter is directed to an item of luggage having a plurality of sides sufficient to define a first volumetric space. An expandable section is disposed within the space between first and second opposing sides. At least the second opposing side defines a boundary for the volumetric space and provides an exterior surface for the item of luggage. The expandable section has a first configuration wherein it is stored within the space and has an expandable side that is adjacent to the first opposing side. It has a second configuration wherein the expandable side extends a predetermined distance from the first opposing side to define a boundary for a second volumetric space that is the same as or different from the first volumetric space. 
     The Figures show one of many possible examples of a luggage item that is consistent with the foregoing description. In this example, a luggage item  10  consists of a main luggage item  12  and an optional removable luggage item  14 , such as a backpack, duffel bag or travel or brief case (hereinafter, the removable item will generally be referred to as a “pack” for the sake of convenience). 
       FIG. 1  shows front, left perspective views of a modular assembly of a main luggage item  12  and a removable item  14  coupled to the main luggage item, with the top arrow pointing to the removable item after being decoupled from the main item and the lower arrows indicating possible configurations of the main item following the decoupling of the main item. The lower arrow on the left shows the main item before the deployment of an expandable side  9 . The lower arrow to the right shows the main luggage item after the deployment of the expandable section to define a volumetric configuration that is greater than the pre-deployment configuration indicated by the lower left arrow. 
     The assembly  10  of luggage items provides an overall item that has a front side  1  and an opposing back side  2 . The front and back sides are generally planar and they provide generally planar opposing boundaries that define an overall volumetric space for the interior compartment for the overall luggage item  10  and any intermediate subcompartments. In this example, the removable pack  14  provides the front side  1  of the overall (combined) luggage item  10 . Referring to  FIGS. 11A and 11B , the front side  1  of luggage item  10  has a front surface  141 , which is the front surface of removable pack  14  and a back surface  2 , which happens to be the back side of main luggage item  12 . The back surface  142  of the removable pack faces the interior compartment  7  of the main luggage item  12 . In some embodiments, the removable pack is designed to recede wholly or partially into compartment  7 . In other embodiments, back surface  142  of the removable pack defines a generally planar boundary surface for the compartment. In yet other embodiments, back surface  142  may be concave so that it extends above compartment  7  adding to the volumetric space of that compartment. The front surface  141  of the pack is the front, exterior surface for the overall (combined) luggage item  10 . 
     The overall luggage item  10  also has a top side  3 , bottom side  4 , left side  5  and right side  6 , as well as front and back sides. In the example shown, each pair of front/back sides, top/bottom sides, and right/left sides are opposing sides. Each side has an exterior surface and an interior surface. The sides are the composite of the merged sides of main luggage item  12  and removable pack  14 . (These same reference numerals also indicate the various sides of main luggage item  12  when the removable pack  14  is detached.) In some cases, the space between the exterior facing surface and the interior facing surface may be occupied with one or more plies of material and/or one or more sub-compartments or pockets, for example. 
     Luggage items,  10 ,  12  and  14  are not limited to having six sides; any one can have more or less sides. The overall luggage item  10  or any other item can also be in different shapes, not just rectilinear. For example, any item could be round like a hatbox or it could be pear shaped.  FIG. 15  shows an example of a generally cylindrically shaped assembly  110  of a main luggage item  112  and removable item  114 . Nor must any given side for an item be fully solid. For example, the top side could be left open-sided, or it could be partially sided, with an open-mesh material or a set of straps, for instance, extending across the space of the side. 
     As can be appreciated, a volumetric space can be defined by as few as two or more sides, and other boundaries for the volumetric space extrapolated from the two or more known sides. For instance, referring to the embodiment shown in the Figures, the general volumetric space for the interior compartment  7  of main luggage item  12  may be defined by looking at a combination of any two sides that are orthogonal to each other. These could be the top side or bottom side and any one of the right side or left side, for example. Alternatively, they could be the back side or front side and any one of the right, left, top, or bottom sides. 
     Looking at  FIGS. 7A-7C , the compartment or volumetric space  7  for the main luggage item  12  has dimensions, generally indicated by the brackets of X (width), Y (height) and Z (depth), which also indicate the X, Y and Z axes for the item. The dimensions define the shape and volume of space for the storage compartment  7  for the main luggage item  12 . When the removable pack  14  is removed, the expandable section  9  can be deployed from its first, stowed configuration within the interior of the compartment to a second deployed configuration that increases the Z dimension to a different dimension, Z′, which may be greater or smaller than Z. In the embodiment shown Z′ is greater than Z. Hence, the volume of the storage compartment  7  may be increased. It may be increased to any desired amount, limited only by the space necessary to store the expandable portion within the main luggage item. Suitable increases in the volumetric space of the storage compartment could be 25%, 33%, 40%, 50%, 66%, 75%, 100%, 125%, 150%, 175%, or 200%, for example. 
     In other embodiments, the expandable section  9  or  109  may consist of two or more sub-compartments. The sub-compartments could be arranged in a number of ways along the X, Y and/or Z axes. For example, they could be generally parallel and coextensive to each other along the Z axis, with each capable of independently expanding along the Z axis so that there are a plurality of volumetric shapes along that axis. Similarly, there may be a plurality of sub-compartments arranged along the X and/or Z axes that allow for a plurality of volumetric shapes along one or both such axes. The compartments, sub-compartments, and pockets in the expandable section, and any other section of the luggage item  10 , may have zippers, snaps, drawstrings, hook and loop closures, buttons, etc. for accessing and securely storing things. 
     While the example presented illustrates a combination of luggage items, in some embodiments, a single luggage item is contemplated. For example, the removable luggage item  14  could be replaced by a non-removable panel portion that has front and back surfaces defining a front side of the luggage item, with the back surface facing the interior compartment and the front surface forming an exterior surface of the front side of the luggage item. 
     Further, if a removable luggage item  14  is part of an overall item of luggage  10 , it may be positioned not only on the front side of the main item but on any other side as well. As noted above, the removable pack may occupy some or all the volume of compartment  7 . If it occupies the entire volume its compartments between surfaces  141  and  142 , the overall luggage item  10  may have an overall volumetric space that is about the same as or greater than that of compartment  7 . The overall volumetric space for the overall luggage item  10  can essentially be the volumetric space of compartment  7  plus the volume added by the volumetric portion of removable item  14  that extends above compartment  7 , but not double counting the volume of the removable item that recedes into compartment  7 . Of course, some space may be lost to the arrangement of solid materials used in constructing the removable item. 
     Although the expandable section  9  is disposed between back and front sides, providing expandability along a Z-axis, it may be disposed between any other set of opposing sides. For example, it may be disposed between top and bottom sides  3 ,  4  and expandability would be along the Y-axis. Alternatively, it may be disposed between the left and right sides  5 ,  6  and expandability would be along the x-axis. Still further, the assembly of luggage item  10  and the expandable section  9  may be such that the expandable section has multiple sides and the luggage item may be expandable from a first position stored in the volumetric space for an interior compartment along any one or more of the X, Y, of Z axes. 
     In some embodiments, the expandable section  9  or  109  is permanently fixed to the luggage item, e.g., by sewing, mechanical fasteners, or chemical bonding. In other embodiments, it may be removable by use of zippers, snaps, buttons, etc. 
     Among the possibilities is for the expandable section to have an expandable side, e.g., side  91 , that moves from a first configuration adjacent to any of the sides of the luggage item towards an opposite side or boundary for the luggage item and thereby into a second configuration. The expandable section  9  also may have fully or partially enclosed sides  93 ,  94 ,  95 , and  96  connected at the periphery of front side  91  that extend parallel to the corresponding sides  3 ,  4 ,  5  and  6  of the luggage item. Sides  93  (top),  94  (bottom),  95  (left), and  96  (right) are perpendicular to back side  2  to which the expandable side  91  is adjacent and generally parallel. 
     The expandable section  9  may be made of any flexible material that is suitable for use as siding for a luggage item, such as woven fibers, knit fibers or non-woven flexible materials, such as TPU films, commingled fibers, or other flexible materials. It could also be made of relative rigid materials, such as thermoformed foams, polycarbonate, ABS, PP, PE, PA, or other plastics that are mechanically expandable. For example, an expandable side  91  of expandable section  9  could be a rigid sheet material that is connected at one or more points along its periphery to an expansion system, such as an accordion structure or a telescoping structure or inflatable bladders that form or are disposed at one or more of sides  93 ,  94 ,  95 , and  96 . The expandable section  9  could also be constructed of a combination of flexible and relatively rigid materials. 
     In some embodiments, the expandable section  9  is stored in a first configuration within the compartment  7  wherein one or more sides of the expandable section are parallel to and generally coextensive with a side of the item of luggage. For example, the Figures show a side  91  of the expandable section  9  that overlies the adjacent interior surface of the back side  2  of the main luggage item. In other embodiments, an expandable side could be less than coextensive with an adjacent side of the luggage item. For example, the expandable section  9  could be rolled or folded into a more discrete space within the compartment  7  and could be deployed to a second, expanded configuration by a user or through automatic mechanisms for deployment, e.g., spring, hinge, or inflation systems. 
     The luggage item  10  may include a stay or support system that supports some or all of the expandable section  9  in a desired form.  FIGS. 8 and 12  show a pair of elongate, rigid elements  16  (left) and  18  (right), each having opposing ends. Looking at element  16  as representative, one end may be disposed in or mounted to a left side of the main item of luggage. From that end, the element angles outwardly and downwardly so that the opposite end extends beyond the boundary of the front, bottom side of the compartment  7  for the main luggage item  12 . An opposite end is disposed on or mounted to or near the lower left corner of a flexible expandable section so as to tension the expandable section to the expanded Z′ position ( FIG. 12 ). The right side has a corresponding element that tensions the expandable section at its lower right corner. In the embodiment shown, a receiver, such as pockets  20 ,  22  on luggage item  10  are used to hold the top ends of the elements  16 ,  18  in place. The bottom ends may be hingeably disposed on the luggage item or placed in pockets similar to the top ends, for example. In short, the stay system extends into the second volumetric space intended for the expandable section and supports the expandable section in an intended configuration for defining the second volumetric space. 
     Other mechanisms that could be used to deploy expandable section  9  include other hinged structures, e.g., opposite ends of the elongate elements  16 ,  18  are disposed on the luggage item, and the hinge point is in between the opposing ends of the elongate elements  16 ,  18 . Another option would be to use inflatable bladders that extend along the periphery of one or more sides of the expandable section, for example. 
     Additional stiffening or tensioning elements may be associated with the expandable section. For example, an elongate stiffening element  24  may be disposed or placed in the expandable section along the bottom section  94 , between the left and right corners, as shown in  FIG. 9 , for example. 
     A luggage item according to the inventive principles may be configured with any number of other features to advance and supplement the inventive advantages. For example, as seen in the FIGS., the luggage item may optionally include fixed or telescoping poles  26  with a handgrip  30  on one or more of the telescoping poles. The luggage item may include wheels  32  for rolling the item. It may include one or more shoulder straps  34  so that the luggage item may be carried as a shoulder pack or bag or as a backpack. The luggage item may include storage compartments for stowing the strap. The luggage item may include one or more handgrips on the body of the item to facilitate carrying and handling of the luggage item. The luggage item may include any number or arrangement of sub-compartments and pockets in a similar fashion as described above for the expandable section. 
     One or more removable luggage items may be attached to a main luggage items using zipper systems having one or more complementary zipper tapes  28  ( 28 A,  28 B) mounted along a defined area on each item. The removable items may attach to the main luggage item in other ways, such as by straps, snaps, and other inter-engaging parts. 
       FIGS. 15A-15B  show another example of a modular assembly  110  of a main item  112  of luggage in the form of a duffel bag with a removable item  114  attached at one end, namely a shoulder bag that includes a shoulder strap. The bag and main luggage items may be coupled via a zipper system  128  ( 128 A,  128 B).  FIG. 15B  shows an expanded section  109 , which is stored in a compartment at one end of the duffel bag, in an expanded condition following removal of the shoulder bag  114 . 
     As used herein “adjacent” means directly adjacent or indirectly adjacent, i.e., there may be close spacing but separation by an intermediate layer of material or structure. As used herein, “couple” and variants of that word mean directly or indirectly connected or attached together. 
     Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of the inventive subject matter, and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein. 
     Any patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes.