Abstract:
Backpacks, even those for outdoors sports, generally comprise an envelope of relatively flaccid textile material attached to a structured back-engaging frame, board or pad. Extreme sports such as skiing, motorbike racing, snow boarding, heli-skiing and such would benefit from greater protection to the person&#39;s back, as well as to the contents of the backpack. The disclosed backpack  2  includes a segmented and shaped back board  40  which permits limited flexing in certain directions to help protect the user&#39;s back from overextension. The container or packing portion  24  of the backpack  2  has corresponding rigid segments  16  interconnected by flexible textile portions  20 . The segmented packing portion  24  and the segmented safety board  40  work together to protect both the contents of the backpack  2  and the back of the user.

Description:
[0001]     This application claims the benefit of U.S. provisional patent application 60/636,224 entitled “Backpack with Segmented Construction Body Protecting Features”, filed Dec. 15, 2004. 
     
    
     BACKGROUND  
       [0002]     This invention relates to shoulder carried luggage cases called backpacks specifically designed for outdoor sports like skiing, snowboarding, trekking and the like. The preferred embodiment of this backpack is especially designed for such sports where hyperextension (bending backward) of the wearer&#39;s back is a real possibility. Motor sports have embraced the use of polymer body armor to protect vulnerable portions of the participant&#39;s body from injury. However, no one has combined the features of controlled flexibility body protection, in particular back protection, with a fully functional backpack.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0003]     This invention comprises a backpack system that includes a harness to intimately hold the backpack construction against the back of the wearer. The backpack construction includes a foam covered support board that has limited flexibility both laterally as well as in the bilateral plane of symmetry of the wearer. This support board preferably consists of a series of controllably, preferably elastically, connected segments. This support board is covered with at least one layer of material on the wearer side for comfort and/or ventilation, which may include neoprene, mesh textile, any other type of textile, foam, or any other kind of material, and one or more layer of impact absorbing foam or other material on the other side (facing the content packing portion of the backpack.) Of course, the back board may be covered completely by any material, it may be partially covered, or the back board may remain entirely exposed. Any material could be used in the covering of the back board. For example, the backboard could be covered with a lamination consisting of two foam types, as will be discussed further with regard to the descriptions of  FIGS. 2 and 16 .  
         [0004]     The main content packing portion of the backpack consists of two or more, preferably four, molded segments interconnected, or at least overlapping, at adjacent edges with extensible or ordinary textile membrane or membranes. The resulting jointed shell and the limited flexibility support board connect to one another at a peripheral seam, which preferably includes zipper access to the main packing compartment. The segmented shells, in combination with the limited flexibility support board, serve to help dissipate and redirect impact forces away from the wearer&#39;s back if and when the wearer should fall off a snowboard, fall while skiing, participating in motor-cross sports, etc. Also, the support board, in combination with the rest of the backpack construction, helps prevent hyperextending the user&#39;s back and helps reduce or eliminate the resulting injury to the musculature, the spine, and the nerves that could have resulted from such hyperextension.  
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0005]      FIG. 1  is a line drawing of a perspective view of the present embodiment.  
         [0006]      FIG. 2  is a back view of the present embodiment showing the harness and protective foam barrier worn against the wearer&#39;s back.  
         [0007]      FIG. 3  is a view of the main packing compartment of the present embodiment, with the main zipper access open and showing an interior panel for storing items, and its relation to the shell portion.  
         [0008]      FIG. 4  is a partially exploded, perspective view of the interior panel of  FIG. 5  and its relation to a back board.  
         [0009]      FIG. 5  is a top view of the back board with the organizational panel that has been unzipped and peeled back.  
         [0010]      FIG. 6  is a close up view of the back board shown in  FIG. 5 , illustrating a knuckle and an exposed flexible bridge portion.  
         [0011]      FIG. 7  is a partial view of the back board knuckle undergoing flexure and portion of a longitudinal concave portion.  
         [0012]      FIG. 8  is a close-up view of the portion of the back board shown in  FIG. 7  with the knuckle removed.  
         [0013]      FIG. 9  illustrates flexing of the knuckle of the portion of the back board shown in  FIG. 7  in the opposite direction to that shown in  FIG. 7 .  
         [0014]      FIG. 10  is perspective view of the back board configuration in its entirety.  
         [0015]      FIG. 11  is a side view of a portion of the back board configuration shown in  FIG. 10 .  
         [0016]      FIG. 12  is a view of the back board shown in  FIG. 10  with three knuckles installed.  
         [0017]      FIG. 13  is an illustration of the back board shown in  FIG. 12  with the knuckles shown in dashed lines to reveal the connective bridge portions.  
         [0018]      FIG. 14  is a side view of a portion of  FIG. 12 .  
         [0019]      FIG. 15  is a detailed back view of a portion of the back board and of a knuckle.  
         [0020]      FIG. 16  is a cross-sectional view of the foam panel shown in  FIG. 2 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]      FIGS. 1 and 2  show respectively a pictorial view of an outer side  4  and a wearer&#39;s side  6  of the preferred embodiment of the backpack  2 . The backpack  2  comprises two components central to the preferred embodiment: shell  24 , protruding from the outer side  4  and providing a rigid and stable structure to protect contents therein, and a structural, supportive “back board” portion  40 , designed to conform to the shape of the human spine when worn directly adjacent to a user&#39;s back, providing comfort and protection to the user while maintaining overall stability of the backpack  2 . Back board  40  provides the user with controlled flexibility, resisting the backward bending of the user&#39;s back, thereby helping prevent hyper-extension of the back.  
         [0022]     A frame  8  is constructed of injection-molded polymer, forming a structural basis for the outer side  4  of the pack  2 . Frame  8  may be of a one-piece contiguous construction or may comprise separate pieces. In the preferred embodiment, frame  8  includes rib portions  10  and spacer portions  12 . Looped portions  14  are provided for opening of the shell  24  to reveal an inner packing compartment  36  of the backpack  2 . The frame  8  is of semi-rigid construction and is provided additional structure by shell segments  16  therebetween. Preferably the shell segments  16  are made of a light, strong polymer material, preferably polyethylene, polypropylene, or a self-reinforcing polypropylene composite such as that available from BP Amoco under the trademark “Curv.” These segments  16  are preferably sewn to a peripheral zipper track  22  with a self-hinging portion on the bottom or one side of the perimeter of the backpack  2 . This permits access to the contents of the backpack  2  when necessary. Segments  16  also provide a measure of limited flexibility, lending to the user&#39;s wearability, mobility, and necessary flexibility of the backpack  2  while performing vigorous sporting activities. Of course, the material used for production of frame  8  and shell segment  16  can vary depending upon the design and intended use of the backpack  2 . For example, frame  8  could be produced by any manufacturing methods including any molding method, stamping, forging, cutting method, or other conventional industrial or manual method. Segment  16  could be made of any material including flexible material, soft material, any rigid or semi-rigid material including other types of polymers, metal, composite, or other material. An advantage of using SRP in the construction of the shell segments  16  is substantial weight reduction while maintaining structure to and protection of the contents of the backpack  2  as well as the wearer.  
         [0023]     The frame  8  and shell segments  16  are affixed to one another by fasters  18 , shown by example as rivets in  FIG. 2 . Of course, other methods of attachment could be used for connecting the shell segments  16  to the frame  8  including glue, staples, snaps, pins, catches, sewing, etc. The shell  24  could conversely be manufactured as a solid piece, or as a combination of other types of components including polymer joints and sheets, or composite portions, for example. The overall shape of the shell is that of a streamlined tortoise shell.  
         [0024]     Shell segments  16  of the shell  24  correspond substantially to the segments  46  of the safety board  40 . For example, note that there are four molded segments  16  shown in  FIG. 1 , which correspond in sequence, overall width, longitudinal dimensions, and placement to the four segments  46  of the safety board  40 . The bottom segment  16  comprises a recess. This recessed area of bottom segment  16  houses an external pocket that is separated from the main packing compartment  36  by a barrier, creating a convenient storage area for items meant to remain separate from the contents of compartment  36 , such as matches, keys, or items that may become dirty or wet such as soiled gloves, etc.  
         [0025]     Each of these molded shell segments  16  is attached, preferably by sewing around its edges near access zipper  22 , to a flexible textile portion  20 . Textile portion  20  is preferably made of a tough woven textile such as a ballistic nylon. Textile portions  20  provide breathability to the backpack  2  as well as flexibility, allowing the backpack  2  to bend in any direction, facilitating comfortable mobility of the wearer, but only to a certain degree, such that hyperextension of the back becomes less likely to occur. Textile portions  20  could also be of a knit material to give even more flexible strength and to help restore the shape of the segmented shell  16  when a stress or bending movement by the wearer is terminated. Of course, other materials could be used in the construction of the portions between rigid portions  16  and  8 . Such materials may include mesh, thin sheets of foam, fabric having waterproof properties, a slightly more rigid material, or any other material. Access to the main packing compartment  36  of the backpack  2  is achieved by the peripheral zipper  22  track but conversely could be achieved by other methods that may include the use of Velcro portions, snaps, buttons, straps, molded mating frame portions, tongue and groove mechanisms, reinforced, “hefty” zippers that may comprise backing of an extra layer of textile or other material to act as a rigid hinge, or other methods. An advantage of zipper track  22  is that shell portion  24  can be opened on at least one side up to all four sides while maintaining a secure closure.  
         [0026]     Looking again to  FIG. 2 , a panel of foam  26  is sewn onto the wearer&#39;s side  6  of the backpack  2  for the wearer&#39;s added protection and comfort. Foam panel  26  may include specifically designed contours so as to mimic the individual characteristics of a wearer&#39;s back resulting in a snug fit against the wearer&#39;s body. Of course, panel  26  could comprise any material appropriate for providing comfort to the wearer, including neoprene, etc, but materials with a knit breathable, textile surface of conventional types are preferred. A foam layer adjacent to the back board (seen in  FIG. 8  for example), may be selected from known, impact absorbing lamina to further isolate the back board from the body of the wearer.  
         [0027]     Referring to  FIG. 16 , foam panel  26  may comprise a lamination of two types of foam with a mesh textile on the outside (facing the wearer&#39;s back). One or both of the foam layers may be perforated to provide ventilation. Perforations through both layers of foam would reveal the back board  40  from the outside to provide an aesthetically pleasing and sporty appearance. A transparent film may then be laminated to the foam layer adjacent to the support board. Conversely, only one layer of foam may be perforated, leaving the first layer of foam solid.  
         [0028]     As shown in  FIGS. 2 and 3 , backpack  2  is carried by the wearer via a harness  28 . Harness  28  can comprise a series of adjustable components including shoulder straps  30 , an elastic waist-belt  32  and an elastic sternum strap  34 . Waist belt  32  may comprise wide elastic bands that overlap each other in a “criss-cross” fashion, increasing the snugness of the fit to the wearer. The shoulder straps  30 , waist-belt  32  with multiple elastic webbings for a firm fit, and sternum strap  34  can be individually and collectively adjusted to according to the user&#39;s body size to ensure a snug fit to the user&#39;s body. This has two primary benefits. First is to assure that the backpack  2  remains centered on the back of the user and will not thus hinder the balance and motion of the user in high speed outdoor sports, such as skiing and snow boarding. Secondly, this intimate cinching assures that the backpack  2 , with its segmented safety board  40  and segmented shell-like packing portion  24 , can reduce impact and overextension to which the person&#39;s back would normally be subject.  
         [0029]     Of course, it should be understood by one of ordinary skill in the art that other combinations of straps, buckles, elastics, and/or other materials or mechanisms could be used in construction of harness  28  in order to achieve snug conformation of the backpack  2  to the wearer&#39;s body. Such materials and mechanisms could include neoprene, nylon straps, bungee cords, hooks, or other methods. Backpack  2  may also be outfitted with a series of additional external straps, including buckled straps or bungee cords attached to loop  14  for example, that would permit the user to attach ropes, blankets, emergency equipment like shovels and ice picks to the outside of the backpack  2 . These accessory attachments can be done without unduly hindering the controlled flexing of the shell segments  16  and the attached portions of the back board  40 . This helps protect the relatively less robust textile portions  20  from abrasion, even when packed items within the main packing compartment  36  would tend to push these textile portions  20  outwardly. The textile segments  20  may be sized and tensioned when being attached to the segmented shell  24  to provide an inwardly directed biasing force against such packed items. This would prevent such items from interfering with the opening and closing of the shell  24  during controlled flexing of the back board  40 .  
         [0030]      FIG. 3  shows the relationship between shell  24  and back board  40 . Main packing compartment  36  may include provisions for secure storage of items such as zippered pockets, compartments with snaps, Velcro, or other closure devices, open pockets, dedicated pockets for items such as keys, phones, flashlights, first aid necessities, etc. As such, a structured interior panel  42  is provided, which can be constructed of any material typical to liner construction in the art, including waterproof textile material. As shown in  FIG. 3 , the shell  24  is joined to back board  40  by zipper  22 , operated by zipper sliders  23 . Back board  40  is surrounded by organizational panel  38 . The interior surface of organizational panel  38  comprises interior panel  42  in which personal items may be stored. Organizational panel  38  surrounds back board  40  and can be peripherally zippered on by inner zipper  44 , operated by inner zipper sliders  45 . Of course other mechanisms can be provided to surround and/or protect back board  40  including layers of foam and other textiles typical of the art. A benefit of providing inner zipper  44  is that the organizational panel  38  can be unzipped and interior panel  42  peeled back, exposing back board  40  for inspection, removal and repair, as well as to help instruct the user in the proper functioning of the inventive backpack  2 . This open construction also enhances convective ventilation. Of course, organizational panel  38  may be constructed of any material, including textile panels, mesh textile, a combination of both textile and mesh textile wherein mesh textile may be used to reveal and/or ventilate portions of the back board  40  such as the center portions of the panels  42  and knuckles  50 , neoprene, foam, or any other material.  
         [0031]     Referring to  FIGS. 4 and 5  respectively, back board  40  is shown as being partially exposed by interior panel  42  and shown as being entirely exposed.  FIG. 6  shows a close-up view of back board  40 . Back board  40  comprises a contiguous plate or board having at least one flexible segment  46 . In the present embodiment, back board comprises four back board segments  46 . The top segment  46 , that rests against the upper portion of the user&#39;s back below the neck, includes a cut-out  66 . This cutout  66  provides an opening for the wiring associated with headphones, cell phone accessories, or the like. As shown in  FIG. 6 , back board  40  is mounted over a layer of material  64  added to provide additional comfort and protection to the wearer while maintaining breathability and air flow. Backboard  40  may be attached to at least the inner layer of material  64  by many methods, including fastener  58  that protrudes through aperture  60  as shown by example in  FIGS. 6 and 10 . Back board segments  46  are semi-rigid yet adequately flexible in nature for the purpose of maintaining mobility while the user engages in rigorous sports. The segments  46  are shown as solid polymer sheets with formed contours for shape and comfort. Of course, apertures  60 , holes, and thickened edges, such as those shown in  FIG. 10 , would benefit this embodiment but can vary depending upon the design and/or intended use of the present embodiment. The apertures in each of the segments  46  lighten the overall construction but are not necessary to the present embodiment.  
         [0032]     It should be understood by one of ordinary skill in the art that many methods of manufacturing can be used to produce the back board  40  and other components of the backpack  2 , depending upon the nature of the materials used in its construction. For example, any plastic molding method can be used including thermoplastic and thermoset injection molding, blow molding, rotational molding, thermoforming, structural foam molding, compression molding, resin transfer molding (RTM), and so on.  
         [0033]     Each of the segments  46  of the support board  40  interconnects with its adjacent neighbor by a flexible hinge or “bridge portion”  48 . Flexible bridge portion  48  is covered by a flexible rubber knuckle  50 . This rubber knuckle  50  comprises indentations or slots and has a T-shaped cross-section (shown in  FIG. 14 ) to give flexing ability as outlined above with regard to  FIG. 6 . Bending along the plane of the back board  40  is further illustrated by  FIGS. 7 and 9 . As shown in  FIG. 7 , the wearer can perform forward bending, provided by the flexible nature of the knuckle  50  and the back board components. Looking to  FIG. 9 , hyperextension or backward bending of the back is limited but allowed by slots  53  and indentations  51  of knuckles  50 . These rubber knuckles  50  are firmly attached to each of the adjacent segments  46  by an extension  57 , shown in  FIG. 15 , which protrudes through apertures  54  of the bridge portions  48 . Of course, other methods could be used for attaching the knuckles  50  to back board  40 , including tapering slotted extensions that grip the bridge  48 . Conversely, knuckles  50  could be attached to the back board  40  by separate penetrating fasteners (not shown), by adhesives, or by being overmolded to adjacent segments  46  which have apertures to receive the molten knuckle material. Mechanical attachment using interengaging ribs or slots may be used as well, thus permitting easy after market replacement of individual damaged knuckles  50  or back board segments  46 . The knuckles comprise thermoplastic elastomer injection molding compounds of known composition and physical characteristics.  
         [0034]     The rubber knuckle  50  has a butterfly wing shape which has indentations molded substantially, but not entirely through its cross section to enhance its flexing ability. These rubber knuckles  50  are firmly attached to each adjacent flexible back board segment  46  by overlapping bridge portions  48  having slots and a concave shape as well as an aperture through which the extension  57  of the flexible knuckle  50  protrudes (see  FIG. 15 ). An advantage of the present embodiment of the rubber knuckles  50  is that knuckles  50  permit limited flexing of the segments  46  towards one another in the plane substantially containing the back board  40  [that is at a right angle to the bilateral symmetrical plane of the back board  40 ]. The construction of the knuckles  50  permits relatively easy bending towards the user&#39;s back [as for example might stoop over or roll into a ball] but elastically resists being compressed by bending in the other direction, that is in the direction which could lead to hyperextension of the wearer&#39;s back.  FIGS. 7 and 9  show an example of bending allowed by the design and construction of knuckle  50  and semi-cylindrical indentation  52  and back board segments  46 . As shown in  FIG. 8 , a close up view of a flexible bridge portion  48  is shown with knuckle  50  removed. Shown in  FIG. 8  and  FIG. 15  are apertures  54  and semi-cylindrical cut-outs  56 . Semi-cylindrical cut-outs  56  allow flexibility of bridge  48 . Again, bridge portion  48  allows limited movement of the back board segments  46  relative to one another. This creates allowance for adequate motion of the user&#39;s back in three planes, yet limits the motion such that the back is less likely to be hyper-extended.  
         [0035]     Of course, it should be understood by one of ordinary skill in the art that the exact placement of holes and structure of back board  40  and its components can vary, provided that the structurally semi-rigid/semi-flexible design of the back board  40  remains intact.  
         [0036]     An advantage of the present embodiment is that each of the segments  46  can bend relative to one another in a path parallel with the line of symmetry to a controlled amount and can also flex at right angles to this plane of symmetry by being squeezed towards one another at their longitudinal edges. In the preferred embodiment, back board  40  has four polymer segments  46  interconnected by the three elastomeric or rubber knuckles as described above. Of course, any number of segments  46  can be used, for example, in the construction of a backpack  2  for use by a petite person or by a child.  
         [0037]     Note how the terminal corners of the back board segments  46  and the corners of the shell segments  16  are held adjacent to one another by textile  20 , knuckles  50 , and the zippered closure  22  which attaches the main portions of the backpack  2  together. In this way the back board  40  and segments  46  can easily flex together, giving the user a sense of freedom of movement. However, the shell segments  16  help limit hyperextension, primarily by engaging one another when the back board  40  bends towards the shell segments  16 .  
         [0038]     Functionally, one can see that the knuckles  50  act as means for permitting limited flexing of the segments  46  towards one another in the plane substantially containing the backboard  40  (that is at a right angle to the bilateral symmetrical plane of the back board  40 ). Also, the slots in each of the knuckles  50  permits relatively easy bending towards the user&#39;s back (as for example when the user might stoop over or roll into a ball) but elastically resists bending in the other direction, that is in the direction which could lead to hyperextension of the user&#39;s back.  
         [0039]     As seen in  FIGS. 7 through 15 , back board segments  46  each comprise a semi-cylindrical indentation  52 , running lengthwise along the entire length of the mid-portion of each segment, and  46  facing the user&#39;s back. Indentation  52  is designed to mimic the structure of and therefore provide allowance for outward protrusion of the human spine. Indentation  52  helps further isolates the delicate musculature in and surrounding the spinal column from impacts to the backpack  2 . Note that the indentation  52  includes contouring that varies from a slightly less degree of indentation (a shallower indentation) at the end portions of each segment  46  to a greater degree of indentation (a deeper indentation) at the center portion of each segment  46 . This contouring helps the end portions of the segments  46  firmly engage the associated knuckles  50 . Of course, indentation  52  could consist of other types of contouring or none at all.  
         [0040]     Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.