Container and method of manufacturing a container

Abstract

The present invention relates to a container / bag for holding and transporting objects, such as a container carried by a person, for example a rucksack / backpack. The container includes a body portion a

Description

This invention relates generally to a container. More specifically, although not exclusively, this invention relates to a container for holding and transporting objects, for example a container carried by a person. The invention also relates to a method of manufacturing a container. Containers, for example bags, are used to hold one or more objects to enable a person to carry the object or objects more easily. Rucksacks and backpacks are examples of containers or bags, which are worn on a person's back, thereby leaving the person's hands free to hold other items. Rucksacks and backpacks are often worn by cyclists or motorcylists to enable them to carry objects when riding their bicycle or motorcycle. It would therefore be advantageous to provide a container for one or more objects that protects objects in the container in the event the container is dropped, for example if the container falls from the person's back. There is a particular need to provide a container that is able to support objects, such as laptop computers, cameras and the like, in the event the container is dropped from a person's back at speed, for example while they are riding a motorcycle. An aspect of the invention provides a base portion for a container. The base portion may include one or more layers. The base portion may include, for example, a first layer and a second layer. The base portion may include a foot portion. The base portion may include a plurality of foot portions. The or each foot portion may be located between the first layer and the second layer of the container. The or each foot portion may be embedded in the first layer. The or each foot portion may form a projection. The or each projection may extend from an outer skin of the container. Advantageously, the layered structure and the provision of foot portions within the base portion improves the impact resistance of the container in order to protect objects within the container. The or each foot portion may form a recess. The or each recess may be formed on an inner surface of the container, for example on an inner surface of the first layer of the base portion. The or each recess advantageously provides an connection between the first and second layers of the base portion during manufacture. The container may be configured to be carried by a person, for example on the back of a person. The container may be configured to be carried by a person while they ride a bicycle or motorcycle, for example. The first layer may include a first material. The or each foot portion may include a second material. The first material may be different to the second material. One or more properties of the first material may be different to one or more properties of the second material. The first material may, for example, have a first density and a first hardness. Similarly, the second material may have a second density and a second hardness. The second density may be greater than the first density. The second hardness may be greater than the first hardness. By optimising the properties of the first and second materials of the first layer and the or each foot portion of the base portion, the mechanical properties of the container are enhanced without increasing the weight of the container unecessarily. The second layer may include a third material. The third material may be different to the first material and / or the second material. Alternatively, the third material may be the same as the first material and / or the second material. One or more properties of the third material material may be different to one or more properties of the first material and / or the second material. Alternaitvely, the one or more properties of the third material may be the same as the one or more properties of the first material and / or the second material. The third material material may, for example, have a third density and a third hardness. The third density may be the same as the first density. The third hardness may be less than the first hardness. By optimising the properties of the third material of the second layer, the mechanical properties of the container are further enhanced to protect objects inside the container without increasing the weight of the container unecessarily. According to another aspect of the invention, there is provided a container. The container may be configured to be carried by a person, for example on the back of a person. The container may be configured to be carried by a person while they ride a bicycle or motorcycle, for example. The container may include a body portion and a base portion. The body portion may include an outer wall, for example an outer wall that is configured to contain one or more objects. The one or more objects may include, for example, items to be carried by a person, e.g. a laptop computer, a camera, or other fragile electronic or non-electronic items. The base portion may be attached to the body portion. The base portion may be a base portion according to a preceding aspect of the invention. The base portion may include one or more layers. The base portion may include, for example, a first layer and a second layer. The base portion may include a foot portion. The foot portion may be located between the first layer and the second layer of the base portion. In a further aspect of the invention, there is provided a container including a body portion. The body portion includes an outer wall that is configured to contain one or more objects. The container also includes a base portion connected to the body portion. The base portion includes a first layer, a second layer, and a foot portion. The foot portion is located between the first layer and the second layer. The base portion may include a plurality of foot portions. The base portion may, for example, include one, two, three, four or more foot portions. The base portion may include any number of foot portions. The or each foot portion may be embedded in the first layer. The first layer and the or each foot portion may be integrally formed. The first layer and the or each foot portion may be co-moulded. Advantageously, the layered structure and the provision of foot portions within the base portion, for example integrating the or each foot portion within the first layer, improves the impact resistance of the base portion in order to protect objects within the container. The or each foot portion may include a protrusion. The protrusion may be configured to extend into the first layer of the base portion such that the or each foot portion is secured to or interlocked with the first layer of the base portion. The first layer may include a first material. The or each foot portion may include a second material. The first material may be different to the second material. One or more properties of the first material may be different to one or more properties of the second material. The first material may, for example, have a first density and a first hardness. Similarly, the second material may have a second density and a second hardness. The second density may be greater than the first density. The second hardness may be greater than the first hardness. The second layer may include a third material. The third material may be different to the first material and / or the second material. Alternatively, the third material may be the same as the first material and / or the second material. One or more properties of the third material material may be different to one or more properties of the first material and / or the second material. Alternaitvely, the one or more properties of the third material may be the same as the one or more properties of the first material and / or the second material. The third material material may, for example, have a third density and a third hardness. The third density may be the same as the first density. The third hardness may be less than the first hardness. By optimising the properties of the first, second and third materials of the different components of the base portion, the mechanical properties of the container are enhanced to protect objects inside the container without increasing the weight of the container unecessarily. The first layer of the base portion may form a portion of an outer skin of the container. The portion may be a first portion of the outer skin of the container. The first layer may, for example, form a first portion of the outer skin of the container. The outer wall of the body portion may form a portion of the outer skin of the container. The portion may be a second portion of the outer skin of the container. The outer wall of the body portion may, for example, form a second portion of the outer skin of the container. The first portion and the second portion may, together, form the outer skin of the container. The or each foot portion may form a projection on the outer skin of the container. The or each foot portion may, for example, form a projection on the first layer of the base portion, the first layer of the base portion forming a portion, for example the first portion, of the outer skin of the container. The or each foot portion forms a recess on an inner surface of the base portion. The inner surface of the base portion may include an indentation. The inner surface of the base portion includes a plurality of indentations. The base portion of the container may have an impact resistance of less than 35 kN, for example less than 30 kN, for example less than 20 kN. The base portion of the container may have an impact resistance that meets, or exceeds, the requirements of EN 1621-2012. The container may be a bag. In some examples, the container may be a rucksack or a backpack. A yet further aspect of the invention provides a method of manufacturing the base portion and / or the container of the preceding aspects of the invention. The method include placing the or each foot portion into a mould. The method may include co-moulding the or each foot portion and the first layer of the base portion in the mould. According to an aspect of the invention there is provided a method of manufacturing a container according to the preceding aspects of the invention. The method includes placing the or each foot portion into a mould, for example a metal mould, e.g. a steel mould. The method also includes co-moulding the or each foot portion and the first layer of the base portion in the mould. The material of the first layer of the base portion may be a first material. The method may include forming the or each foot portion from a second material. The method may include co-moulding the foot portion with the first material m order to form the first layer with the or each foot portion embedded within it. The method may include vulcanising the or each foot portion and the first layer of the base portion. The method may include injecting the material of the second layer, e.g. a third material, onto an inner surface of the first layer, for example an inner surface of the base portion, in order to form the second layer. The method may include attaching the base portion to the body portion. The method may include attaching the base portion to the body portion by any suitable attachment means. Nonlimiting examples of suitable attachment means include adhesive materials, for example glue, stitches formed by sewing, stapling or other fastening means as will be apparatent to the skilled person. The method may also include attaching a carrying member to the container. The method may include attaching the carrying member, for example a strap to the body portion of the container by any suitable attachment means. The method may include attaching more than one carrying member, for example more than one strap, to the body portion of the container by any suitable means. Non-limiting examples of suitable attachment means include adhesive materials, for example glue, stitches formed by sewing, stapling or other fastening means as will be apparent to the skilled person. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims. For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the container may comprise any one or more features of the base portion relevant to the container and / or the method may comprise any one or more features or steps relevant to one or more features of the base portion or the container. Another aspect of the invention provides a computer program element comprising and / or describing and / or defining a three-dimensional design, e.g. of the base portion described above or an embodiment thereof. The three-dimensional design may be for use with a simulation means or an additive or subtractive manufacturing means, system or device. The computer program element may be for causing, or operable or configured to cause, an additive or subtractive manufacturing means, system or device to manufacture the base portion described above or an embodiment thereof. The computer program element may comprise computer readable program code means for causing an additive or subtractive manufacturing means, system or device to execute a procedure to manufacture the base portion described above or an embodiment thereof. A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides the computer program element embodied on a computer readable medium. A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium. For purposes of this disclosure, and notwithstanding the above, it is to be understood that any controller(s), control units and / or control modules described herein may each comprise a control unit or computational device having one or more electronic processors. The controller may comprise a single control unit or electronic controller or alternatively different functions of the control of the system or apparatus may be embodied in, or hosted in, different control units or controllers or control modules. As used herein, the terms “control unit” and “controller” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause said controller(s) or control unit(s) or control module(s) to implement the control techniques described herein (including the method(s) described herein). The set of instructions may be embedded in one or more electronic processors, or alternatively, may be provided as software to be executed by one or more electronic processor(s). For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present invention is not intended to be limited to any particular arrangement. In any event, the set of instructions described herein may be embedded in a computer-readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors / computational device, including, without limitation: a magnetic storage medium (e.g., floppy diskette); optical storage medium (e.g., CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information / instructions. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and / or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings m which: FIG. 1A is a side perspective view of a container in accordance with an embodiment of the present invention; FIG. IB is a rear view of the container of FIG. 1A; FIG. 2A illustrates a foot portion for a base portion for the container of FIG. 1A; FIG. 2B illustrates a first layer for the base portion for the container of FIG. 1A; FIG. 2C illustrates a bottom view of the base portion for the container of FIG. 1 A; FIG. 2D illustrates an alternative bottom view of the base portion of FIG. 2C; FIG. 2E illustrates a top view of the first layer of the base portion of FIG. 2C; FIG. 2F illustrates an a top view of the first layer and the second layer of the base portion of FIG. 2C; FIG. 3 A is a flow chart illustrating the steps in a method of manufacturing a container in accordance with an embodiment of the present invention; FIG. 3B illustrates an additional step in the method of FIG. 3 A; FIG. 3C illustrates an additional step in the method of FIG 3A; FIG. 3D illustrates an additional step in the method of FIG. 3 A; and FIG. 3E illustrates an additional step in the method of FIG. 3 A. A container 102 in accordance with an embodiment of the present invention is described herein with reference to FIG. 1A and FIG. IB. With particular reference to FIG. 2A to FIG. 2F, the container 102 includes a base portion 108. A method of manufacturing the container 102 is described with reference to FIG. 3A to FIG. 3E. Referring now to FIG. 1A, there is shown a container 102 in the form of a backpack 104. The backpack 104 has a body portion 106 and a base portion 108. The body portion 106 includes an outer wall 112 that is configured to contain one or more objects. The base portion 108 is connected to the body portion 106, as will be described further below. The outer wall 112 of the body portion 106 forms a second portion 118 of an outer skin 114 of the container 102. With particular reference to FIG. IB, the body portion 106 includes two carrying members 110, which may be used by a person to carry the container 102, for example on the person's back. The base portion 108 of the backpack 104 will now be described with particular reference to FIG. 2A to FIG. 2F. A foot portion 202 for the base portion 108 is shown in FIG. 2A. The foot portion 202 may be any shape, but is smaller than the overall size of the first layer 204 in order that one or more foot portions 202 may be incorporated into the first layer 204, as will be described further. In other words, the size and shape of the foot portion 202 may be adapted according to the requirements of the base portion 108 of the backpack 104. The or each foot portion 202 is made from a material including rubber, for example a rubber material having a density of 0.55 and a hardness of 90A. The or each foot portion may include one or more protrusions 224, which form an interlocking connection between the foot portion 202 and the first layer 204 of the base portion 108 during manufacture. FIG. 2B illustrates a first layer 204 of the base portion 108 of the backpack 104. The first layer 204 has a generally planar inner surface 220 surface from which an upstanding wall 232 extends. The generally planar inner surface 220 corresponds to the inner surface 220 of the first layer 204, and includes a number of indentations 222 and grooves 230. The first layer 204 is formed from a first material 208, which like the material of the or each foot portion 202 may be a material including rubber. The first material 208 has different mechanical properties to the rubber material of the or each foot portions 202 (the second material 210). The first material 208 may, for example have a density of 0.4 and a hardness of 60A. In other words, the second material 210 of the foot portions 202 has a greater density and greater hardness than the first material 208 of the first layer 204. As will be described in more detail, the first layer 204 and the or each foot portion 202 are co-moulded such that the or each foot portion 202 is integrate with the first layer 204. The protrusions 224 of the or each foot portion 202 are moulded into the first layer 204 to form an interlocking connection between the or each foot portion 202 and the first layer 204 of the base portion 108. Referring now to FIG. 2C, the moulded first layer 204 of the base portion 108 me ludes four integral foot portions 202. As shown in FIG. 2D, each of the four integral foot portions 202 form a projection 216 which extends from the outer skin 114 of the container 102. More specifically, each of the projections 216 extends from a first portion 116 of the outer skin 114, which is formed by the first layer 204 of the base portion 108. With reference to FIG. 2E, the inner surface 220 of the first layer 204 with four integral foot portions 202 can be seen. The inner surface 220 has four recesses 218, which are formed by the four foot portions 202. The inner surface 220 also includes a rim 226 defining a central portion 228 of the inner surface 220, within which central portion 228 the recesses 218 are located, along with a plurality of indentations 222 and a plurality of grooves 230. Referring now to FIG. 2F, there is shown a base portion 108 including the first layer 204 , the integral foot portions 202 and the second layer 206. The second layer 206 is formed from a third material 212 and is located within the central portion 228, which is defined by the rim 226 on the inner surface 220. The third material 212 may be a polymeric material, for example a polyurethane foam, and may have a density of 0.4 and a hardness of 45C. In other words, the third material 212 of the second layer 206 has a density that is the same as, or similar to, the density of the first material 208 of the first layer 204 and a hardness that is less than the hardness of the first material 208 of the first layer 204. A method 300 of manufacturing a container 102 according to an embodiment of the invention will now be described with particular reference to FIG. 3A to FIG. 3E. The base portion 108 is manufactured as follows. In step 302, the or each foot portion 202 is placed within a mould (not shown). The first material 208 is then poured into the mould and the first layer 204 and the or each foot portion 202 are co-moulded (step 304). Protrusions in the or each foot portion 202 form interlocking connections between the first layer 204 and the or each foot portion 202 when the moulding process is complete. In this way, the or each foot portion 202 is embedded in, or integral with, the first layer 204. In step 306, as shown in FIG. 3B, the first layer 204 and the or each foot portion 202 are vulcanised in order to increase the hardness of the first layer 204. The third material 212 is then injected onto the inner surface 220 of the first layer 204 such that the third material 212 fills the central portion 228 of the first layer 204 (step 316). The third material 212 thus fills the recesses 218, the indentations 222 and the grooves on the inner surface 220 of the first layer 204. The third material 212 within the recesses 218, the indentations 222 and the grooves 230 forms interlocking connections between the first layer 204 and the second layer 206. The container 102 is manufactured by attaching the base portion 108 to the body portion 106 (step 318 of FIG. 3D). The base portion 108 may be attached to the body portion 106 using any suitable fastening or attachment means. The base portion 108 may, for example, be adhered to the body portion 106 using an adhesive. Additionally, or alternatively, the base portion 108 may be fastened to the body portion 106 using stitches, staples or other fastening mechanisms. To enable a person to easily carry the container 102, one or more carrying members 110 are attached to the container 102 (step 320 of FIG. 3D). As shown in FIG. IB, two carrying members 110 may be attached to the container 102, resulting in the provision of a backpack 104. It has been found that a container 102 having a base portion 108 as described above is particularly resistant to mechanical impacts. The resistance of the base portion 108 of the backpack 104 to impact (i.e. its impact resistance) has been assessed according to the standards set for assessing motorcyclists' protective clothing against mechanical impact (EN 1621-2012). The test is typically used to assess the protective qualities of armour worn on limb joints while riding a motorcycle. The lower the force that a protector transmits, the more protective a product is considered to be. To pass the standard, the mean maximum transmitted force must be below 35 kN, and no single test value should be over 50 kN. The impact resistance of the base portion 108 of the backpack 104 was found to be less than 20 kN. It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, in the embodiment described above, the container 102 is a backpack 104. It will be appreciated that a base portion 108 as described above may be used in other containers 102 to protect objects within the container 102, for example other bags or rucksacks or the like. In the embodiment described above, the first layer 204 and the four foot portions 202 are co-moulded. It will be appreciated that, in other embodiments of the invention, the first layer and the or each foot portion may be manufactured using other methods that enables the or each foot portion to be encapsulated or embedded within the first layer, for example the first layer and the or each foot portion may be manufactured using an additive manufacturing process, for example 3D printing. In the embodiment described above, the second layer 206 is injected into the first layer 204 to form the base portion 108. It will be appreciated that, in other embodiments of the invention, the second layer and the first layer may be manufactured using other methods that enables the second layer and the first layer to be mechanically interlocked. The second layer and the first layer may, for example, be manufactured using an additive manufacturing process, for example 3D printing. In yet further embodiments of the invention, the second layer may be provided as a foam pad which is cut to the required size and shape and adhered, or otherwise fastened, to the first layer. It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and / or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1. A container comprising:a body portion comprising an outer wall that is configured to contain one or more objects; anda base portion connected to the body portion; wherein the base portion comprises:a first layer;a second layer; anda foot portion; wherein the foot portion is located between the first layer and the second layer.

2. The container of claim 1, wherein the base portion comprises a plurality of foot portions.

3. The container of claim 1 or 2, wherein the or each foot portion is embedded in the first layer.

4. The container of any one of claims 1 to 3, wherein the first layer comprises a first material having a first density and a first hardness and the or each foot portion comprises a second material having a second density and a second hardness.

5. The container of claim 4, wherein the second density is greater than the first density.

6. The container of claim 4 or 5, wherein the second hardness is greater than the first hardness.

7. The container of claim 6, wherein the second layer comprises a third material having a third density and a third hardness.

8. The container of claim 7, wherein the third density is the same as the first density.

9. The container of claim 7 or 8, wherein the third hardness is less than the first hardness.

10. The container of any one of claims 1 to 9, wherein the first layer forms a portion of an outer skin of the container.

11. The container of claim 10, wherein the first layer forms a first portion of the outer skin of the container and the outer wall of the body portion forms a second portion of the outer skin of the container.

12. The container of claim 10 or 11, wherein the first portion and the second portion together form the outer skin of the container.

13. The container of any one of claims 1 to 12, wherein the or each foot portion forms a projection on the outer skin of the container.

14. The container of any one of claims 1 to 13, wherein the or each foot portion forms a recess on an inner surface of the base portion.

15. The container of claim 14, wherein the inner surface of the base portion comprises an indentation.

16. The container of claim 15, wherein the inner surface of the base portion comprises a plurality of indentations.

17. The container of any one of claims 1 to 16, wherein the base portion has an impact resistance of less than 35 kN.

18. The container of any one of claims 1 to 17, wherein the container is a bag.

19. The container of any one of claims 1 to 18, wherein the container is a rucksack.

20. The container of any one of claims 1 to 19, wherein the container is a backpack.

21. A method of manufacturing a container of any one of claims 1 to 20, comprising:placing the or each foot portion into a mould; and co-moulding the or each foot portion and the first layer of the base portion in the mould.

22. The method of claim 21, comprising:vulcanising the or each foot portion and the first layer of the base portion.

23. The method of claim 21 or 22, when dependent on any one of claims 7 to 9, comprising: injecting the third material onto an inner surface of the first layer.

24. The method of any one of claims 21 to 23, comprising: attaching the base portion to the body portion.

25. The method of any one of claims 21 to 24, comprising:attaching a carrying member to the container.

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