Integrated inner rim for injection-molded hard-side luggage case

Abstract

To provide a molded luggage case requiring less molding components in a molding step and having a desired structure and intensity.SOLUTION: A luggage case (100, 500) includes at least one injection-molded shell (118, 120, 520) including a side wall (152, 154, 552, 554) having an inner region and defining an outer rim (202, 602) at least partially integrally formed and an inner rim (212, 612) arranged inside the outer rim (202, 602) and integrally molded. The inner rim (212, 612) extends along at least a part of a length of the outer rim (202, 602) and extends by an acute angle (240, 406, 412) in a direction away from the side wall (152, 154, 552, 554). A support structure (222, 622) extends between the outer rim (202, 602) and the inner rim (212, 612).SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The described embodiments generally relate to injection molded luggage cases and methods for molding same. [Background technology]

[0002] Travelers often prefer hardside luggage cases due to their durability and the protection they provide to their contents during travel. Hardside luggage cases can also be aesthetically appealing to travelers. Common forms of hardside luggage cases include metal and plastic luggage cases. However, metal luggage cases are often significantly heavier and more expensive to manufacture. Plastic cases are lighter and less expensive to manufacture than metal luggage cases, but often require multi-piece molds, such as those using sliders, to provide the desired shape, durability level, or structural integrity. When multi-piece molds are used, the molding methods and techniques can be more complex and expensive, and the resulting exterior structure can detract from the aesthetic appeal of plastic cases. Summary of the Invention [Problem to be solved by the invention]

[0003] Therefore, there is a need for molded luggage cases that are durable and have the desired structural integrity. There is also a need for molded luggage cases that require fewer molded parts in the molding process and have the desired structure and strength. [Means for solving the problem]

[0004] An embodiment of the present invention relates to a luggage case comprising at least one injection-molded shell containing an interior storage volume and including a sidewall defining an at least partially integrally molded outer rim and an integrally molded inner rim disposed within the outer rim, wherein the inner rim extends along at least a portion of the length of the outer rim, the inner rim extends at an acute angle away from the sidewall, and a support structure extends between the outer rim and the inner rim.

[0005] In another embodiment, a luggage case can include at least one injection molded shell including a major surface and at least one sidewall that together define an interior storage volume, the sidewall defining an integrally formed outer rim and at least a portion of an integrally formed inner rim disposed within the outer rim, the inner rim extending along at least a portion of the length of the outer rim and the inner rim extending at an acute angle away from the sidewall.

[0006] Additionally, in some embodiments, the sidewall extends along at least a portion of the periphery of the major panel, the sidewall including at least one corner region, the outer rim is defined to extend at least partially along the sidewall and the at least one corner region, and the inner rim extends along at least a portion of the sidewall and the at least one corner region.

[0007] In some embodiments, the inner rim extends along at least a portion of each of at least two adjacent sidewalls and at least one corner region.

[0008] In some embodiments, the inner rim is offset below the outer rim.

[0009] In some embodiments, the inner rim extends around about 50 to 90 percent of the length of the outer rim.

[0010] In some embodiments, the inner rim extends continuously along the majority of the length of the sidewall.

[0011] In some embodiments, the inner rim extends linearly along the sidewall.

[0012] In some embodiments, the inner rim extends around the entire length of the outer rim.

[0013] In some embodiments, at least a portion of the inner rim is positioned further inwardly of the interior volume than the sidewall.

[0014] In some embodiments, the inner rim formed on the sidewall is continuous, while in other embodiments, it is interrupted. A continuous inner rim provides greater rigidity relative to the outer rim. An interrupted inner rim uses less material than a continuous inner rim while still providing some rigidity.

[0015] In some embodiments, the inner rim defines a ledge (also a flange or collar) extending from at least one sidewall.

[0016] In some embodiments, the support structure extends between the outer rim and the inner rim. Additionally, the support structure can extend at a non-orthogonal angle between the outer rim and the inner rim, which provides sufficient strength while allowing some flexing between the inner and outer rims.

[0017] In some embodiments, the support structure is oriented perpendicular to the major panel, which is the mold release direction, making it more convenient to release the support structure.

[0018] In some embodiments, the support structure is resilient, allowing the inner rim to flex relative to the outer rim.

[0019] In some embodiments, the outer rim is flush with the outer surface of at least one sidewall. In some embodiments, the rim band is flush with the field region. In some embodiments, the rim band is free of raised structural features. In some embodiments, the outer rim is free of external raised structural features. In some embodiments, the outer rim is flush with the outer surface of at least one sidewall. Having a flush surface, such as a surface without raised structural features, provides a cleaner appearance. In some embodiments, the sidewall extends perpendicularly from the major panel. In other embodiments, the sidewall includes a top panel and an opposing bottom panel, the bottom panel extending from the major panel at an angle of approximately 90-98 degrees. In some embodiments, the bottom panel extends from the major panel at an angle of approximately 98 degrees relative to the major panel. These angles allow other panels of the luggage case, such as the top panel opposing the bottom panel, to be perpendicular to the major surface while providing sufficient draft angle in the mold for proper release from the mold.

[0020] In some embodiments, the acute angle between the inner rim and the sidewall is between about 1 degree and about 14 degrees, or between about 4 degrees and about 6 degrees. In other embodiments, it may be about 6 degrees.

[0021] In some embodiments, the acute angle between the inner rim and the sidewall is between about 80 degrees and 94 degrees relative to the major panel.

[0022] In some embodiments, the shell includes a first portion of the side wall oriented orthogonally relative to the major surface panel and a second portion of the side wall oriented at a greater outward angle relative to the major surface panel than the first side wall.

[0023] In some embodiments, the inner rim forms a beveled surface for sliding contact with the mold core when the shell is released from the mold. In some embodiments, the inner rim flexes outward upon release from the mold core. In some embodiments, the inner rim and the outer rim flex outward upon release from the mold core.

[0024] In some embodiments, the inner rim includes a first portion and a second portion extending along different portions of the outer rim and defining a gap therebetween. In some embodiments, an insert is coupled to a first end of the first portion and a second end of the second portion and extends across the gap. In some embodiments, the first and second portions of the inner rim are adjacent to the corner region, defining the gap in the corner region. In some embodiments, the outer rim has a first thickness and a thinner second thickness in the corner region. In some embodiments, the insert includes a shelf (e.g., a shoulder) extending along the corner region between adjacent sides for supporting the corner region, and the insert rim extends from the shelf and is positioned adjacent to the outer rim. In some embodiments, the insert rim and the outer rim in the corner region have a combined thickness similar to or the same as the first thickness. In some embodiments, the insert rim and the outer rim are joined by a stitched joint. In some embodiments, a closure mechanism is joined to the outer rim by a stitch.

[0025] In some embodiments, the first and second portions of the inner rim and the gap formed therebetween are disposed on one sidewall of the shell. In some embodiments, the insert includes a handle extending outwardly relative to an outer surface of the shell. In some embodiments, the inner rim defines mounting structures at opposing first and second ends. In some embodiments, the insert defines receiving grooves at each opposing end, and the mounting structures are received in the respective receiving grooves to couple the insert to the inner rim. In some embodiments, the inner rim is disposed in a corner region of the shell.

[0026] In some embodiments, the second sidewall is oriented at an angle between 90 degrees and 98 degrees relative to the major surface panel.

[0027] In some embodiments, the injection molded shell includes two or more sidewalls and a corner region disposed between at least two of the sidewalls, and the shell is formed in a mold including a mold core. In some embodiments, the inner rim resiliently deflects outward when it engages the mold core during separation of the injection molded shell and the mold core.

[0028] In some embodiments, two or more side walls resiliently flex outward and corner regions resiliently flex inward when the side walls engage the mold core during separation of the injection mold shell and mold core.

[0029] In some embodiments, the shell further includes corner regions that resiliently deflect inwardly upon separation of the shell and mold core.

[0030] In some embodiments, the inner rim extends continuously through the corner region and defines a first width between the inner rim and the outer rim. Upon separation of the shell and mold core, the inner rim resiliently flexes outward to define a second width between the inner rim and the outer rim, the second width being less than the first width.

[0031] In some embodiments, the luggage case further includes at least one wheel attached to a corner region of the bottom panel of the luggage shell and a towing handle attached to the rear major surface panel of the luggage shell. In another embodiment, a method of injection molding a luggage case is disclosed. The method includes providing a mold core movably disposed within an outer mold defining a mold cavity. The mold core defines an interior cavity of the shell, and the outer mold defines an exterior of the shell. A portion of the mold cavity defines at least one sidewall of the shell, and another portion of the mold cavity defines an inner rim disposed on the at least one sidewall, the inner rim being disposed more inwardly toward the interior cavity of the shell than the at least one sidewall. Furthermore, the mold core and outer mold separate along a separation direction, and the portion of the mold cavity defining the major surface of the luggage shell is oriented non-orthogonal to the separation direction.

[0032] In some embodiments, a portion of the mold cavity defines a first sidewall of the injection molded shell, a second sidewall of the injection molded shell, and a corner area having a radius of curvature and defining an intersection between the first sidewall and the second sidewall.

[0033] In some embodiments, upon separation of the mold core and injection molded shell, the first sidewall and the second sidewall flare outwardly, increasing the radius of curvature of the corner regions.

[0034] In some embodiments, a portion of the mold cavity defines a top sidewall of the injection molded shell and another portion defines a bottom sidewall of the injection molded shell.

[0035] In some embodiments, the first sidewall is a top sidewall and the second sidewall is a bottom sidewall.

[0036] In some embodiments, the outer mold and mold core separate along a separation direction that is non-orthogonal to the portion of the mold cavity that defines the major panel.

[0037] In some embodiments, a portion of the mold cavity defines a top sidewall that is perpendicular to the major panel, and another portion of the mold cavity defines a bottom sidewall that is at an angle to the major panel.

[0038] In some embodiments, the acute angle between the inner and outer rims elastically decreases upon separation of the mold core from the injection molded shell.

[0039] In some embodiments, the inner rim extends parallel to or at an angle that intersects the direction of separation of the mold core and outer mold.

[0040] In some embodiments of a luggage case formed by this method, the injection-molded shell includes a panel defining a front or rear of the luggage case, and the one or more side walls include an orthogonal sidewall extending from the panel and an opposing sidewall extending from the panel opposite the orthogonal sidewall, the opposing sidewall extending outwardly relative to the orthogonal sidewall.

[0041] In some embodiments, the orthogonal sidewall is a top sidewall and the opposing sidewall is a bottom sidewall.

[0042] In some embodiments, the opposing side walls extend outwardly at an angle of 90 to 98 degrees relative to the panel.

[0043] In some embodiments, the inner rim extends along at least a portion of each of the orthogonal and opposing side walls.

[0044] In some embodiments, the acute angle between the inner rim and one or more sidewalls is between about 1 and 14 degrees.

[0045] In some embodiments, the acute angle between the inner rim and the one or more sidewalls is about 6 degrees.

[0046] In some embodiments of a luggage case formed by this method, the luggage case further includes at least one wheel attached to a corner region of the bottom panel of the luggage shell and a towing handle attached to the rear major panel of the luggage shell.

[0047] In another embodiment, a luggage case is disclosed. The luggage case comprises a single-piece injection-molded shell containing an interior storage volume, the single-piece injection-molded shell including a major surface, a first sidewall extending substantially perpendicularly from the major surface, a second sidewall opposite the first sidewall and extending at an angle outward relative to the first sidewall, an outer rim, and an integral inner rim disposed along an interior portion of either the first sidewall or the second sidewall. The inner rim extends along at least a portion of the length of the outer rim, and the inner rim extends inward away from the sidewall at an acute angle.

[0048] In some embodiments, the angle of the second sidewall is about 4-8 degrees. In some embodiments, the acute angle between the inner rim and the sidewall is about 0-4 degrees. In some embodiments, the inner rim flexes upon release of the mold core. In some embodiments, the inner rim and the outer rim flex outward upon release from the mold core. In some embodiments, the support structure extends at a non-orthogonal angle between the inner rim and the outer rim. In some embodiments, the inner rim extends continuously along a majority of the periphery of the luggage shell. In some embodiments, an acute angle is defined between the inner rim and the first or second sidewall, and the acute angle is about 0-4 degrees.

[0049] In another embodiment, a mold assembly for forming a luggage shell for a luggage case is disclosed. The mold assembly includes a mold core and an outer mold. The mold core and outer mold define a mold cavity that defines the integrally molded shell. The mold core and outer mold separate along a separation direction. The portions of the mold cavity that define the major surfaces are oriented non-orthogonally relative to the separation direction.

[0050] In some embodiments, the angle of the mold cavity portion defining the sidewall is about 86-94 degrees relative to the mold cavity portion defining the major surface. In other embodiments, the angle between the mold cavity portion defining the inner rim and the mold cavity portion defining the sidewall is about 1-14 degrees.

[0051] In another embodiment, an injection mold assembly for injection molding a luggage shell for a luggage case includes a mold core and an outer mold, the mold core and outer mold defining a mold cavity, the mold core and outer mold separating along a separation direction, a portion of the mold cavity defining a major surface of the luggage shell being oriented non-orthogonal to the separation direction, and further, the angle of the portion of the mold cavity defining the sidewall of the luggage shell relative to the portion of the mold cavity defining the major surface is between about 86 and 94 degrees.

[0052] Additionally or optionally, the acute angle between the portion of the mold cavity defining the inner rim of the luggage shell and the portion of the mold cavity defining the sidewall is between about 1 and 14 degrees.

[0053] Many refinements and additional features are applicable and contemplated in light of the present disclosure. These refinements and additional features may be used individually or in any combination. Thus, each feature described below may be used with any combination of other features of the first aspect, but need not be used.

[0054] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions.

[0055] The present disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals indicate like structural elements. [Brief explanation of the drawings]

[0056] [Figure 1] FIG. 1 is a right-front perspective view of an exemplary luggage case. [Figure 2] FIG. 1 is a right-front perspective view of an exemplary luggage case in an open configuration. [Figure 3A] FIG. 1 is a perspective view of a rim portion of an exemplary luggage shell and an insert coupled to the rim portion. [Figure 3B] FIG. 3B is an exploded view of the rim portion and insert of FIG. 3A. [Figure 4A] FIG. 1 is a plan view of the rim and corner areas of an exemplary luggage shell. [Figure 4B] 4B is a cross-sectional view of the rim portion taken along line 4B-4B of FIG. 4A. [Figure 5A] FIG. 1 is a perspective view of an exemplary corner insert. [Figure 5B] 5B is a perspective view of the exemplary corner insert of FIG. 5A coupled to an exemplary rim portion. [Figure 5C] 5C is a cross-sectional view of an exemplary corner insert and rim portion as shown by line 5C-5C in FIG. 5B. [Figure 5D] 5B is a plan view of the exemplary corner insert of FIG. 5A coupled to an exemplary rim portion. [Figure 6] FIG. 1 is a perspective view of a corner area of ​​an exemplary luggage case including corner inserts and an opening and closing mechanism. [Figure 7] 7A is a cross-sectional view of an exemplary handle insert as shown by line 7A-7A in FIG. 3A. [Figure 8A] 1 is a cross-sectional view of an exemplary luggage shell including a rim portion and an exemplary male mold. [Figure 8B] FIG. 8B is a cross-sectional view of the exemplary luggage shell of FIG. 8A upon removal of the male mold. [Figure 8C] FIG. 8B is a plan view of the exemplary luggage shell and male mold of FIG. 8A. [Figure 8D]8D is a cross-sectional plan view of the exemplary luggage shell and male mold upon removal of the male mold, as shown by line 8D-8D in FIG. 8B. [Figure 9A] 9A is a cross-sectional view of an exemplary luggage shell taken along line 9A-9A of FIG. 2. [Figure 9B] FIG. 1 is an exploded cross-sectional view of an exemplary luggage shell and mold assembly. [Figure 9C] 10A and 10B are diagrams showing angles between the top wall and the main surface, the bottom wall and the main surface, and the side wall and the main surface, respectively. [Figure 10] FIG. 1 is a perspective view of an exemplary luggage shell and rim portion. [Figure 11A] FIG. 1 is a plan view of an exemplary male mold and an exemplary luggage shell. [Figure 11B] FIG. 12 is a top view of the exemplary luggage shell of FIG. 11 upon removal of the exemplary male mold. DETAILED DESCRIPTION OF THE INVENTION

[0057] The description below includes sample products, systems, methods, and / or devices that embody various elements of the present disclosure, although it should be understood that the described disclosure may be implemented in a variety of forms in addition to those described herein.

[0058] The following disclosure generally relates to at least one molded luggage shell having an integrally formed inner rim. The luggage case may include two or more shells selectively connected by an opening / closing mechanism. The shell may include a rim portion. The rim portion may include a peripheral or outer rim. The rim portion may include an integrally formed inner rim disposed inward of the shell relative to the peripheral or outer rim. The inner rim may extend along a portion of the length of the interior of the shell. In some embodiments, the inner rim may extend discontinuously along the peripheral rim. In some embodiments, the inner rim may extend continuously along the peripheral rim of the shell. For example, the inner rim may extend along all or a portion of the length of the shell's sidewall and / or along the corners of the shell. The inner rim extends inward, i.e., toward the interior of the shell relative to the outer rim. Structural support structures may extend between the outer rim and the inner rim. The inner rim may provide structural support to the shell. Optionally, the exterior of the shell adjacent the rim portion may be unstructured or smooth for an aesthetically pleasing exterior. For example, the exterior of the shell adjacent the outer rim may or may not include a raised ridge or shoulder, hi some embodiments, the rim portion may include a raised ridge or shoulder to hide or reduce the appearance of molding process imperfections such as sink marks.

[0059] In embodiments where the inner rim is discontinuous, the luggage case can optionally include an insert disposed in all or part of the gap in the inner rim. The insert can be bonded to the inner rim. For example, the inner rim can include two or more sections that define the gap, and the insert can be positioned to extend between the two sections. The insert can provide structural support to the shell. In one embodiment, the gap is in a corner region of the outer rim, and the insert can be a corner insert that extends to support the corner region of the shell. The insert can reinforce the corner of the shell. In another embodiment, the gap can be positioned along the side of the outer rim. The insert can form at least part of the structure that connects the outer carry handle to the shell. The handle insert can reinforce the rim region of the shell and support concentrated loads (e.g., "point" loads) created when the luggage case is supported by the carry handle.

[0060] The luggage shell can be formed by molding. For example, the molding can be injection molding. The injection mold assembly can include an outer mold that defines the exterior shape of the shell. The injection mold assembly can include a mold core that defines the interior of the shell. When the mold core and outer mold are positioned together, a mold cavity can be defined between the two parts. Heated material can be injected into the mold cavity to form the luggage shell or case. The mold core and outer mold can be separated in a separation direction to remove the molded article. To enable separation without damage to the molded luggage shell, the shapes of the mold core and outer mold can be positioned or defined with a draft angle relative to the separation direction to limit contact between the molded luggage shell and the mold core or outer mold.

[0061] Luggage cases of the present disclosure can be configured so that a portion of the shell flexes, stretches, or bends during separation of the shell and mold core. For example, the inner rim can flex in response to contact with the mold core during separation of the shell and mold core. In some embodiments, the sidewalls of the shell can flex outward. Corner areas of the shell can stretch or bend inward to accommodate bowing of the inner rim or sidewall. By bowing a portion of the luggage case outward, such as by stretching the inner rim inward, it is possible to form the luggage case or rim portion without using a traditional mold slider (an internal mold component that can move transversely to the direction of separation).

[0062] In some embodiments, the inner rim is discontinuous, forming a gap along one or more corner regions of the shell. During separation, the corner regions are allowed to deflect inward. The inward deflection of the corner regions can cause other regions (the inner rim and / or the outer rim, or both) to stretch or deflect outward or to deflect more outward. The draft angle can be selected to limit or prevent plastic deformation of the corner regions. In another embodiment, the inner rim contacts the mold core and is allowed to deflect outward toward the outer rim.

[0063] In some embodiments, the inner rim extends along at least a portion of the rim of the shell, including one or more corner regions of the shell. During separation of the molded article and mold core, the inner rim can resiliently bend, flex, or deflect outward in some regions, allowing the mold sections to separate and the shell to be ejected. The corner regions may or may not extend outward. The inner rim is capable of deflecting outwardly toward the outer rim. The outer rim is capable of deflecting outwardly with the inner rim. The draft angle can be selected to limit or eliminate plastic or permanent deformation in the corner region.

[0064] In some embodiments, the mold core and outer mold can define a mold cavity or mold cavity volume oriented at an offset angle relative to the separation direction. For example, a mold cavity portion defining a major surface can be offset at an angle relative to the separation direction. In some embodiments, one of the sidewalls can be positioned perpendicular to the separation direction. The opposing sidewall can extend at an outward angle relative to the major surface. Upon separation of the mold core and outer mold, the angle and offset angle of the opposing sidewall can provide a draft angle for both the perpendicular and opposing sidewalls. By orienting the mold core and outer mold at an angle, the core draft angle can define a draft angle for the perpendicular sidewall by reducing the outward angle of the opposing sidewall.

[0065] Reference will now be made to the accompanying drawings, which serve to illustrate various features of the present disclosure. The following description is for purposes of illustration and description. Moreover, the description is not intended to limit the embodiments of the present invention to the form disclosed herein. Consequently, variations and modifications commensurate with the teachings below, and the skill and knowledge of the relevant art, are within the scope of the embodiments of the present invention.

[0066] FIG. 1 illustrates an exemplary luggage case 100 in a closed configuration. Luggage case 100 may alternatively be referred to as a luggage item, suitcase, bag, trolley, etc. In one embodiment, luggage case 100 may be a vertical, hard-sided case, such as a spinner luggage case. In other examples, luggage item 100 may be any of a number of types of luggage, including soft-sided spinner cases with molded interior shells or panels, hybrid spinner cases, containers, etc. Luggage case 100 may include at least two shells, such as a first top shell 118 and a second bottom shell 120. Shells 118, 120 may define an interior storage volume for transporting or storing a traveler's belongings.

[0067] Luggage case 100 may include multiple panels or sides. For example, the luggage case may include a front panel 104 and an opposing back panel 106, a top panel 112 and opposing bottom sides or panels 114, and opposing left and right panels 108, 110. Each panel may include an exterior surface 138 and an interior surface 136, with the interior surface 136 defining the interior storage volume 130.

[0068] The luggage case 100 or shell 118, 120 can include at least one sidewall extending around the periphery of the major panel. In one embodiment, the at least one sidewall can include two or more sidewalls. The at least one sidewall can at least partially define a panel. For example, the shells 118, 120 can each include a short sidewall 152 and a long sidewall 154. The short sidewall 152 and the long sidewall 154 can extend from or intersect at a corner region 160 of the shells 118, 120. In some embodiments, each luggage shell 118, 120 includes at least two short sidewalls 152 and two long sidewalls 154. In some embodiments, the luggage case 100 or shell 118, 120 can be of various shapes or orientations. Thus, the reference to a short sidewall 152 or a long sidewall 154 can be for identification purposes only. In one embodiment, luggage case 100 may be a carry-on luggage case. In such an embodiment, long side walls 154 may be approximately 490 mm and short side walls may be 390 mm. Corner areas 160 may have an initial or final radius of approximately 40 mm.

[0069] The side walls 152, 154 can be positioned around or adjacent to a major surface or panel 156 of the luggage case 100 or shell 118, 120. In some embodiments, the major surface 156 can be or define the front panel 104 or the back panel 106 of the luggage case 100. As described herein, such as with reference to FIG. 9A , the side walls 152, 154 can be oriented at an angle relative to the major surface 156. The side walls 152, 154 can be oriented at the same angle or at different angles. In some embodiments, opposing side walls relative to the major surface can be formed at the same angle or at different angles. In one embodiment, the top panel 112 can be oriented perpendicular to the major surface 156. The bottom panel 114 can extend outwardly relative to the major surface 156. For example, the bottom panel 114 can be at an angle of approximately 90-98 degrees relative to the major surface 156. The outward angle of the bottom panel 114 can provide sufficient draft for both the top panel 112 and the bottom panel 114 during molding.

[0070] Luggage case 100 is movable between a closed configuration in which rim portions 200 of the two or more shells 118, 120 are positioned adjacent to one another, and an open configuration, shown in FIG. 2, that provides access to interior storage volume 130. Luggage case 100 can be selectively opened and closed by an opening and closing mechanism 144. Opening and closing mechanism 144 may be a latch or zipper that extends along a connection line between the two or more shells 118, 120. While reference is made to either first shell 118 or second shell 120, it should be understood that either shell 118, 120 may include the same or similar features.

[0071] Each shell 118, 120 can be integrally formed from a single material. For example, the shells 118, 120 can be formed, in whole or in part, from a molded polymer. In some embodiments, the shells 118, 120 can be formed from polypropylene or polypropylene blends, polycarbonate, ABS polymer, glass-filled or glass-mixed materials, or various combinations thereof. Either or both shells 118, 120 can be formed as a single unit, with at least some features of the shells 118, 120 integrally molded therewith. For example, the rim portion 200 can be integrally molded with the shells 118, 120. In some embodiments, portions of the luggage case 100 can be fabricated by injection molding all or part of each shell 118, 120 and connecting additional or outer portions to the exterior of the shells.

[0072] In some embodiments, the luggage article 100 includes one or more carry handles 128 and / or a telescoping towing handle 126. The towing handle 126 can be attached to or extend from a bezel, recess, or the like in the rear panel of the luggage article 100. The carry handle 128 can be defined by or attached to the luggage article 100. The luggage article 100 includes one or more leg elements 140. The leg elements 140 can be wheels, casters, swivels, supports, or combinations thereof that support the luggage article 100 on a supporting surface or allow the luggage article 100 to move across a supporting surface, such as a floor, street, sidewalk, or ground. In one embodiment, the wheels 140 can be coupled to the shells 118, 120 along the bottom side or bottom panel 114. In some embodiments, the wheels 140 can be connected to corner regions 160 of the shells 118, 120.

[0073] 2-4B, luggage case 100 includes a rim portion 200. Rim portion 200 is defined along the periphery or edge of one or both shells 118, 120. Rim portion 200 may be continuous or discontinuous along shells 118, 120. Rim portion 200 includes an outer or peripheral rim 202 and an inner or second rim 212.

[0074] The inner rim 212 extends inwardly from the inner surface 136 of the luggage shell 118, 120. The inner rim 212 may extend along a short sidewall 152, a long sidewall 154, a corner 160, or the like. Thus, the inner rim 212 may be spaced inwardly of the outer rim 202 or disposed within the outer rim 202. The inner rim 212 may be defined by a flange 230 having opposed inner and outer ends 234, 236. The inner end 234 is engaged with the sidewall 152, 154 (on which the inner rim 212 resides). Referring at least to FIG. 4B , the outer end 236 forms a free end distal to the inner end 234 and is disposed spaced apart from the sidewall 152, 154 because the flange 230 is angled from the sidewall 152, 154. At least a portion of the inner rim 212 can be positioned further inward into the containment volume 130 than the sidewalls 152, 154. In one embodiment, the free end 236 is positioned further inward into the containment volume 130 than the sidewalls 152, 154. The free end 236 can, in some embodiments, be flexible upon removal from the mold, as described in more detail below. The inner rim 212 can extend along all or part of the outer rim 202. As discussed herein, the inner rim 212 can be integrally molded to or with the shells 118, 120.

[0075] In some embodiments, the outer surface 138 of the rim portion 200 optionally defines a featureless, flat rim band 210. For example, the outer rim 202 may be flush with the sidewalls 152, 154. The rim band 210 may be defined on the outer surface of at least one of the sidewalls 152, 154 adjacent to the peripheral rim 202. In one embodiment, the rim band 210 is not raised relative to the outer surface 138. In another embodiment, the rim band 210 is flush with the field area.

[0076] Optionally, the outer surface 138 of the rim portion 200 defines or includes a ridge or shoulder. The shoulder can be located adjacent the inner rim 212. In some embodiments, the shoulder can provide a gap between the peripheral rim 202 and the inner rim 212, e.g., 1-5 mm from the inner rim 212 at the intersection between the inner rim 212 and the peripheral rim 202. In some embodiments, a recess or step can hide or obscure evidence of the formation of the rim portion 200, such as during molding.

[0077] 2 and 3A, where the inner rim 212 is discontinuous, an insert 250 may be coupled to the inner rim 212, optionally along gap 235, for example, to support the shell 120. The insert 250 may be at least partially coupled to the inner rim 212 or luggage shell 118, 120 and support the rim portion 200 along gap 235. The insert 250 may be a rim insert 252 that supports portions of the rim portion 200 in the corner areas 160 or along the side panels 152, 154. The insert 250 may also be a handle insert 270 to allow attachment or definition of a carry handle 274 to the exterior 138 of the luggage shell 120.

[0078] Figure 3A is a partial enlarged view of luggage shell 120 of Figure 2. Figure 3B is an exploded view of luggage shell 120 shown in Figure 3A. With continued reference to Figures 3A and 3B, and with reference to Figures 4A and 4B, luggage shell 120 includes a rim portion 200 including an outer rim 202 and an inner rim 212.

[0079] As discussed herein, the rim portion 200 may be defined at or along the periphery of the shells 118, 120. Both the outer rim 202 and the inner rim 212 may be integrally formed or molded with the shells 118, 120.

[0080] The outer rim 202 can define the perimeter or periphery of the luggage shell 118, 120. The outer rim 202 can be defined in part by the sidewalls 152, 154. The outer rim 202 can include a perimeter 204. The outer perimeter 204 can represent the boundary or intersection between the inner surface 136 and the outer surface 138 of the shell 120. The outer rim 202 can extend in the same or similar direction as the sidewalls. In some embodiments, the outer rim 202 or sidewalls 152, 154 can be orthogonal (e.g., substantially perpendicular) to the major surface 156, or can be disposed at an angle, such as a draft angle, to facilitate removal from a mold. For example, the outer rim 202 or sidewalls 152, 154 can be disposed at an angle of approximately 0 to 8 degrees relative to the orthogonal direction to the major surface 156. In some embodiments, the outer rim 202 can extend approximately 2 to 6 cm from its intersection with the inner rim 212 to the perimeter 204. In one embodiment, the outer rim extends approximately 4 cm.

[0081] The outer rim 202 can have a rim thickness dimension 206 along a portion of the short sidewall 152 or the long sidewall 154. The rim thickness 206 can be the same as the thickness at the outer peripheral edge 204 along the sidewalls 152, 154, i.e., the panels of the shell 120. In some embodiments, the outer rim 202 can have a second corner thickness 208 at the corner region 160. The corner thickness 208 can be thinner than the rim thickness 206. The corner thickness 208 can be thinner only adjacent the outer peripheral edge 204 or between the outer peripheral edge 204 and the major surface 156. The thinner corner thickness 208 can be a recess in the inner surface 136 of the corner region 160. As discussed herein, the thinner corner thickness 208 allows the corner region 160 of the shell 120 to flex or bend during the molding process when the mold parts are removed from the shell 120 after molding.

[0082] The inner rim 212 may be a shelf-like or annular projection extending from the sidewalls 152, 154. For example, the inner rim 212 may be a solid structure extending inward from the sidewalls 152, 154. In some embodiments, the inner rim 212 may extend linearly from the sidewalls 152, 154. The inner rim 212 may extend to the inner periphery 220. The inner rim 212 may extend inward from or relative to the sidewalls 152, 154 or one or more corners 160. The inner periphery 220 may be positioned below the outer periphery 204 to prevent interference between the inner rims 212 of the two shells 118, 120 in the closed configuration. A gap or groove 214 may be defined between the outer rim 202 and the inner rim 212.

[0083] The inner rim 212 can extend at a rim angle 240 relative to the sidewall 152 or corner region 160 from which it extends. The rim angle 240 can be an acute angle or a non-perpendicular angle relative to the sidewall 152, 154, for example, relative to the sidewall 152, 154 or the outer rim 202. The rim angle 240 can be between 1 and 14 degrees relative to the sidewall 152, 154 or the outer rim 202. In one embodiment, the rim angle 240 can be between approximately 4 and 6 degrees, inclusive. In another embodiment, the rim angle 240 can be approximately 6 degrees. The inner rim 212 can extend 0.5 to 4 cm from the sidewall to the inner peripheral edge 220. In one embodiment, the inner rim 212 can extend approximately 2.5 cm inward relative to the sidewall 152, 154. In some embodiments, the rim angle 240 can be an angle relative to the major surface 156 of the luggage case 100. For example, the inner rim 212 may extend inwardly at an angle of approximately 1 to 14 degrees relative to the normal of the major surface 156. Due to the draft angle of the sidewall 152 or 154, the inner rim 212 may be at an angle of approximately 80 to 94 degrees relative to the major surface 156. Because the rim angle 240 is inward relative to the sidewall 152, 154, the rim angle 240 is sometimes referred to as a negative draft angle 240.

[0084] The rim portion 200 can include one or more support structures or trusses 222 extending between the outer rim 202, i.e., the inner surface 136, and the inner rim 212. The trusses 222 can be disposed in the grooves 214. The support structures 222 extend non-orthogonally between the outer rim 202 and the inner rim 212. For example, the support structures 222 can extend at an acute or obtuse angle between the inner surface 136 and the inner rim 212. In some embodiments, the support structures 222 can have a triangular, honeycomb, or zigzag pattern. The support structures 222 can be integrally formed with the shells 118, 120 or the rim portion 200. In alternative examples, the support structures 222 can be coupled to the rim portion 200. The support structures 222 can be oriented perpendicular to the major surfaces. The support structures 222 can provide structural support or rigidity to the rim portion 200, enhancing or improving the durability of the shells 118, 120.

[0085] The inner rim 212 can extend continuously along a portion of the interior 136 of the shell 120. In some embodiments, the inner rim 212 can be segmented or otherwise discontinuous. In embodiments where the inner rim 212 is discontinuous, the inner rim 212 can include a first portion 216 spaced apart from a second portion 218. For example, if the inner rim 212 extends discontinuously along the outer rim 202, the portion of the inner rim 212 can include or terminate at one or more lateral ends 224. The first portion 216 and the second portion 218 can define a gap 235. Each lateral end 224 can define a mounting portion 226 for coupling or engaging with a portion of the insert 250 that spans the gap 235 between the lateral ends 224. The mounting portion 226 can include a T-shaped flange 228.

[0086] In one embodiment, first portion 216 extends along a portion of long sidewall 154 and second portion 218 extends along a portion of short sidewall 152. Gap 235 may be defined in corner region 160. Thus, inner rim 212 is disposed adjacent corner region 160 and does not extend through the corner region.

[0087] In some embodiments, inner rim 212 includes a third portion 232. Second portion 218 and third portion 232 may be disposed along a portion of the same side wall, such as short side wall 152, and define another gap 235 therebetween. Respective ends of second portion 218 and third portion 232 respectively define mounting portions 226.

[0088] With continued reference to FIGS. 3A and 3B, and with further reference to FIGS. 5A-7, luggage shell 120 can include one or more inserts 250 disposed in gaps 235 in inner rim 212. Inserts 250 can be selectively coupled to the interior of luggage shells 118, 120. For example, inserts 250 can be at least partially coupled to inner rim 212. In some embodiments, inserts 250 can be curved or bent to form corner inserts 252 that fit into gaps 235 formed in corner regions 160 (as shown in FIGS. 5A-6 in addition to FIGS. 3A and 3B). Inserts 250 can include special attachment structure to act as carry handle inserts 270, as shown in FIG. 7 in addition to FIGS. 3A and 3B.

[0089] The insert 250 may comprise a rigid, semi-rigid, or flexible material. The corner inserts 252 may be used when the luggage shells 118, 120 are made of polycarbonate, ABS polymer, glass-filled, or glass-mixed materials. The carry handle 270, or insert 250 generally, may be selectively attached or detached from the luggage case 100 to add, remove, or select color features for the luggage case 100.

[0090] The corner insert 252 may include an insert rim 257 that defines a thinner upper portion of the corner insert 252. The insert rim 257 may be a fin or a flange. The insert rim 257 may have an insert thickness 259. The corner insert 252 may include a ledge 262 (e.g., a shoulder). The ledge 262 may be the main body of the corner insert 252. The ledge 262 may define a receiving groove 264 in a bottom or side of the ledge 262 opposite the insert rim 257. The receiving groove 264 may be defined in an insert end 266 of the ledge 262. The ledge 262 may include two spaced-apart insert ends 266.

[0091] 5B and 3A show an exemplary corner insert 252 coupled to the shell 120. In one embodiment, the corner insert 252 is coupled to the first portion 216 and the second portion 218 of the inner rim 212 and is positioned in a gap 235 formed in the corner region 160. For example, the corner insert 252 extends from the lateral end 224 of the first portion 216 to the lateral end 224 of the second portion 218.

[0092] The corner insert 252 is attached to a portion of the inner rim 212 by receiving the mounting portion 226 in the receiving groove 264. As shown in FIG. 5C, when the T-shaped mounting portion 226 is received in a corresponding T-shaped groove, the flange 228 can be retained by the groove 264. Correspondingly, the mounting portion 226 couples the corner insert 252 to the inner rim 212.

[0093] When the corner insert 252 is coupled to the inner rim 212, the corner insert 252 can contact the inner surface 136 of the corner region 160. The ledge 262 can provide structural support or rigidity to the shell 120, such as the corner region 160. The insert rim 257 can extend the inner surface 136 of the corner region 160 to or adjacent the outer peripheral edge 204. As shown in FIG. 5D , the combined thickness 268 of the insert thickness 259 of the insert rim 257 and the corner thickness 208 of the corner region 160 can be similar to or equal to the outer rim thickness adjacent the corner region 160. The combined thickness 268 of the insert rim 257 and the outer peripheral edge 204 of the corner region 160 can make the corner region 160 of the shell 120 stronger or more durable.

[0094] 6, insert 250 can be secured to shell 120 by stitching 148. In one embodiment, a portion of closure mechanism 144, such as a zipper tape, can be stitched to shell 120 along with corner insert 252. Closure mechanism 144 can be stitched to either the inside 136 or the outside 138 of shell 120. A thin insert rim 257 allows a stitching device to penetrate corner insert 252 while also providing support to rim portion 160.

[0095] 3A, 3B, and 7, insert 250 may be a carry handle insert 270. Carry handle insert 270 may include a handle structure positionable on the exterior of luggage shell 120. Carry handle insert 270 may include anchor portions 278 used to attach handle portion 274 through luggage sidewalls 152, 154. Anchor portions 278 or carry handle insert 270 may be coupled to shell 120, such as at inner rim 212.

[0096] Handle portion 274 may be a handle, hook, or other feature for a traveler to grasp. Handle portion 274 may define one or more openings 280a. Openings 280a may be arranged and shaped to receive fasteners, such as flat head screws or screws. In one embodiment, at least two openings 280a are defined on opposite ends of handle portion 274 to receive fasteners for attachment to handle portion 274.

[0097] The anchor portions 278 may be features for engaging or connecting to the shell 120 and the handle portion 274. The anchor portions 278 may be a reinforcing feature for strengthening the rim 202 in the absence of an inner rim 212. For example, the anchor portions 278 may reinforce the rim portion 200 and support "point" loads that occur when the luggage case is transported by the carry handle 274. The anchor portions 278 may be shaped to conform to the luggage shell 120 of the case 100 or the interior shape of the luggage case 100.

[0098] The anchor portion 278 can define a receiving groove 282 on opposite ends. The receiving groove 282 can be the same as or similar to the T-shaped receiving groove 264. Thus, the receiving groove 282 can be an opening having a corresponding shape, such as a T-shape, relative to the mounting portion 226 or the flange 228.

[0099] In embodiments in which the shell 120 includes a carry handle insert 270, the inner rim 212 can be discontinuous or substantially continuous and define a portion that receives the carry handle insert 270. For example, the inner rim 212 can define a gap 235 between two portions of the inner rim 212, such as the second portion 218 and the third portion 232. The anchor portion 278 can be coupled to the handle portion 274. In some embodiments, the shell 120 defines one or more shell openings 272 spaced apart corresponding to the openings 280a. Fasteners can couple the insert 270 to the shell 120 or couple the anchor portion 278 to the inner rim 212.

[0100] 8A and 8B show an example of forming a single piece shell 120. FIG.

[0101] To allow portions of the shell 120 to flex, flex, or stretch upon separation of the mold core 303, the shell 120 may be formed of a polypropylene or polypropylene blend material. The polypropylene material may have advantageous melt flow properties that aid in the formation of the shell by injection molding. The polypropylene material may be elastic at low temperatures or as it cools after the luggage case 100 is formed. The polypropylene material may also resist visible or permanent deformation, such as whitening, upon bending, flexing, or stretching. One or more of these materials may include or be ABS, polycarbonate, or a glass-filled or glass-mixed material.

[0102] As shown in FIG. 9B , mold core 303 and outer mold 315 can be part of mold assembly 300. When closed together, mold core 303 and outer mold 315 define mold cavity 301 (see description of FIGS. 9A and 9B ) into which material can be injected to produce shell 120 by injection molding. To insert or remove mold core 303 from outer mold 315, mold core 303 and / or outer mold 315 typically move relative to one another along a single axis or direction. For example, mold core 303 can move only in direction 330. Mold core 303 can define the interior structure of luggage shell 120. For example, mold core 303 can have a surface that corresponds to the interior shape of shell 120. Outer mold 315 can define the exterior structure of luggage shell 120. In some embodiments, rim portion 200 is defined, at least in part, by mold core 303 and outer mold 315. In some embodiments, the outer mold 315 may be separated from the luggage shell 120 before the mold core 303 is separated from the luggage shell 120 .

[0103] Generally, to release a molded article from a mold core, the mold core and molded article are often shaped to limit or reduce contact so that the mold core does not damage the molded part. To accomplish this, the molded part and mold core are typically defined with a draft angle, or tapered shape. Thus, upon movement of the mold core 303 in the separation direction 330 (also referred to as the separation direction), a space is created between the molded part and the mold core that expands as the mold core is removed. Furthermore, inwardly facing features often require additional mold components, such as sliders, that move laterally relative to the separation direction 330. However, these laterally moving components add complexity and expense and can result in aesthetically unpleasing surface structures or other visible defects to travelers.

[0104] 8A-8D , to enable the formation of an inner rim 212 extending inward from the inside 136 of the shell 120, one or more portions of the shell 120 are designed to flex or bend when separated from the mold core 303, without requiring the use of a lateral moving component such as a slider. As the mold core 303 is moved in the separation direction 330, the mold core 303 may contact the sloped surface of the inner rim 212, causing the inner rim to resiliently flex outward, such as in direction 344. In some embodiments, certain regions of the shell 120, such as the sidewalls 152, 154, may flex outward to a flexed position 342 to enable removal of the mold core 303. This may also include the flexing of the inner rim 212. In some embodiments, the inner rim 212 flexes outward (e.g., moves toward the outer rim 202), with only a small amount of flexing of the sidewalls 152, 154. In some embodiments, the rim angle 240 between the inner rim 212 and the outer rim 202 may decrease during separation of the mold core 303 from the shell 120. The inner rim 212 may be formed at an inward angle (e.g., a negative draft angle), which may allow elastic deflection of the sidewalls 152, 154 and / or the inner rim 212, thereby allowing the use of a slider-less mold. Alternatively or additionally, forming structural features, such as shoulders, on the exterior of the luggage shell 120 near the rim portion 200 may be reduced or eliminated. Alternatively or additionally, aesthetic defects in the resulting luggage shell 120 may also be reduced.

[0105] 8C and 8D show cross-sectional views of an exemplary mold core 303 during separation from the shell 120. Figures 8C and 8D illustrate the deflection or bending of the corner region 160 to separate the mold core 303 and luggage shell 120. In some embodiments, the deflection can be achieved by defining the corner region 160 without an inner rim 212 and / or with a reduced corner thickness 208. For example, the corner region 160 may move inward and the side walls 152, 154 may bend outward, thereby allowing the mold core 303 to pass through the inner rim 212 and separate from the shell 120.

[0106] Figure 8C shows a top view of mold core 303 within the formed luggage shell 120. The cross section shown by line 8C-8C in Figure 8A is taken at a depth that cuts through rim portion 200, including outer rim 202 and inner rim 212. Portion 307 of mold core 303 below cut line 8C-8C is shown in dashed lines. Lower portion 307 indicates the draft or taper (e.g., difference in width due to difference in height) of mold core 303. Lower portion 307 may be the bottom, middle, or other region of mold core 303.

[0107] In the corner region 160, the outer rim 202 can define a first radius of curvature 346 in the initial position 340. The first radius of curvature 346 can correspond to the radius of the corner 160 after or before separation from the mold core 303 (e.g., after the luggage shell 120 is formed).

[0108] FIG. 8D shows a cross-section of the mold core 303 and shell 120 during removal, for example, in the direction 330 shown in FIG. 8B . During removal, as discussed herein, the mold core 303 contacts the inner rim 212, causing the sidewalls 152, 154 to deflect outward, such as in direction 344. In some embodiments, the outward bending of the sidewalls 152, 154 can cause the corner region 160 of the shell 120 to elastically flex or bend inward, such as in direction 349. For example, the radius of the corner 160 increases from a first radius of curvature 346 to a second radius of curvature 348 as the outer edge 204 moves inward at the corner region 160. To increase the radius of curvature, the lower portion 307 can contact the inner rim 212, forcing the corner region 160 inward to contact the lower portion 307. By allowing corner regions 160 to bend or flex, an inwardly extending inner rim 212 for stiffening rim 200 can be formed without the use of lateral mold parts (eg, sliders).

[0109] In some embodiments, the material of shell 120 may be allowed to flex while resisting stretching or deformation (e.g., permanent or substantial change in dimensions such as width, thickness, or length of portions of shell 120) during separation of shell 120 and mold core 303. For example, corner regions 160 may be able to flex inward without stretching. In embodiments where only corner regions 160 flex, the material of shell 120 may be relatively stiff or durable. In some embodiments, support structure 222 may help prevent stretching of the portion of shell 120 where inner rim 212 is located.

[0110] In some embodiments, when the inner rim 212 deflects toward the outer rim 202, it also elastically deflects or deforms the supports or trusses 222. As a result, the width of the groove 214 may decrease, aiding in the separation of the shell 120 from the mold core 303. By positioning the supports or trusses 222 in a non-orthogonal position relative to the inner rim 212 and the outer rim 202, the support structures 222 can support the inner rim 212 while allowing it to elastically deflect.

[0111] 9A and 9B show an exemplary mold assembly 300 for forming the exemplary luggage shells 118, 120.

[0112] In Figure 9A, luggage case 100 includes sidewalls 152, 154 (see Figure 2) that may extend from a major surface wall 156 defined by mold cavity 301. Sidewall 152 or sidewall 154 may be top sidewall 112 or bottom sidewall 114. In some embodiments, the angle of sidewall 112, 114 relative to major surface 156 may be approximately perpendicular or oriented outward. In one embodiment, the angle is between approximately 90 and 98 degrees relative to major surface 156.

[0113] 9A and 9B, the luggage shells 118, 120 are designed with sides, such as the top panel 112, that extend at an angle 320, or perpendicular, relative to the major wall 156. The opposing side, such as the bottom panel 114, may extend at an angle 247 outward from a normal, or perpendicular, to the major wall 156. The angle 247 may be approximately 8 degrees. The angle 322 between the major wall 156 and the bottom panel 114, inclusive of the perpendicular and the angle 247, is approximately 98 degrees. For example, the bottom panel 114 may extend outward from the major wall 156 at an angle 322 of approximately 98 degrees.

[0114] Referring to FIG. 9B , the mold cavity is typically vertically oriented and “faces” the mold separation direction 330. The mold separation direction 330 is the direction of relative movement between the mold core 303 and outer mold 315 as they separate to remove the molded part. The offset angle 305 of the mold cavity 301 in the present embodiment is relative to the mold separation direction 330. Generally, a draft angle can be defined relative to the separation direction 330 to reduce, minimize, or prevent interference between mold parts or molding sections. The draft angle is between 1 and 5 degrees, although alternative draft angles may be greater or less than this range. For reference, in one embodiment, the draft angle may be 4 degrees. Because a draft angle may be required for the mold, structures that are angled parallel to or inward from the mold movement direction 330 (e.g., have a negative draft angle) are often difficult to remove from the mold without damaging the structures. For example, when the mold assemblies are separated and the molded parts are demolded, the mold core or outer mold may contact and damage structures in the molded parts.

[0115] Mold assembly 300 includes a mold core 303, i.e., a male mold, and a female mold, i.e., outer mold 315. Mold core 303 and outer mold 315 may define a mold cavity 301 therebetween into which luggage shell material is injected to form luggage shells 118, 120. Mold cavity 301 may correspond to the shape and configuration of luggage shells 118, 120. For example, mold cavity 301 may define the sidewalls and rim portion 200 of shells 118, 120 upon injection of mold material.

[0116] In the assembled configuration, the walls 309a, 309b and bottom wall 319 of the mold core 303, and the walls 310a, 310b and bottom wall 318 of the outer mold 315, can be aligned and spaced apart (e.g., not touching or interfering) to define at least a portion of the mold cavity 301. The walls 309a, 310a of the mold core 303 and outer mold 315 can define the orientation of the top wall 112 relative to the major surface 156 by an angle 320. The angle 320 can be approximately perpendicular or a right angle. The walls 309b, 310b of the mold core 303 and outer mold 315 can define the orientation of the bottom wall 114 relative to the major surface 156 by an angle 322. The angle 322 can be greater than the perpendicular angle, e.g., 0 to 8 degrees greater than the perpendicular angle. Thus, the angle 322 can be approximately 90 to 98 degrees.

[0117] In a typical mold assembly with vertically aligned mold cavities, a 90-degree angle 320 between the top panel 112 and the major wall 156 would not be feasible due to insufficient draft angle for the molded portion to be released from the mold assembly. Furthermore, the inner rim 212 may be angled relative to the sidewalls toward the interior storage volume 130 of the luggage shell 120, resulting in a negative draft angle. This may result in the inner rim 212 engaging the mold core 303 when the shells 118, 120 are released from the outer mold 315. In some embodiments, the inner rim 212 may be angled relative to the parallel direction or may extend transversely to the removal direction but inward relative to the sidewalls 112, 114 or outer rim 202. For example, the inner rim 212 may extend at an angle toward or transverse to the separation direction 330 of the mold core 303 and outer mold 315.

[0118] Walls 309a and 309b can include a cavity structure 328 that defines the inner rim 212. Walls 309a, 309b can be continuous around outer mold 315 and mold core 303 and define the short sidewalls 152 and long sidewalls 154 of the shells 118, 120. Cavity structure 328 is disposed on the mold core where it is desired that the inner rim 212 be disposed and positioned to extend along the luggage shells 118, 120, as referred to herein. Cavity structure 328 is configured to form the inner rim 212. In some embodiments, the inner rim 212 can be defined on the short sidewalls 152 and long sidewalls 154.

[0119] The mold cavity 301 may be oriented within the mold assembly 300 at an offset angle 305 relative to the separation direction 330. The orientation angle 305 can facilitate separation of the shells 118, 120 from the core 303 by deflecting the inner rim 212 and outer rim 202 outward during separation. The offset angle 305 of the mold cavity 301 may be approximately 4 degrees below horizontal and approximately 94 degrees relative to the mold release or separation direction 330. The major surface 156 forms a 4 degree angle 400 with the horizontal and approximately 94 degrees from the mold separation direction 330.

[0120] The offset angle 305 results in a draft angle 402 of approximately 4 degrees for the top panel 112. The draft angle 402 is determined by the sum of angle 320 and offset angle 305. The draft angle is measured relative to the mold separation direction 330. The draft angle 406 of the inner rim 212a (on the top panel 112) is negative and is approximately −4 degrees. The bottom panel 114 of the mold cavity 301 has a draft angle 410 of approximately 4 degrees. The draft angle 410 of the bottom panel 114 results from the difference between the offset angle 305 and the mold cavity angle 322. Therefore, the draft angle 402 for the top wall 112 is defined by offsetting the mold cavity by angle 305, such that angle 322 is greater than draft angle 410. By way of example and reference, the draft angle 414 of the inner rim 212b may be negative and is approximately −4 degrees relative to the normal of the major surface 156. 9B can vary depending on the size of the luggage case, the materials used, or the intended design of the luggage case. For example, offset angle 305 can be approximately half of angle 322 to provide symmetrical draft on opposing sides or walls. In some embodiments, offset angle 305 is equal to draft angle 402, which is intended for orthogonally oriented walls after molding.

[0121] As shown in Figure 9B, by positioning the mold cavity 301 at an offset angle within the mold assembly 300, the problem of negative draft is mitigated. The top panel 112 has sufficient draft relative to the mold separation direction 330 to allow separation of the luggage shells 118, 120 from the mold core 303. The draft angle 402 for the top panel 112 is due to the increased or greater draft of the bottom panel 114, defined by angle 322. The draft angle 402 for the top panel 112 helps reduce separation or contact between the top wall 112 and the mold core 303 during separation.

[0122] Additionally or alternatively, the negative draft angle 240 of the inner rim 212 may be sufficiently reduced to allow the inner rim 212 and / or outer rim 202 to flex outwardly to permit release of the mold core 303 from the shell 118, 120. The undercut shape formed by the inner rim 212 may be gentle enough to allow sliding movement without binding as the mold core 303 moves past the inner rim 212. For example, the inner rim 212 may form a cam surface angled in the direction of relative motion to allow gentle outward deflection of the inner rim 212 and / or outer rim 202 in response to sliding contact with the mold core 303. In some embodiments, the offset angle 305 may orient the inner rim 212 closer to or parallel to the direction of mold movement 325, thereby allowing a smaller negative draft angle to be overcome during release from the mold assembly.

[0123] Thus, the structure of shells 118, 120 is configured to clear mold parts 300 upon demolding and flex under contact with the mold parts, avoiding undesirable damage caused by contact with mold core 303. This allows luggage shells 118, 120 to be injection molded more efficiently and less expensively with mold assembly 300, as the mold assembly may not require complex moving parts, such as sliders, which increase expense, maintenance costs, and complexity of the molding operation.

[0124] Referring to FIG. 9C , an example rear luggage shell 120 is shown, which may be the same or similar to that shown in FIG. 2 , with the wheels, carry handle, and towing handle removed for clarity. The storage volume 130 of the luggage shell 120 is shown, having a top wall 112, opposing side walls 108, 110, and a bottom wall 114 attached to and extending from a main panel 156. As described herein and by way of example, the angle 320 between the top wall 112 and the main panel 156 is approximately 90 degrees. In one embodiment, the molded draft angle of the top wall may be approximately 4 degrees. The angle 322 between the bottom wall 114 and the main panel 156 may be approximately 98 degrees. In one embodiment, the molded draft angle of the bottom wall may be approximately 8 degrees. This draft angle is approximately double the typical 4-degree draft angle for similar sidewall structures in luggage cases. The angle 324 between the opposing side walls 108, 110 and the major panel 156 may each be approximately 94 degrees. In one embodiment, the draft angle of each of these walls may be approximately 4 degrees.

[0125] 9C, in this embodiment, the inner rim 212 of the luggage case 100 is continuous through at least one corner area and extends around all four corner areas of the shell as shown. In some embodiments, such as those shown, the inner rim 212 extends around the majority of the length of the peripheral rim 202 of the shell 120, and may extend around the entire length of the peripheral rim 202 of the shell 120.

[0126] 10, 11A, and 11B, the exemplary luggage case 500 shows an inner rim 612 that extends continuously through at least one or more corner regions 560. The luggage case 500 may be similar to the luggage case 100 previously described in FIGS. 1-9B, with the primary difference being that the inner rim 612 extends through at least one corner region 560. For example, the luggage case 500 may include two or more shells 520. The shell 520 may include side walls, such as a short side wall 552 and a long side wall 554. The side walls 552 and 554 may intersect or transition at the corner regions 160. The luggage shell 520 may have an inner surface 536 and an outer surface 538.

[0127] Luggage case 500 includes a rim portion 600. Rim portion 600 may be similar to rim portion 200 and includes an outer rim 602 and an inner rim 612. Outer rim 602 may define an outer peripheral edge 604. Inner rim 612 may extend inward from inner surface 536 of sidewalls 652, 654 to an inner peripheral edge 620. Thus, inner rim 612 may be spaced apart from outer rim 602. For example, a groove 614 may be defined between inner rim 612 and outer rim 602. Rim portion 600 may include a support structure or truss 622. Support or truss 622 may extend between inner rim 612 and outer rim 602, such as within groove 614. Support 622 may be oriented at a non-orthogonal angle between inner rim 612 and outer rim 602. The inner rim 612 and truss 622 may support or add rigidity to the shell 520 along the rim portion 600 .

[0128] The inner rim 612 of the luggage case 500 may be continuous or discontinuous. The inner rim 612 of the luggage case 500 is continuous through at least one corner region 560 of the shell 520. In some embodiments, the inner rim 612 may extend continuously along a majority of the periphery of the luggage case 500. The inner rim 612 may extend continuously between 50 and 90 percent of the periphery of the luggage case 500. For example, the inner rim 612 extends along the outer rim 602 through the corner region 560 of the shell 520. In some embodiments, the inner rim 612 may extend continuously along or around the periphery of the shell 500, except for a portion, i.e., a gap, for receiving or coupling an insert 650, such as a handle for the luggage case. If the inner rim 612 optionally includes a gap for a handle structure or insert, the inner rim 612 may include two or more lateral ends 624. The lateral ends 624 can define mounting structures 626 for receiving or connecting one or more inserts 650, such as the carry handles previously described with respect to Figures 1-9B.

[0129] 11A and 11B show cross-sectional top views of the luggage shell 520 and mold core 703. As discussed herein, the luggage shell 500 can be formed by molding, such as injection molding, with a mold assembly including the mold core 703. Separation of the luggage shell 520 from the mold core 703 can be similar to the separation of the luggage shell 120 from the mold core 303, as discussed herein. For separation of the luggage shell 520, which includes an inner rim 612 that is continuous through the corner region 560, the inner rim 612 flexes toward the outer rim 602 or sidewalls 552, 554. The outer rim 602 or sidewalls 552, 554 can also elastically flex outward to allow the inner rim 612 to pass over the mold core 703 during extraction. For example, the corner region 560 can stretch or flex to provide increased space for separation of the mold core 703.

[0130] The material of shell 520 can be the same as or different from the material of shell 120. For example, shell 520 can be polypropylene, ABS, polycarbonate, glass-filled or glass-mixed materials, or mixtures and combinations thereof. In some embodiments, continuous inner rim 612 allows a portion of shell 520 to stretch or elastically deform to separate from mold core 703. To allow the material to stretch, the material can be made more flexible or thinner to reduce resistance to stretching. Polypropylene or other materials that resist visual changes upon stretching, such as whitening, can be used for shell 520.

[0131] 11A , prior to release from the mold core 703, the inner rim 612 may be spaced from the outer rim 602 by a distance 640, which may be the groove width 640. The groove width 640 may be defined between the inner periphery 620 and the outer periphery 604. Such a configuration may also correspond to the final position of the inner rim 612.

[0132] Referring to FIG. 11B, the mold core 703 is removable in a separation direction. The separation direction may be parallel to the line of sight (e.g., into or out of the page). As also shown in FIGS. 8B and 8D, because the inner rim 612 faces inward, a portion of the mold core 703 may contact the inner rim 612. As the mold core 703 separates from the luggage shell 520, the inner rim 612 may flex toward the outer rim 602 or the side walls 552, 554. For example, a reduced groove width 642 may be defined between the inner rim 612 and the outer rim 602. The outward flexing, i.e., the reduced groove width 642, allows the resilient deflection of the inwardly extending inner rim 612 to separate the mold core 703 and the luggage shell 620 without damaging the shell 520. In some embodiments, the side walls 552, 554 may also flex outward. In such an embodiment, inner rim 612 is able to elastically deflect a greater distance than outer rim 602, thereby reducing groove width 642.

[0133] Flexing of the inner rim 612 can be facilitated by elastic flexing and bending of the supports 622 and the inner rim 612. For example, a non-orthogonal orientation of the supports 622 allows flexing of the inner rim 612 by distributing the load across the inner rim 612 as it flexes between the outer rim 602 and the inner rim 612. In contrast, orthogonally oriented supports, which are optionally used, may be stiffer and have less flexing and deformation.

[0134] In some embodiments, the corner region 560 can stretch to allow more space for the shell 520 and mold core 703 to separate. In some embodiments, both the corner region 560 and the inner rim 612 can stretch or flex, e.g., interdigitated with one another. The stretching of the corner region 560 can be along the inner rim 612. The stretching of the shell 520 can be along a portion of the corner region 560 spaced from or adjacent to the inner rim 612. For example, the inner rim 612 can resist stretching and deformation. In such embodiments, the continuous inner rim 612 can help maintain a perimeter dimension of the shell 520, such as the predetermined length of a closure mechanism, such as a zipper tape.

[0135] Other examples and implementations are within the scope and spirit of this disclosure and the appended claims. For example, a structure implementing a function may be physically located in various locations, including being distributed so that portions of the function are implemented in different physical locations. Also, as used herein, including the claims, "or" when used in a list of items preceded by "at least one" indicates a separable list; for example, the list "at least one of A, B, or C" means A, or B, or C, or AB, or AC, or BC, or ABC (i.e., A and B and C). Furthermore, the term "exemplary" does not imply that the described example is a preferred example or an example superior to others.

[0136] The foregoing description, for purposes of explanation, uses specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to those skilled in the art that specific details are not required to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to those skilled in the art that numerous modifications and variations are possible in light of the above teachings.

Claims

1. A luggage case (100, 500), at least one injection molded shell (118, 120, 520) including a major surface panel (156) and at least one sidewall (152, 154, 552, 554) that together define an interior storage volume (130); the sidewall (152, 154, 552, 554) defines an at least partially integrally formed outer rim (202, 602) and an integrally formed inner rim (212, 612) disposed within the outer rim (202, 602); the inner rim (212, 612) extends along at least a portion of the length of the outer rim (202, 602); the inner rim (212, 612) extends at an acute angle (240, 406, 412) away from the sidewall (152, 154, 552, 554); Luggage case (100, 500).

2. the sidewalls (152, 154, 552, 554) extend from a periphery of the main panel (156) along at least a portion of the periphery, the sidewalls (152, 154, 552, 554) including at least one corner region (160, 560) and the outer rim (202, 602) defined to extend at least partially along the sidewalls (152, 154, 552, 554) and the at least one corner region (160, 560); 2. The luggage case (100, 500) of claim 1, wherein the inner rim (212, 612) extends along at least a portion of a sidewall (152, 154, 552, 554) and along at least one corner region (160, 560).

3. The luggage case (100, 500) of any one of claims 1 to 2, wherein the inner rim (212, 612) extends around approximately 50 to 90 percent of the length of the outer rim (202, 602).

4. The luggage case (100, 500) of any one of claims 1 to 3, wherein the inner rim (212, 612) extends continuously along the majority of the length of the side wall (152, 154, 552, 554).

5. The luggage case (100, 500) of any one of claims 1 to 4, wherein the inner rim (212, 612) extends around the entire length of the outer rim (202, 602).

6. The luggage case (100, 500) of any one of claims 1 to 5, wherein a support structure (222, 622) extends between the outer rim (202, 602) and the inner rim (212, 612).

7. The luggage case (100, 500) of any one of claims 1 to 6, wherein the outer rim (202, 602) is flush with an outer surface (138, 210, 538) of at least one side wall (152, 154, 552, 554).

8. The luggage case (100, 500) of any one of claims 1 to 7, wherein at least a portion of the side wall (152, 154, 552, 554) extends substantially perpendicularly from the main panel (156).

9. the side walls (152, 154, 552, 554) include a top panel (112) and an opposing bottom panel (114); 3. The luggage case (100, 500) of claim 2, wherein the bottom panel (114) extends from the main panel (156) at an angle between approximately 90 degrees and 98 degrees.

10. The luggage case (100, 500) of any one of claims 1 to 9, wherein the acute angle (240, 406, 412) between the inner rim (212, 612) and the side wall (152, 154, 552, 554) is between about 1 degree and 14 degrees, or between about 4 degrees and 6 degrees.

11. The luggage case (100, 500) of any one of claims 1 to 10, wherein the inner rim (212, 612) is at an angle relative to the main face panel (156) of between about 80 degrees and 94 degrees.

12. 2. The luggage case (100, 500) of claim 1, wherein the at least one injection molded shell (118, 120, 520) comprises a first portion (152, 154, 552, 554) of the side wall that is perpendicular to the main surface panel (156) and a second portion (152, 154, 552, 554) of the side wall that is oriented at a greater outward angle (247, 320, 322) relative to the main surface panel (156) than the first portion (152, 154, 552, 554) of the side wall.

13. The luggage case (100, 500) of any one of claims 1 to 12, wherein the inner rim (212, 612) forms a beveled surface for sliding contact with a mold core (303, 703) when the injection molded shell (118, 120, 520) is removed from the mold (300, 303, 315, 703).

14. The luggage case (100, 500) of any one of claims 1 to 12, wherein the inner rim (212, 612) flexes outward upon release from the mold core (303, 503), or the inner rim (212, 612) and the outer rim (202, 602) flex outward upon release from the mold core (303, 503).

15. at least one wheel (140) attached to a corner area (160, 560) of the bottom panel (114) of said injection molded shell (118, 120, 520); a towing handle (126) attached to the rear major panel (156) of said injection molded shell (118, 120, 520); The luggage case (100, 500) of claim 1 further comprising:

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