Suitcase with integrated roller trolley

Abstract

A wheeled suitcase with a suitcase body, one or more wheels mounted on the suitcase body and a handle assembly fixed to the suitcase body with at least one telescopic rod with a moving arm of a single piece of carbon fiber tube or material equivalent thereto extendable to a height of at least 1 meter is provided.

Description

[0001] This patent application claims the benefit of priority from U.S. Provisional Application Ser. No. 63 / 490,604 filed Mar. 16, 2023 and U.S. Provisional Application Ser. No. 63 / 431,973 filed Dec. 12, 2022, teachings of each of which are incorporated herein by reference in their entireties.FIELD

[0002] A wheeled suitcase comprising a suitcase body having integrally connected thereto a laterally extendable handle at its upper end with a moving arm comprising a single piece of carbon fiber tube or a material equivalent thereto and one or more wheels at its lower end is disclosed. To effect transport, the handle is moved from a lowered, compact, position to a raised position allowing a user to manually pull or push the luggage assembly.BACKGROUND OF THE INVENTION

[0003] Suitcases are available in a wide variety of shapes and sizes. Traditionally, suitcases have been provided with a single carrying handle to allow the user to lift the suitcase and carry it from place to place. However, extensive travel often requires the traveler to handle their own luggage in walking through airports, hotels, or other various assembling and marshalling areas. The luggage is usually heavy when fully loaded and, therefore, the traveler often uses a dolly truck, bell-hop, or sky-cap to transport the luggage through these assembling and marshalling areas. These methods of transporting the luggage, however, are sometimes impractical, difficult, expensive, or burdensome to the traveler.

[0004] In order to ease the load that a traveler must bear while manually moving a suitcase from place to place, it is desirable to provide rollers on the bottom of the case. Rollers permit the suitcase to be rolled across a surface, such as a floor. It is also desirable to have some type of handle secured to the case to permit the user to steer the rolling suitcase.

[0005] Some such suitcases have handles, or straps, which permit the entire weight of the case to be carried by the rollers. Other types have handles that require the user to lift up, or tilt down, the suitcase so that a portion of the suitcase's weight is carried by the handle.

[0006] When a rigid handle is provided, it is desirable for the handle to be movable between a storage position and an operable position. In that way, the handle can be stored when not in use and will be less susceptible to damage when the suitcase is moved through luggage handling systems in airports and the like. However, without means for locking the handle into the storage position, it could accidentally deploy and be damaged during transit.

[0007] U.S. Pat. No. 4,995,487 discloses a commuter suitcase of unitary design containing a retractable handle arrangement and two recessed roller wheels on the underside portion thereof which effectively facilitates an efficient and convenient means for transporting one's personal belongings while traveling. The handle assembly contains an offset guide means connected to the interior of the suitcase into which is disposed, in sliding telescoping relationship, the main handle which becomes lodged by friction against said offset guide means when in the extended position.

[0008] U.S. Pat. No. 5,240,106 discloses a retractable U-shaped handle having telescoping rods used to pull the bag on a pair of wheels when desired. The telescoping rods become journaled in tubular guides disposed within the interior of the bag.

[0009] Additional examples of patents disclosing suitcases with various extendable tow handles include U.S. Pat. Nos. 7,670,072, 7,407,337, 6,761,501, 5,692,856, 5,549,407, 5,622,446, 5,417,511, 5,407,295, 5,011,319, 5,048,998, 4,824,302, 4,653,142, 4,329,076, 4,076,437, 3,515,418 and 2,949,692.

[0010] Typical extendable tow handles are telescopic and include an inner member or tube slidably received within an outer member or tube to adjust the height of a tow handle grip on the distal end of the handle relative the luggage case at preset heights for ease of use by a user. Unfortunately, the clearances and / or locking engagement between the inner and outer tube to allow easy sliding may be such that the tow handle moves or wobbles when manipulated by a user. Additionally, the locking engagement may be difficult to disengage. The preset heights of the tow handle may also be set at undesirable positions, especially for users of taller or shorter stature.

[0011] In addition, the tubes receiving the arms are often positioned inside the suitcase so that a certain volume is lost to the suitcase user.

[0012] U.S. Pat. No. 11,185,141 discloses a suitcase wherein the two tubes of the handle assembly are disposed along the two edges outside the body of the suitcase.

[0013] There is need for wheeled suitcases with handle assemblies with less wobble and movement and which minimize volume lost to the suitcase user.SUMMARY OF THE INVENTION

[0014] Provided by this disclosure is a wheeled suitcase with a handle assembly with less wobble and movement and which minimize volume lost to the suitcase user from the handle assembly. The wheeled suitcase comprises a suitcase body with a top and a bottom shell with at least a portion of the shells being connected. The suitcase further comprises one or more wheels mounted on a bottom face of one or both shells of the suitcase body. In addition, the suitcase has a handle assembly comprising at least one telescopic rod comprising a moving arm comprising a single piece of carbon fiber tube or a material equivalent thereto, a handle with an actuation button attached to the top of the moving arm, an actuation means connected to the actuation button for sliding the moving arm away from and toward the top of the suitcase, and a tube fixed to the bottom shell of the suitcase body and extending longitudinally from the bottom face to the top face of the suitcase body which is sized to slidingly fit the moving arm. Production of the moving arm from a single piece of carbon fiber tube or material equivalent thereto provides for a much thinner, yet stronger handle assembly as compared to standard aluminum handle assemblies, thereby decreasing wobble and movement in the handle while minimizing volume lost to the suitcase user from the handle assembly.BRIEF DESCRIPTION OF DRAWINGS

[0015] FIG. 1 is a perspective view of a nonlimiting embodiment of a wheeled suitcase in compliance with this invention depicting a twin rod handle assembly on the outside of the suitcase body in a retracted position.

[0016] FIG. 2 is a perspective view of a nonlimiting embodiment of a wheeled suitcase in compliance with this invention depicting a twin rod handle assembly on the outside of the suitcase body in an extended position.

[0017] FIG. 3 is a perspective view of part of the suitcase shown in FIG. 2, revealing the inside of the suitcase and especially the bottom of the suitcase bearing the twin rod handle assembly.

[0018] FIG. 4 is a close up of the top of a nonlimiting embodiment of a moving arm of carbon fiber tube inside the fixed tube.

[0019] FIG. 5 is a diagram showing comparison in size of a top and bottom of a nonlimiting embodiment of a tapered moving arm of carbon fiber tube.

[0020] FIG. 6 is a perspective view of a nonlimiting embodiment of a tapered moving arm machined at its bottom end to include one or more pin holes and a notch.

[0021] FIG. 7A is a perspective close-up side view of the tight fit of the handle when in the upright position and

[0022] FIG. 7B is a perspective close-up top view of the tight fit of the inner tube in the sliding bushing.

[0023] FIG. 8A is a perspective close-up side view of the looser fit of the handle when in the retracted position and FIG. 8B is a perspective close-up top view of the looser fit of the inner tube in the upper bushing.

[0024] FIGS. 9A and 9B are perspective views of a nonlimiting embodiment of an offset bushing contact with upper and sliding bushings at the bottom end of the moving arm at near full extension (FIG. 9A) of the handle and at full extension of the handle (FIG. 9B).

[0025] FIGS. 10A through 10D are various perspective views of a nonlimiting asymmetric lock pin assembly embodiment useful in the wheeled suitcase of this disclosure.

[0026] FIGS. 11A through 11D are various perspective views of a nonlimiting embodiment of a handle assembly with handle, actuation button and actuation means and its attachment to the carbon fiber tube.

[0027] FIG. 12 is a perspective view of a standard handle design with guide ribs.

[0028] FIGS. 13A and 13B are perspective views of a nonlimiting embodiment of a modified handle design with actuation button and actuation means useful in the wheeled suitcase of this disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0029] The figures that will be described show an embodiment of a wheeled suitcase in compliance with the invention. However, it should be understood that the invention is not specifically limited to the embodiment presented in the figures and that it extends to the implementation of any equivalent means.

[0030] In the various figures, the same references designate identical or similar elements. In addition, the terms “lower,”“upper,”“top”“bottom,”“front,”“back” etc. are used in reference to the drawings for further clarity. They should not be understood as being limitations on the scope of the invention.

[0031] The wheeled suitcase 1 represented in FIG. 1 through 3 is of the “trolley” type and comprises a suitcase body 2 comprising a top shell 3 and a bottom shell 4 with each shell having an outer side 7 and inner side 8 and a top face 9 and bottom face 10.

[0032] In one nonlimiting embodiment, the suitcase body 2 has a substantially rectangular cross-section. However, as will be understood by the skilled artisan upon reading this disclosure, the handle assembly described herein may be routinely adapted to alternative luggage designs, such as, but in no way limited to softer duffle bags, and such alternative luggage designs are encompassed by this invention.

[0033] At least a portion of the shells 3, 4 are connected. Various means for connection can be used including, but in no way limited to, zippers, buckles and snaps.

[0034] In one nonlimiting embodiment, at least a portion of the shells 3, 4 are further connected together by a hinge. In one nonlimiting embodiment, the hinge is integrated at the bottom and provides for controlled opening of the suitcase. In this nonlimiting embodiment, one or more drawstraps may be attached to the inner side of the suitcase body further connecting the top and bottom shells to assist in holding the top shell in place when opened.

[0035] In one nonlimiting embodiment, the upper shell 3 and / or bottom shell 4 are rigid or semi-rigid shells, for example obtained at least in part by molding. In one nonlimiting embodiment, the shells a made from vacuum formed polycarbonate sheet.

[0036] In another nonlimiting embodiment, the upper shell and / or bottom shell are a softer material such as woven nylon, such as cordura, ballistic, or ripstop.

[0037] Suitcase body 2 is mounted on one or more wheels 11 at the bottom face 10 of the bottom and / or upper shells. FIG. 3 depicts 4 wheels 11. However, it should be understood that the wheeled devices can be different without departing from the context of the invention; for example, the devices may only comprise a single wheel or two or more wheels.

[0038] In one nonlimiting embodiment, one or more wheels is a controlled wheel for improved tracking and steering control of the wheeled suitcase when it is in motion and / or braking. A nonlimiting example of a controlled wheel useful in the wheeled suitcase of this invention is set forth in U.S. Pat. No. 8,875,855, teachings of which are incorporated by reference in their entirety. The inventors herein have found that by having 1 or more of the wheel assemblies releasably restrained in opposing directions, the suitcase assembly of this invention is effectively deterred from rolling without a more intentional force input from the user.

[0039] As depicted in FIGS. 1 and / or 2, the wheeled suitcase 1 further comprises a handle assembly 32. The handle assembly 32 comprises at least one telescopic rod 12 attached to the suitcase body comprising a moving arm 13 and a fixed tube 16 sized to fit the moving arm. Most carry-on style rollers have a 3-segment trolley with one fixed tube and two moving tubes in order to achieve the needed deploy height of at least 1 meter for comfortable handle ergonomics. In contrast, the moving arm 13 of the present invention comprises a single piece of carbon fiber tube or a material equivalent thereto with an inside 17, an outside 18, a center 19, a top end 20 and a bottom end 21. The moving arm 13 is connected to the handle 14 via its top end 20 and is slidingly fitted into the fixed tube 16. See FIGS. 4 and 6.

[0040] For purposes of the present invention, by “a material equivalent to carbon fiber tube” it is meant to encompass any alternative polymer or metal exhibiting similar strength and stiffness to carbon fiber tube such that a thinner, yet stronger handle assembly as compared to standard aluminum handle assemblies can still be produced.

[0041] In one nonlimiting embodiment, the tube 16 is fixed to the bottom shell 4 of the suitcase body 2 and extends longitudinally from the bottom face 10 to the top face 9 of the suitcase body 2.

[0042] It is preferred that the fixed tube 16 be prepared from components other than carbon fiber tube. In one nonlimiting embodiment, the fixed tube comprises aluminum, magnesium or steel.

[0043] The handle assembly 32 further comprises a handle 14 with an actuation button 15, an actuation means 29 connected to the actuation button 15 for sliding the moving arm 13 away from and toward the top of the suitcase body 2.

[0044] In one nonlimiting embodiment, as depicted in FIGS. 1 and 2, the telescopic rod 12 is a telescopic twin rod comprising two moving arms 13 and two fixed tubes 16 with the handle 14 positioned between and connecting the two moving arms 13. However, as will be understood by the skilled artisan upon reading this disclosure, alternative embodiments of handle assemblies with a single telescopic rod or more than two telescopic rods are encompassed with the scope of this invention.

[0045] The telescopic rod 12 attached to suitcase body 2, may adopt a multitude of positions between two extreme positions: A retracted position shown in FIG. 1 and an extended position shown in FIG. 2.

[0046] As depicted in FIG. 1 through 3, in one nonlimiting embodiment, the bottom shell 4 of the suitcase body has recessed portions 22 into which the handle 14 and fixed tubes 16 are positioned. However, alternative positioning of the handle assembly such as attachment to the bottom shell without recessed portions or attachment to the inside of the suitcase body are also encompassed by this invention.

[0047] By using carbon fiber tube or a material equivalent thereto as the moving arm, which has a much higher ultimate strength than a comparable aluminum tube, the overall telescopic rods can be at least 2x less in thickness than standard aluminum telescopic rod assemblies, thereby resulting in much lower disruption to internal volume from any recessed portion of the suitcase body from the handle assembly. See FIG. 4. In one nonlimiting embodiment, the thickness of the fixed tube is 11 mm while the thickness of the top end of the carbon fiber tube is 6.9 mm. In this way, and as may be seen in particular in FIG. 3, the inner side 8 of bottom shell 4 presents a relatively flat bottom face 10 as volumes of the recessed portions for the fixed tubes are minimized.

[0048] In one nonlimiting embodiment, as depicted in FIGS. 5 and 6, the moving arm is tapered so that the lower portion of the moving arm is larger in cross section that the upper portion of the moving arm. In one nonlimiting embodiment, the lower portion is 1 to 40% larger in cross-section than the upper portion. In one nonlimiting embodiment, the cross section of the lower portion of the moving arm is 7.4 mm while the cross section of the upper portion of the moving arm is 6.9 mm. In one nonlimiting embodiment, the upper tube has an inner length of 26.8 mm and an outer length of 30.5±0.15 mm and an inner height of 3.7 mm and an outer height of 6.9±0.1 mm while the lower tube has an outer length of 31±0.15 mm and an outer height of 7.4±0.1 mm.

[0049] In one nonlimiting embodiment, the moving arm of carbon fiber tube or material equivalent thereto is spherocylindrical in shape. Alternative shapes, such as, but not limited to, rectangular, oval, and trapezoidal can also be used.

[0050] As shown in FIGS. 7A through 8B, by tapering the moving arm when the handle is extended the inner tube lower section with the larger cross section tightly fits into the mating upper bushing part. This creates a handle assembly with minimal slop and thus a quality feel for the user while maneuvering the bag using the handle. When the handle is retracted, the moving arm upper section with the smaller cross section fits more loosely into the mating upper bushing part. This helps to ensure the trolley moves smoothly up and down and allows a larger acceptable assembly tolerance for the critical moving parts within the trolley and handle assembly.

[0051] As depicted in FIGS. 9A and 9B, the telescopic rod may further comprise an upper bushing 23 and sliding bushing 24 with offset surface contacts fitted over the bottom end 21 of the moving arm 13. The upper bushing 23 and sliding bushing 24 are sized to fit inside the fixed tube 16. In one nonlimiting embodiment, as depicted in FIG. 9B, the upper bushing 23 may comprise one or more assembly bosses 25 for extra upper bushing assembly support.

[0052] As shown in FIGS. 10A through 10D, the telescopic rod may further comprise an asymmetric lock pin assembly 26 with a lock pin 27 fitted into the sliding bushing 24 so that the lock pin 27 is offset from the center 19 of the moving arm 13. In this nonlimiting embodiment, the sliding bushing may comprise a housing 32 for fitting of the lock pin assembly 26. Further, in this nonlimiting embodiment, the bottom end 21 of the moving arm 13 may be machined as depicted in FIG. 6 to comprise one or more pin holes 33 and a notch 34 which fits the housing 32 of the sliding bushing 24.

[0053] This unique offset bushing contact design provides advantages in that the left side of the upper bushing has assembly bosses for strength, the left side of the moving tube can extend further into the fixed tube for maximal tube to tube overlap thus allowing for extension of the single piece moving arm to at least 1 meter in height, and the right side of the sliding bushing has extra volume for packaging the lock pin mechanism. The asymmetric design further allows the lock pin mechanism to fit into the thin cross section of the moving arm.

[0054] FIGS. 11A through 11D and FIGS. 13A and 13B depict a nonlimiting embodiment of a handle 14 useful in the suitcase assembly 1 of this invention. The handle 14 houses an actuation button 15. Traditionally, the up / down translation movement of the actuation button inside the handle is constrained using guiding ribs in the handle shell parts. These ribs surround the button perimeter consuming a lot of packaging volume within the handle assembly. See FIG. 12 showing this standard design with the guide ribs around the perimeter of the button consuming a lot of volume within the assembly. In contrast, a nonlimiting embodiment of a handle for use in this invention, as depicted in FIGS. 13A and 13B, comprises an actuation button 15 with a pin 30, which when pressed, activates the actuation means 29 comprising a rod 31 extending inside the moving arm 13 from the top 20 to the bottom 21 which fits into the lock pin assembly 26.

[0055] FIGS. 11A to 11D show a nonlimiting embodiment of a handle wherein a one piece alloy handle chassis part 50 that can fit within the tight confines of the alternative handle assembly depicted in FIGS. 13A and 13B is used to create a robust connection between the handle and moving arm. In one nonlimiting embodiment, there is a very thin connection between the handle and inner tube. In one nonlimiting embodiment, the handle comprises an aluminum plate extending the length of the handle. However, alternative components such as other metals and plastics can also be used. The handle chassis 50 is securely bolted to the moving arm 13 via an alloy biscuit 28 that is bonded to the moving arm and then machined to receive the handle fasteners 52. In order to minimize the required size of the button inside the handle, its translational movement is constrained.

Claims

1. A wheeled suitcase comprising:a suitcase body, said suitcase body comprising a top and a bottom shell, at least a portion of the shells being connected, each shell having an outer and inner side and a top and bottom face;one or more wheels mounted on the bottom face of one or both shells;a handle assembly comprising at least one telescopic rod comprising a moving arm, a handle with an actuation button, an actuation means connected to the actuation button for sliding the moving arm away from and toward the top of the suitcase, and a fixed tube sized to fit the moving arm, said moving arm comprising a single piece of carbon fiber tube or material equivalent thereto with an inside, an outside, a center, a top end and a bottom end being connected to the handle via the top end and slidingly fitted into the fixed tube,wherein the tube is fixed to the bottom shell of the suitcase body and extends longitudinally from the bottom face to the top face of the suitcase body.

2. The wheeled suitcase of claim 1 wherein the telescopic rod is a telescopic twin rod comprising two moving arms and two fixed tubes with the handle positioned between and connecting the two moving arms.

3. The wheeled suitcase of claim 1 wherein the telescopic rod is positioned in a recess on the outside of the bottom face of the suitcase.

4. The wheeled suitcase of claim 1 wherein the moving arm is at least 2 times thinner in thickness than standard aluminum arms.

5. The wheeled suitcase of claim 1 wherein the moving arm is tapered so that the lower portion of the moving arm is larger in cross section than the upper portion of the moving arm.

6. The wheeled suitcase of claim 5 where the cross section of the lower portion of the moving arm is 1 to 40% larger in cross-section than the upper portion.

7. The wheeled suitcase of claim 1 wherein the moving arm is spherocylindrical in shape.

8. The wheeled suitcase of claim 1 wherein at least one telescopic rod comprises an upper bushing and sliding bushing with offset surface contacts fitted over the bottom end of the moving arm, said upper bushing and sliding bushing being sized to fit inside the fixed tube.

9. The wheeled suitcase of claim 8 wherein the upper bushing comprises one or more assembly bosses.

10. The wheeled suitcase of claim 8 wherein the sliding bushing comprises a housing for fitting a lock pin assembly and the bottom end of the moving arm is machined to comprise one or more pin holes and a notch which fits the housing of the sliding bushing.

11. The wheeled suitcase of claim 8 further comprising an asymmetric lock pin assembly with a lock pin fitted into the sliding bushing so that the lock pin is offset from the center of the moving arm.

12. The wheeled suitcase of claim 11 wherein the actuation button of the handle comprises a button and pin, which when pressed, activates the actuation means comprising a rod extending inside the moving arm from the top to the bottom which fits into the lock pin assembly.

13. The wheeled suitcase of claim 12 wherein the handle comprises an aluminum plate extending the length of the handle.

14. The wheeled suitcase of claim 1 wherein the handle is attached to the moving arm via a biscuit.

15. The wheeled suitcase of claim 14 wherein the biscuit is bonded to the inside, top of the moving arm and the handle is fixed to the biscuit.

16. The wheeled suitcase of claim 15 wherein the handle is fixed to at least a portion of the carbon fiber tube or material equivalent thereto of the top of the moving arm.

17. The wheeled suitcase of claim 1 wherein height of the suitcase when the telescopic rod is deployed is at least 1 meter.

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