MULTI-PIECE HARD SIDE LUGGAGE SHELL

Abstract

 A multi-piece hard side luggage article (100) that is lightweight and durable is provided. The luggage article (100) includes a first shell (120) and a second shell (122), at least one of which is comprised of more than one moulded hard side portion (130, 132, 134, 136, 138, 140, 172, 174, 176, 178). The moulded hard side portions (130, 132, 134, 136, 138, 140, 172, 174, 176, 178) may have different thicknesses, and portions subjected to the most stress may be thicker than other portions. The portions (130, 132, 134, 136, 138, 140) may be constructed of different materials. Two adjacent moulded hard side portions (130, 132, 134, 136, 138, 140, 172, 174, 176, 178) may be joined by a joint structure 119, which may be a resilient strip member (150).

Description

TECHNOLOGICAL FIELD

[0001] The present disclosure generally relates to luggage articles and, in particular, to the use of multiple separate portions or sections of hard side material in the shell structure of a luggage case.

BACKGROUND

[0002] Hard side luggage cases provide durability and support by using formable, relatively hard materials to create the exterior of the case. One drawback of hard side cases is that they can be heavier than soft side cases. However, soft side cases are often less durable than hard side cases, and their construction involves high labor input and material cost. Hybrid luggage cases that include both hard side and soft side materials are often lighter than hard side cases, but also can be less durable. Rolling luggage cases, in particular hard side luggage cases, over rough surfaces causes vibrations and noise and subjects the cases to impact forces.

[0003] Documents that may be related to the present disclosure in that they include various approaches to multi-piece luggage construction include US20130220755, EP20130747635, US20110186396, US 20130213752, and GB2415955. These proposals, however, may be improved.

[0004] It is therefore desirable to provide an improved luggage article, and in particular an improved multi-piece hard side shell, that is lightweight, durable, can absorb an impact force, can maintain structural integrity under stress, and can reduce or minimize vibration and/or noise caused by its use.

SUMMARY

[0005] According to the present invention there is therefore provided a luggage article as defined in the accompanying claims.

[0006] The present disclosure in particular provides an improved shell structure for a luggage article that is lightweight, durable, can absorb an impact force, can maintain structural integrity under stress, and can minimize vibration and noise during use. The shell includes multiple separate portions of select thickness (such as a different thickness) to reduce the overall shell weight and/or maintain structural integrity in the areas of the luggage article subjected to the highest levels of stress. The multiple portions may be made of different materials, which may further reduce overall shell weight. The portions are joined by flexible joint structures, which may be resilient strip members (also referred to as joint members). The resilient strip members may absorb or dissipate impact and forces transmitted between adjacent sections of the shell, which provides durability to the luggage article and minimizes noise production.

[0007] In one example, a luggage article includes a shell and another shell separable along a split line, the shells pivotally joined together to define a storage volume. The shell includes a first moulded hard portion and a second moulded hard portion, and at least one joint structure. The joint structure fixedly joins the first moulded hard portion to the second moulded hard portion to form at least part of an integrated external shell.

[0008] In a further example, the joint structure includes a resilient joint member that receives and secures a peripheral edge region of the first moulded hard portion, and receives and secures a peripheral edge region of the second moulded hard portion.

[0009] In some examples, the joint structure includes a resilient bridge portion from which opposing channels extend to receive a respective peripheral edge region of adjacent moulded hard portions. Each channel may be configured by a pair of spaced-apart arms extending from the bridge portion. The outer portion of the joint member on the outside of the luggage case may include a side surface of a central portion of the bridge portion, one leg of one channel and one leg of the opposing channel. The outer portion of the resilient member may have a convex portion for a smooth contour.

[0010] In one example, a luggage article includes a shell and another shell separable along a split line, the shells pivotally joined together to define a storage volume. The shell includes a first moulded hard portion, a second moulded hard portion positioned at a region of the first shell that is distal from the first moulded hard portion, and at least one joint structure. A third moulded hard portion is positioned at least partially between the first moulded hard portion and the second moulded hard portion and fixedly joined to the first moulded hard portion by a joint structure, and the third moulded hard portion joined to the second moulded hard portion by a joint structure to form at least part of an integrated external shell.

[0011] In an example, a luggage article having a multi-piece hard side shell is provided. The luggage article includes a first shell and a second shell separable along a split line and pivotally joined to the first shell to define a storage volume. The luggage article further includes at least one joint structure. The first shell includes a first upper moulded hard portion and a second lower moulded hard portion positioned at a region of the first shell that is distal from the first lower moulded hard portion. The first shell also includes at least one resilient strip member. A third intermediate moulded hard portion is positioned between the first and second moulded hard upper and lower portions, and is fixedly joined to each of the first and second moulded hard upper and lower portions by resilient strip members to form an integrated external shell.

[0012] In a further example, the first molded hard portion may be an upper hard portion. The second molded hard portion may be a lower hard portion. The third moulded hard portion may be an intermediate hard portion.

[0013] In a further example, the first molded hard portion may be a side hard portion. The second molded hard portion may be an opposing side hard portion. The third moulded hard portion may be an intermediate hard portion positioned between the first molded hard portion and the second molded hard portion.

[0014] In a further example, the first molded hard portion may include at least a part of one of a top panel and/or a bottom panel and/or a side panel. The second molded hard portion includes at least a part of one of a top panel and/or a bottom panel and/or a side panel. The third moulded hard portion includes at least part of one of a top panel and/or a bottom panel and/or a side panel. The first hard portion and/or the second hard portion includes a corner region and/or a corner edge. Also, one of the at least one joint structures intersects the split line.

[0015] In one example, the luggage article comprises a fourth moulded hard portion, a fifth moulded hard portion positioned at a region of the second shell that is distal from the fourth moulded hard portion, at least one joint structure, and a sixth moulded hard portion positioned between the fourth moulded hard portion and the fifth moulded hard portion and fixedly joined to the fourth moulded hard portion by a joint structure the sixth moulded hard portion joined to the fifth moulded hard portion by a joint structure to form at least a hard portion of an integrated external shell.

[0016] In another example, the joint structure is a resilient joint member and may be positioned between and secured to peripheral edge regions of adjacent moulded hard portions.

[0017] In an example, the first moulded hard portion and the second moulded hard portion comprise at least in part a material independently selected from acrylonitrile-butadiene-styrene ("ABS") plastic, polycarbonate plastic, and ABS/polycarbonate plastic blend; or the first moulded hard portion and the second moulded portion are the same material. The third moulded hard portion is made of a different material than, or is thinner than, the first moulded hard portion and/or the second moulded hard portion.

[0018] In another example, any one or more of a thickness, a density, a hardness, or a stiffness property(ies) of the first moulded hard portion and/or the second molded hard portion is greater than the same property or properties of the third moulded hard portion.

[0019] In an example, each moulded hard portion further comprises a peripheral edge, and the peripheral edge of a moulded hard portion generally corresponds to or generally matches the peripheral edge of an adjacent moulded hard portion. In some examples, each moulded hard portion further comprises a peripheral edge and the peripheral edge between adjacent moulded hard portions is not linear. The joint member may include a bridge portion that includes a resilient central portion that may deform to absorb forces and/or vibration. The joint member also includes opposing channels, each of the opposing channels securely receiving a respective peripheral edge to form at least part of an integrated shell. The resilient central portion may be solid, or may include side walls defining a hollow chamber along at least a portion of the length of the joint member.

[0020] In another example, the luggage article includes a top panel, bottom panel, and two side panels; the first shell comprises a front panel, the second shell comprises a rear panel, and each of the front panel and rear panel is positioned between the top panel and the bottom panel and horizontally between the side panels, and each moulded hard portion extends between at least two adjacent panels.

[0021] In an example, at least one wheel assembly may be joined to at least one of the moulded portions encompassing at least a portion of a bottom panel of the luggage article.

[0022] In an example, the joint member is extruded, and/or is made of rubber, plastic, or metal, or fabric.

[0023] In some examples, the second shell includes a fourth upper moulded hard portion and a fifth lower moulded hard portion positioned at a region of the second shell that is distal from the fourth upper moulded hard portion. The second shell also includes at least one resilient strip member. A sixth intermediate moulded hard portion is positioned between the fourth and fifth moulded hard upper and lower portions, and is fixedly joined to each of the fourth and fifth moulded hard upper and lower portions by resilient strip members to form an integrated external shell.

[0024] In some examples, the resilient strip member is secured to adjacent moulded hard portions by sewing.

[0025] In some examples, the intermediate moulded hard portions are comprised of a material that is different from the material from which the moulded hard upper and lower portions are made.

[0026] In some examples, a density of each of the moulded hard upper and lower portions is each greater than a density of the intermediate moulded hard portion.

[0027] In some examples, a hardness of each of the moulded hard upper and lower portions is each greater than a hardness of the intermediate moulded hard portion.

[0028] In some examples, a stiffness of each of the moulded hard upper and lower portions is each greater than a stiffness of the intermediate moulded hard portion.

[0029] In some examples, a thickness of each of the moulded hard upper and lower portions is each greater than a thickness of the intermediate moulded hard portion.

[0030] In some examples, the thickness of the moulded hard upper and lower portions is the same.

[0031] In some examples, the thickness of the intermediate moulded hard portions is the same.

[0032] In some examples, the luggage article also includes at least one support structure joined to a corner region of the lower moulded hard portion.

[0033] In some examples, the support structure is a spinner wheel.

[0034] In some examples, the peripheral edges of adjacent moulded hard portions extend in two planes of the luggage article. For example, the peripheral edges may extend around a corner edge of the luggage case from a front panel to a side panel or from a rear panel to a side panel. The joint member securely connecting the adjacent moulded hard portions may flexibly bend around a corner edge.

[0035] In some examples, the resilient strip member defines two channels for receiving and securing peripheral edges of adjacent moulded hard portions.

[0036] In some examples, the joint structures between the shell portions on the front shell are aligned with the joint structures between the shell portions on the rear shell. For example, the joints between the first and second moulded portions are aligned with the joints between the fourth and fifth moulded portions.

[0037] In some examples, the first shell and second shell meet at a split line when the luggage article is in the closed position and the resilient strip member extends laterally or longitudinally between the split line and across each of the first and second shell.

[0038] In some examples, complimentarily shaped adjacent moulded hard portions include a joint structure formed by the interlocking peripheral edge regions of adjacent mould portions. For example, the terminal end of one peripheral edge region of one mold portion forms a tab extending at an angle from to form a substantially L-shaped rim. A channel is formed in the peripheral edge region of an adjacent mould portion, the channel being spaced away from the terminal end of the peripheral edge. The tab is received in the channel and engages a channel sidewall. A portion of the peripheral edge region of one mould portion overlaps a portion of the peripheral edge region of the adjacent mould portion, which are secured together. The securement may be by means of a line of stitching, glue, adhesive, epoxy, and/or other mechanical or chemical fasteners.

[0039] Additional embodiments and features are set forth in part in the description that follows, and will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosed subject matter. A further understanding of the nature and advantages of the present disclosure may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure. One of skill in the art will understand that each of the various aspects and features of the disclosure may advantageously be used separately in some instances, or in combination with other aspects and features of the disclosure in other instances.

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The description will be more fully understood with reference to the following figures in which components are not drawn to scale, which are presented as various embodiments of the disclosure and should not be construed as a complete recitation of the scope of the disclosure, characterized in that:

Fig. 1 is a front perspective view of a luggage article formed using multiple pieces that are joined together according to one example.

Fig. 2 is an enlarged fragmentary view of Detail 2 of Fig. 1.

Fig. 2A is a fragmentary cross sectional illustration taken along line 2A-2A of Fig. 2

Fig. 3 is a front perspective view of a luggage article formed using multiple materials that are joined together according to another example.

Fig. 3A is a fragmentary cross sectional illustration taken along line 3A-3A of Fig. 3.

Figs. 4A-4C are illustrations of joints according to other examples.

DETAILED DESCRIPTION

[0041] The present disclosure provides an improved shell structure for a luggage article. In particular, the present disclosure provides a shell structure that is lightweight, can absorb impact forces, and can minimize noise production. In general, each shell is constructed of multiple separate portions or sections of hard side material. The portions are joined by flexible joints, such as resilient joint members (also referred to herein as strip members), that provide impact absorption and noise dampening. The separate sections may have different thicknesses in order to reduce the overall shell weight. In some examples, and regardless of relative thickness, the portions may be formed from different materials to further decrease weight. The separate portions may each have different relative physical properties, which may be corresponding to their respective location on the shell structure. Additionally, having separate hard material portions on different areas of the luggage case allows for different combinations of aesthetic appearances, as well as textural characteristics, to create an intended appearance and feel. Each of the distinctions between the separate sections or portions noted herein, including those above, may be employed individually or in any combination.

[0042] This type of shell construction accommodates the use of a particular or selected hard material moulded portion in the areas of the case, such as for example the corners, top and bottom areas, which may require structural integrity and/or impact resistance, while using a different hard material moulded portion in the areas of the shell, such as the mid-section that are subject to different demands. This arrangement maintains the strength and/or durability of the shell where desired while beneficially reducing the weight of the shell since the different portions or sections can have different weight characteristics.

[0043] Referring to Fig. 1, a hard side luggage article 100 is defined by a housing 102 and includes a front panel 104, a rear panel 106, a top panel 108, a bottom panel 110, a right side panel 112, and a left side panel 114. Corner regions 116 are defined by the intersection of any three adjacent panels 104, 106, 108, 110, 112, 114. Corner edges 117 are defined by the intersection of any to adjacent panels 104, 106, 108, 110, 112, 114. The panels 104, 106, 108, 110, 112, 114 as described herein may also be referred to as "sides." Thus, a first side, a second side, and/or a third side of the luggage article 100 may each be any of the various panels 104, 106, 108, 110, 112, 114 described herein. The housing 102 may also define a split line 118, which divides the housing 102 into a first, or front, shell 122 and a second, or rear, shell 120. A closure mechanism, such as a zipper, extends along the split line 118. A hinge (not shown) for pivotally connecting the two shells 120,122 together is positioned along the split line 118. Various types of closure mechanisms and hinge structures are acceptable, including latches, clamps, buckles, or other structures.

[0044] The luggage article 100 may include support structures 124, which may be wheels or studs. With reference to Fig. 1, the luggage article may include four support structures 124, such as spinner type wheels, to allow the user to pull or tow the luggage article 100 at an angle, or to guide it along in an upright position. Alternatively, the luggage article 100 may include two wheel support structures 124 positioned on one of the shells 120, 122, with one or more studs positioned on the opposite shell. As another alternative, the support structures 124 may be only studs. The luggage article 100 may include a top carry handle 126 on the top panel 108 and a side carry handle 128 on a side panel 112, 114. The luggage article 100 may also include an extendable pull handle (not shown) attached to or configured with the rear panel 106.

[0045] One or both of the shells 120,122 forming the housing 102 may include more than one moulded portion affixed together to form an integrated shell. Each moulded portion may form part or all of the any of the panels, including the front panel 104, rear panel 106, top panel 108, bottom panel 110, right side panel 112, left side panel 114, or one or more corner regions 116 or corner edges. Each moulded portion may form part of two adjacent panels, such as the front panel 104 and right side panel 112 or the rear panel 106 and bottom panel 110, each of which may encompass of include a corner edge 117. Each moulded portion may form part of three adjacent panels, such as the front panel 104, right side panel 112, and top panel 108 or the rear panel 106, bottom panel 110, and right side edge panel 112, each of which may encompass or include a corner region 116 and a corner edge 117.

[0046] With reference to an upright luggage article 100 as shown in Fig. 1, each moulded portion may extend generally across at least a portion of the width dimension of the luggage shell, or laterally or horizontally, in Fig. 1. Each moulded portion may engage or operably connect with at least one adjacent moulded portion at a joint structure 119 formed along laterally extending adjacent edges of the adjacent portions. Alternatively, or additionally, each moulded portion may extend generally along a length dimension of the luggage shell, or longitudinally or vertically, in Fig. 1, and meet at a joint structure 119 (in dash) formed along vertically-extending adjacent edges of the adjacent portions.

[0047] The moulded portions may have peripheral edges that extend at angles or in directions between the horizontal and vertical (relative to Fig. 1), and the peripheral edges may include lengths that are linear, curved, linear sections at angles to adjacent linear sections (e.g. saw-tooth pattern), or many other shapes and configurations. The joint structure 119 formed along the adjacent edges of adjacent portions may also then extend at angles or in directions between the horizontal and vertical (relative to Fig. 1). In one example, the joint structure 119 extends along with the adjacent edges of moulded hard portions 136 and 140, which extend linearly and laterally (Fig. 1) across the front panel 104 of the first shell 122, and extends between the split line 118 on the right side panel 112 and the split line 118 on the left side panel 114.

[0048] Alternatively, the adjacent edges (and thus the joint structure 119) of moulded portions may included linear, curved, or angular sections, or a combination thereof. As is shown in Fig. 3, the joint structure 119 extends linearly along a first section 123, and then angles downwardly along a second section 125 toward the middle of the front panel 104, and then near the corner edge 117 a section 127 extends laterally along the right side panel 112 to the split line 118. The joint structure 119 positioned between the intermediate portion 140 and the lower portion 138 extends in a mirror image. The extension of the joint structure 119 between the molded portions forming the second shell 120 may be aligned with the extension of the joint structures 119 on the first shell 122, or may have a different configuration based on the shape, size and orientation of the molded portions. Multiple moulded portions may meet at a split line 118, which may extend generally horizontally, vertically, or in other desired orientations. With reference to Fig. 1, the first shell 122 may be defined by three moulded portions, a first upper moulded portion 136, a second lower moulded portion 138 positioned opposite the first upper moulded portion 136, and an intermediate portion 140 positioned between the opposing first 136 and second 138 moulded portions. The first upper moulded portion 136 includes portions of the top panel 108, front panel 104, and side panels 112, 114, and includes two corner regions 116 and a corner edge 117. The second lower moulded portion 138 includes portions of the bottom panel 110, front panel 104, and side panels 112, 114, as well as two corner regions 116 and a corner edge 117. The intermediate portion 140 disposed between the first upper moulded hard portion 136 and second lower moulded portion 138 includes a portion of the side panels 112, 114 as well as a portion of the front panel 104, and a pair of corner edges 117. The second shell 120 may have portions corresponding to the portions of the first shell described above and in some examples the portions may be symmetrically positioned between the first and second shells. For example, it may include a fourth upper moulded portion 130 that includes portions of the top panel 108, rear panel 106, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The second shell 120 may also include a fifth lower moulded portion 132 that includes portions of the bottom panel 110, rear panel 106, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The second shell 120 may also include a sixth intermediate moulded portion 134 disposed between the fourth upper moulded hard portion 130 and fifth lower moulded portion 132 and that defines a portion of the side panels 112, 114 as well as a portion of the rear panel 106, and a pair of corner edges 117.

[0049] With reference to Fig. 1, when the two shells 120, 122 are in the closed position, the first and fourth upper moulded portions 136, 130 are positioned at least partially adjacent to each other about the split line 118 such that together the upper moulded portions 136, 130 form a cap structure encompassing at least a portion of the top panel 108, and may encompass the entirety of the top panel 108, and extending down over the corners 116 to extend along a top region of each of the side panels 112,114 and front and rear panels 104, 106. The second and fifth lower moulded portions 138, 132 are also positioned adjacent to each other about the split line 118 such that together the lower moulded portions 138,132 form a tray structure encompassing at least a portion of the bottom panel, and may encompass the entirety of the bottom panel 108, and extending up over the corners 116 to extend along a bottom region of each of the side panels 112, 114 and front and rear panels 104, 106. The third and sixth intermediate moulded portions 140, 134 are also positioned at least partially adjacent to each other about the split line 118 and extend around the periphery of the central portion of the housing 102 to form a lateral band structure.

[0050] In one example, the first portion 136 is positioned at a region of the first shell 122 that is distal from the position of the second portion 138. The third portion 140 is positioned between the first moulded portion 136 and the second molded portion 138, and fixedly joined to the first moulded portion by the joint structure 119. The third portion 140 is fixedly joined to the second moulded portion 138 by the joint structure 119. This forms a part of an integrated external first shell 122. The fourth 130, fifth 132, and sixth 134 portions are similarly configured to be joined together to form at least part of an integrated external second shell 120.

[0051] Additionally or alternatively, one or both of the shells 120, 122 may be defined by a plurality of vertically (longitudinally) oriented moulded portions. With reference to Fig. 1, the first shell 122 may include a seventh left moulded portion 172 that includes at least portions of the of the top panel 108, front panel 104, bottom panel 110, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The first shell 122 may also include an eighth right moulded portion 174 that includes at least portions of the top panel 108, front panel 104, bottom panel 110, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The first shell 122 may also include a ninth intermediate moulded portion 181 that includes at least portions of the top panel 108, front panel 104, bottom panel 110, and at least one corner edge 117. The second shell 120 may have portions corresponding to the portions of the first shell described above, and in some examples the portions may be symmetrically positioned between the first and second shells. For example, it may include a tenth left moulded portion 176 that includes portions of the of the top panel 108, front panel 104, bottom panel 110, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The second shell 120 may also include a right eleventh moulded portion 178 that defines portions of the top panel 108, front panel 104, bottom panel 110, and side panels 112, 114 as well as two corner regions 116 and a corner edge 117. The second shell 120 may also include an intermediate twelfth moulded portion 179 that includes at least portions of the top panel 108, rear panel 106, bottom panel 110, and at least one corner edge 117. The seventh through twelfth panels may not include a corner region 116 or a corner edge 117 depending on their particular configuration.

[0052] In this configuration, the seventh and tenth moulded portions 172, 178 are positioned adjacent to each other about the split line 118 such that together the moulded portions 172, 178 form a lateral structure encompassing a portion of each of the top, bottom, front, and rear panels 104, 106, 108, 110 as well as the entire side panel 114, and includes four corner regions 116 and two corner edges. The eighth and ninth moulded portions 174, 176 are also positioned about the split line 118 such that together the moulded portions 174, 176 form a second lateral structure encompassing the remaining portions of each of the top, bottom, front, and rear panels 104, 106, 108, 110 not encompassed by the seventh and tenth moulded portions 172, 178 as well as the entire side portion 112 and includes four corner regions 116 and two corner edges 117. The ninth and twelfth moulded portions 181, 179 are positioned adjacent to each other about the split line 118 such that together the moulded portions 181, 179 form a structure encompassing a portion of each of the top, bottom, front, and rear panels 104, 106, 108, 110 and includes four corner edges 117.

[0053] Where a luggage shell formed of longitudinally extending molded portions secured together, such as left side portion 172, right side portion 174, and intermediate central portion 181 for first shell 122, they are similarly joined together by a joint structure 119 to form one integrated external shell. The joints between adjacent portions 172, 181, and 174 on the first or front shell 122 may be aligned with the joint structures 119 between adjacent portions 176, 179, and 178 on the second or rear shell 120. The joint structures 119 between the portions 172, 181, and 174, and between 176, 179, and 178 may extend from a split line 118 on the top panel 108 across the entire front or panel 104 (respectively) to a split line 118 on the bottom panel 110.

[0054] In one example, the eighth portion 174 is positioned at a region of the first shell 122 that is distal from the position of the seventh portion 172. The ninth portion 181 is positioned between the seventh moulded portion and the eighth molded portion, and fixedly joined to the seventh moulded portion by the joint structure 119. The ninth portion 181 is fixedly joined to the eighth moulded portion by the joint structure 119. This forms a part of an integrated external first shell 122. The tenth 176, eleventh 178, and twelfth 179 portions are similarly configured to be joined together to form at least part of an integrated external second shell 120.

[0055] The moulded portions encompassing a corner region 116 may not integrally form the corner regions 116, such as where the corner regions are separate structural pieces, such as corner bumpers, positioned in or over an aperture formed in the respective moulded portion. This separate corner bumper allows for different materials to be used in the corner regions if desired, such as high-strength hard side material for additional integrity.

[0056] Each of the luggage shells may be defined by the same number or a different number of moulded portions relative to the other luggage shell. Each of the luggage shells may include only laterally-extending moulded portions, or may include only longitudinally extending moulded portions, or may include only moulded portions extending in directions between laterally and longitudinally, or may include a combination of vertically, longitudinally, and/or moulded portions extending in directions between laterally and longitudinally.

[0057] In one example, a luggage article 100 includes a shell 122 and another shell 122 separable along a split line 118, the shells 120, 122 pivotally joined together to define a storage volume. The shell 122 includes a first moulded hard portion 136 and a second moulded hard portion 138, and at least one joint structure 119. The joint structure fixedly joins the first moulded hard portion 136 to the second moulded hard portion 138 to form at least part of an integrated external shell. In this embodiment, the intermediate portion 140 is not required since the moulded portion 136 and moulded portion 138 extend sufficiently so that the peripheral edge region of each portion 136 and 138 may be joined together by a joint structure 119.

[0058] The first luggage shell 122 is described herein, in various examples, as including a first portion 136, second portion 138 and third portion 140. It is also described in another embodiment as including a seventh portion 172, eighth portion 174 and ninth portion 181. Similarly, the second shell 120 is described herein, in various examples, as including a fourth portion 130, fifth portion 132, and sixth portion 134. It is also described in another embodiment as including a tenth portion 176, eleventh portion 178, and twelfth portion 179. These labels are used for clarity in description and for delineation of different portions of the respective luggage shells 120 and 122 in this description. However, these labels are not to be limited to the precise environment or structure in which they are used to describe, for example, in the specification or in the claims, as to which location on a shell, or on which particular shell such portion is included. As used in the specification and/or claims, the terms (and common variations thereof) first portion, second portion, third portion, fourth portion, fifth portion, sixth portion, seventh portion, eighth portion, ninth portion, tenth portion, eleventh portion and/or twelfth portion may be used generically to refer to any portion of a luggage case or other structure as defined in the claims. As used herein, the terms "mould" or "moulded" include various techniques used for shaping and forming hard side materials for use in luggage cases, such as, but not limited to injection moulding, press forming, plug moulding, vacuum moulding, and others. As used herein, the term "moulded portion" or "moulded section" includes a sheet or portion of a sheet of hard side material that does not include or form any two or three-dimensional configuration, for instance, having a planar shape.

[0059] In one example, where each of the moulded hard side portions 130, 132, 134, 136, 138, 140 extend laterally, each moulded hard side portion may have a dimension, or height, along the length (or total height) of the outer surface of the housing 102 (as shown in Fig. 1). The height of each upper moulded portion 136, 130, is H_M1. The height of each intermediate moulded portion 140, 134 is H_M2. The height of each lower portion is HM3. Each of H_M1, H_M2, and H_M3 is less than the height H_T of the entire luggage housing 102 (excluding the extension of the support structures 124 below the housing). The sum of H_M1 + H_M2 + H_M3 may be less than the height H_T of the entire luggage housing 102. The sum of H_M1 + H_M2 + H_M3 is less than the height H_T when a joint strip is used to connect at least two adjacent moulded portions together, which may require a relatively small gap between the adjacent edges, as explained in further detail below.

[0060] The height H_M1, of the corresponding first 136 and fourth 130 upper moulded portions may be the same or different from each other. The height H_M3 of the corresponding second 138 and fifth 132 lower moulded portions may be the same or different from each other. In some examples, the height H_{M1, 3} or vertical dimension of any of the first 136, second 138, fourth 130, and fifth 132 moulded portions is approximately 12 to 21% of the height H_T, or more preferably 15 to 19 % of the height H_T. The height H_M2 of the corresponding third 140 and sixth 134 intermediate moulded portions may be the same or different from one another. , H_M2 may be greater than the height H_M1 or H_M3. In some examples, H_M2 may be approximately 50 to 85% of the height H_T, or more preferably 60 to 75 % of the height H_T.

[0061] The height dimension of the upper portion H_M1 and lower portion H_M3 on a single shell may be the same or different from each other. The height dimension of each of the upper portions, 130, 136 or each of the lower portions, 132, 138, may vary across the width of the shell, including, respectively, the front, back, and side panels 104, 106, 112, 114. Correspondingly, the height of the intermediate portions 134, 140 would vary correspondingly in order to generally mate with and accommodate the change in dimension of each of the respective adjacent upper and lower portions 130, 132, 136, 138.

[0062] In another example, where the first shell 122 includes two moulded hard side portions 172, 174 joined at joint structure 119, and/or second shell 120 includes two moulded hard side portions 176, 178, each of the moulded hard side portions may have a longitudinal dimension, or height, along the length of the housing 102 substantially the same as the height H_T of the entire luggage housing 102 (excluding the extension of the support structures 124 below the housing). The lateral dimension of each of the two moulded hard side portions included in each of shell 122 and/or 120 may be the same, or may be different from each other, but together sum to be equal to or just less than the total width W_T of the luggage case. The sum of the widths may be less than the total width of the luggage case where a joint strip is used to secure the two moulded portions together. There may be more than two moulded hard side portions used to form either of the luggage shells 120, 122, and adjacent moulded hard side portions may be attached together by a joint structure 119 positioned at adjacent edges. Each of the more than two moulded hard side portions may be the same or different width than the other portions, and together have a width equal to or less than the total width H_T of the respective luggage shell.

[0063] In the description herein, examples are provided for either the luggage housing 102 as a whole or for one of the two luggage shells 120 or 122. Where reference is made to only one luggage shell, it is intended that the other luggage shell may have the same or similar features and structures, except if noted.

[0064] Each moulded hard portion (136, 138, 140) forming the first shell 122 and each moulded hard portion (130, 132, 134) forming the second shell 120 may be constructed of the same or different material, based on the desired characteristics of each shell and of the luggage case 102. Suitable materials include acrylonitrile-butadiene-styrene ("ABS") plastic, polycarbonate ("PC") plastic, an ABS/polycarbonate plastic blend, polypropylene ("PP"), polypropylene composite, polycarbonate, polyethylene terephthalate ("PET"), low-density plastic materials, foamed materials (such as ethylene vinyl acetate ("EVA") or foamed PP), fabrics, and others, each being either reinforced or not reinforced. Each moulded hard portion 130, 132, 134, 136, 138, 140, 172, 174, 176, 178 may be constructed of a single layer or multiple layers of any of the foregoing materials, such as a PP overlaid with PET, ABS overlaid with polycarbonate, or any of the foregoing hard plastics overlaid with fabric. The layers may be in many different orders. In one example, the upper and lower moulded portions 136, 138 of the first shell may be constructed of one material, while the intermediate moulded portion 140 is made of a different material. The upper and lower portions may be constructed of, for example, ABS, polycarbonate plastic, or an ABS/polycarbonate plastic blend. The intermediate portion 140, however, may be constructed of polypropylene, polycarbonate, or a low-density plastic material, and may be constructed of a material that is different from the material from which the upper and lower portions of the first shell are constructed. In another example, the upper and lower portions of a shell may be made of a hard side material that is strong and shock absorbent, while the intermediate portion of the shell may be made of a hard side material that is less strong and shock absorbent since the intermediate portion is subject to fewer direct impacts and other stresses.

[0065] The physical properties, such as density, hardness, strength, thickness, surface finish/texture, colour, and/or stiffness, etc., of each moulded portion 130, 132, 134, 136, 138, 140, 172, 174, 176, 178 may be the same or different in order to accommodate the desired structural characteristics or aesthetic appearance of the housing 102. In one example, in the second luggage shell 120, the density of each of the fourth and fifth moulded hard upper and lower portions 130, 132 may be greater than the density of the sixth moulded hard intermediate portion 134. Additionally, in the second luggage shell 122, the density of each of the first and second moulded hard upper and lower portions 136, 138 may be greater than the density of the third moulded hard intermediate portion 140.

[0066] In one example, regarding the first shell 122, the density of the upper and lower moulded portions 136, 138 may be the same, or different from, each other. The density of the intermediate moulded hard portions 140 may be different than that of the upper and lower portions 136, 138, and is preferably relatively less dense. For example, the ratio of the density of the intermediate moulded hard portion 140 to the density of the upper and lower portions 136, 138 may be approximately in the range of 0.9:1, 0.8:1, 0.7:1, 0.5: 1, and is preferably approximately in the range of 0.6:1. The respective densities of the various portions of the second shell 120 are or may be the same or similar.

[0067] Having a more dense upper and lower moulded hard portion 136, 138 compared to the intermediate moulded hard portion 140 may help reduce the overall shell weight to produce a lighter luggage shell 122. By decreasing the density of the intermediate moulded hard portions 140 compared to the upper and lower moulded hard portion 136, 138, the overall shell weight may be reduced. A denser upper and lower moulded hard portions 136, 138 compared to relatively less dense intermediate portion 140 may maintain the structural integrity of the corner areas 116 and corner edges 117 to resist impact damage, and maintain the strength of the bottom panel for mounting the support structures 124. The ability to selectively position the stronger material in the areas of the luggage article 100 that are subjected to the most stress and largest impact forces during use, and selectively position more efficient materials in other areas, allows the overall weight of the luggage case to be acceptable if not desirable.

[0068] The hardness of each moulded portion 136, 138, 140 of the first shell 122 may be the same or different in order to accommodate the desired structural characteristics of the housing 102. The hardness of each of the first and second moulded hard upper and lower portions 136, 138 may be greater than the hardness of the third moulded hard intermediate portion 140. Additionally, the hardness of each of the fourth and fifth moulded hard upper and lower portions 130, 132 may be greater than the hardness of the sixth moulded hard intermediate portion 134.

[0069] In one example, regarding the first shell 122, the hardness of the upper and lower moulded portions 136, 138 may be the same, or different from, each other, or from the corresponding moulded portion on the second shell 120. The hardness of the intermediate moulded hard portions 134, 140 may be different than that of the upper and lower portions, and is preferably relatively less hard or softer. The respective hardnesses of the various portions of the second shell 120 are similar.

[0070] The stiffness of each moulded portion 130, 132, 134, 136, 138, 140 may be the same or different from other moulded portions in order to accommodate the desired structural characteristics of the respective shell 120, 122, and/or the housing 102. For example, the stiffness of each of the first and second moulded hard upper and lower portions 136, 138 may be greater than the stiffness of the third moulded hard intermediate portion 140. This allows the top and bottom portions of each shell to be more rigid than the less rigid intermediate portion. Additionally, in the second shell, the stiffness of each of the fourth and fifth moulded hard upper and lower portions 130, 132 may be greater than the stiffness of the sixth moulded hard intermediate portion 134.

[0071] In one example, regarding the first shell 122, the stiffness of the upper and lower moulded portions 136, 138 may be the same, or different from, each other. The stiffness of the intermediate moulded hard portions 134, 140 may be different than that of the upper and lower portions, and is preferably relatively less stiff or more flexible. The respective stiffnesses of the various portions of the second shell 120 are or may be similar.

[0072] Additionally, or alternatively, to the type of material used in the various separate portions of the shell, the thickness T of each moulded portion 130, 132, 134, 136, 138, 140, 172, 174, 176, 178 may be the same or different in order to accommodate the desired structural and/or weight characteristics of the housing 102. The thickness T of any moulded hard portion 130, 132, 134, 136, 138, 140 may generally be between approximately 1.2 mm and 2.5 mm. Generally, the thickness of an upper moulded portion 130, 136 is greater than the thickness of a respective intermediate portion 134, 140. Similarly, the thickness of a lower moulded portion 132, 138 is greater than the thickness of a respective intermediate portion 134, 140. The thickness of an upper portion and a lower portion on the same shell may be the same or different, but both are preferably greater than the thickness of a respective intermediate portion.

[0073] Referring now to Fig. 2A, and as one example using the first shell 122, the thickness T_O of the first upper moulded hard portion 136 may be greater than the thickness T_M of the third intermediate moulded hard portion 140. In some examples, the thickness T_O is preferably between 1.5 to 2.5 mm, or preferably between 1.8 to 2.2 mm, or approximately 2.0 mm. As noted above, the thickness T_M of the intermediate moulded hard portion 140 may be different than that of the upper portion 136, and is preferably relatively thinner. In some examples, the thickness of the intermediate portion is preferably between 1.2 to 2.0 mm, or preferably between 1.4 to 1.8 mm, or approximately 1.6 mm. The respective thicknesses of the various portions of the second shell 120 are similar in their respective thickness dimensions.

[0074] Having a thinner (T_M < T_O) intermediate moulded hard portion 134, 140 compared to the upper and lower moulded hard portions 130, 136, 132, 138 may help (based on relatively similar material density) reduce the overall shell weight to produce a lighter luggage housing 102. For example, a housing 102 comprising a first and second shell 120, 122 each having a constant thickness T of 2.0 mm may weigh 900 g. By decreasing the thickness T_M of the intermediate moulded hard portions 134, 140 from 2.0 mm to 1.6 mm, the weight of the intermediate moulded hard portions is reduced by 20%, which in turn reduces the overall weight of the housing 102 proportional to the amount of the housing formed by the intermediate moulded hard portions 134,140. The strength of the shell is beneficially retained in the upper and lower portions.

[0075] Constructing a shell 120, 122 from multiple moulded hard portions also increases the diversity of exterior appearance options for a luggage article 100 compared to a single-piece shell. For example, each moulded hard portion may have a different texture, surface feature, finish, and/or color. As shown in Fig. 2, both moulded hard portions 136, 140 include surface features 166, such as moulded ribs or grooves. However, the first upper moulded hard portion 136 may have a stippled or rough surface texture, while a third intermediate moulded hard portion 140 may have a smooth surface texture. This is but one example of the variation that may be created between the separate sections of the luggage case in this disclosure.

[0076] As noted above, each shell 120, 122 may be constructed of multiple portions secured together. In one example, shown in Fig. 1, an upper portion 136, intermediate portion 140, and lower portion 138 are joined together to form the first integrated shell 122, and shell 120 is formed by joining together upper portion 130, intermediate portion 134, and lower portion 132. Alternatively, in one example, shell 122 is formed of portions 172 and 174 joined together, and shell 120 is formed by joining together portions 176 and 178. Each moulded portion is joined to an adjacent moulded portion by a joint structure 119.

[0077] Each molded portion may be joined by a joint structure 119 to at least one other adjacent molded portion along co-extending adjacent peripheral edges. As an example, and referring to Figs. 2 and 2A, the joint structure 119 utilized to secure the upper molded portion 136 to the intermediate portion 140 of the first shell 122 is described. Figures 3A, 4A, and 4B show examples of joint structures that are similar to or the same as joint structure 119 of Fig. 2A, and Fig. 4C is an example of a joint structure where the adjacent edge regions of the adjacent molded portions are secured directly together, such as by interlocking along the respective peripheral edge regions, without the use of a joint member.

[0078] Continuing with Fig. 2A, the upper portion 136 includes at least one peripheral edge region 164, including a terminal end 190. The intermediate portion 140 includes at least one peripheral edge region 165, including a terminal end 192. The joint structure 119 is formed by or positioned between adjacent edges of adjacent moulded portions. The joint structure 119 is formed by adjacent edges of adjacent molded portions when the adjacent edges are secured to one another by direct connection, such as by overlapping the adjacent edges and securing together with a line of stitching (see Fig. 4C). The joint structure 119 is positioned between adjacent edges of adjacent portions through use of an intermediate structure, such as a joint member 150 that connects or secures the adjacent edge regions together. The joint member 150 may be a resilient strip of flexible material, such as vinyl, rubber, plastic, or the like, or may be a woven or non-woven fabric, metal, or other material, all being shaped to received and secure adjacent edges of molded portions. The joint member 150 has sufficient structural properties to withstand the forces in tension, shear, compression, and torsion that may occur between adjacent moulded portions.

[0079] Opposing arm portions 152a, 154a; 152b, 154b may be able to bend or flex towards or away from each other to accommodate a variety of thicknesses of, and relative movement between, adjacent moulded hard portions 136,140.

[0080] With continuing reference to Fig. 2A, the resilient member 150 is positioned between the two moulded hard portions 136, 140. The resilient strip 150 is elongated with a generally flat aspect ratio. In cross section, as shown, it has a central bridge section 156 with a pair of arms 152, 154 extending away from the central bridge section 156, and a pair of arms 157, 159 extending away from the bridge section 156 oppositely from the arms 152, 154. The arms 152, 154 define a channel 158 sized to receive the peripheral edge region 164 of the upper portion 136. The pair of arms 157, 159 define a channel 161 sized to receive the peripheral edge region 165 of the intermediate portion 140. The peripheral edge 164 is received within the channel 158, with terminal end 190 preferably engaging the abutment wall 156a. The peripheral edge 165 is received in channel 161, with terminal end 192 preferably engaging the abutment wall 156b. In this configuration, arms 152 and 157 are positioned towards the outside of the luggage shell, and arms 154 and 159 are positioned towards the inside of the luggage shell. Arms 152, 157 and the outer wall of the bridge 156 together may form a convex region to help smooth out the profile of the joint structure 119 and reduce the joint structure 119 from catching or snagging other articles during use.

[0081] Each of the peripheral edge regions 164 and 165 are secured within their respective channels 158, 161 to secure the adjacent upper molded portion 136 and intermediate molded portion140 together. Specifically, in Fig. 2A, the peripheral edge 164 is secured within the channel 158 by stitching a sew line 162 through the sandwich structure formed by arm 152, edge region 164, and arm 154. The peripheral edge 165 is secured within the channel 161 by stitching a sew line 162 through the sandwich structure formed by arm 157, edge region 165, and arm 159. While Fig. 2A shows gaps between the components of the sandwich structure after being secured together, the sew line 162 may secure the sandwich structure tightly together so that no gaps remain between the components. The line of stitching 162 may be located in a groove 160 formed in the outer surface of each of the arms 154, 157 so that it will be somewhat protected from abrasion during use since it is seated below or flush with the outer surface. As noted above, the joint member 150 may be secured to the adjacent edges of the adjacent moulded portions by other securement means, such as glue, adhesive, epoxy, mechanical fasteners, or the like.

[0082] In the example of Fig. 2A, the bridge 156 includes a central region 155. The central region 155 is flexible and resilient, and in this example defines a hollow chamber 163 formed at least partially along the length of the flexible strip 150. The central region 155 may not include a hollow chamber. The bridge section 156 may resiliently deform to absorb the various relative forces, such as compression, tension, bending, and torsion forces, applied between the adjacent moulded portions attached to the flexible strip. The bridge 156 thus acts to dampen or otherwise mitigate these forces while at the same time providing a sufficient structural connection between the adjacent moulded portions to accommodate the loads during use, as well as maintain the shape of the luggage case. As such, the resilient strip member 150 may provide impact resistance, which reduces the likelihood of damage to the luggage article 100 compared to a single-piece shell. The resilient strip member 150 may also reduce noise generation by absorbing vibrations caused by rolling the luggage over a rough surface, compared to a single-piece shell.

[0083] The resilient strip member 150 may also be effective at securing the moulded hard portions in more than one plane. Because the moulded hard portions may have two-dimensional or three-dimensional shapes, the resilient strip member 150 may be sufficiently flexible to allow it to bend and otherwise deform. One such location where this benefit is utilized is at the corner edge 117 between front panel 104 and side panel 112, where the joint structure 119 at the adjacent edges of the upper portion 136 and lower 140 extends around the corner edge 117. This capability allows the strip member 150 to maintain the structural shape and integrity of the shell even though the shell is made of two or more individual separate portions secured together. Other examples of the joint structure 119 are shown in Figs. 3A, 4A, 4B, and have the same or similar structure, except as noted. Similar reference numerals are used for similar features between the different examples.

[0084] In another example, joint structure 119' is shown in Fig. 3A. As with joint structure 119 in Fig. 2A, the joint member 150' includes a bridge 156 including a central region 155 that is flexibly and compressibly resilient for absorbing external forces, and may include a hollow chamber 163. Arms 152, 154 extend from the bridge 156 to form channel 158, and arms 157 and 159 extend oppositely from the bridge 156 to form channel 161. Channel 158 receives edge region 164, which is secured therein by a sewing line 162. Channel 161 receives peripheral edge region 165, which is secured therein by sewing line 162. Arm 152 and arm 157, along with the outer surface of the bridge 156 are linearly aligned. In this example, the peripheral edge region 164 includes an angled section 167 that offsets the peripheral region 164 inwardly (to the right in Fig. 3A) from the planar field of the upper portion 136. Similarly, the peripheral edge region 165 includes an angled section 169 that offsets the peripheral edge region 165 inwardly from the planar field of the intermediate portion 140. The amount of the offset is about the same or greater than the dimension of the arms 152 and 157 in order to reduce the extension of the joint member 150' above the outer surface formed by the adjacent upper and intermediate portions 136, 140, respectively. Preferably the joint member 150' is flush or below flush with the outer surface of the adjacent portions 136, 140.

[0085] In another example, joint structure 119" is shown in Fig. 4A. As with joint structure 119 in Fig. 2A, the joint member 150" includes a bridge 156 including a central region 155 that is flexibly and compressibly resilient for absorbing external forces, and may include a hollow chamber 163. Arms 152, 154 extend from the bridge 156 to form channel 158, and arms 157 and 159 extend oppositely from the bridge 156 to form channel 161. Channel 158 receives edge region 164, which is secured to arm 152 by a sewing line 162. Channel 161 receives peripheral edge region 165, which is secured to arm 157 by sewing line 162. Arm 152 and arm 157, along with the outer surface (left side in Fig. 4A) of the bridge 156 form a convex portion 169 which is curved. In this example, the peripheral edge region 164 includes an angled section 171 that offsets the peripheral region 164 outwardly (to the left in Fig. 4A) from the planar field of the upper portion 136. Similarly, the peripheral edge region 165 includes an angled section 171 that offsets the peripheral edge region 165 outwardly from the planar field of the intermediate portion 140. The amount of the offset is about the same or greater than the thickness dimension of the arms 154 and 159 in order to reduce the extension of the joint member 150" above the inner surface formed by the adjacent upper and intermediate portions 136, 140, respectively. Preferably the joint member 150" is flush or below flush with the inner surface of the adjacent portions 136, 140. Arm 152 and arm 157 are shorter than corresponding arms 154 and 159, and follow the contour of the outwardly offset peripheral edges 164, 165 to extend beyond the offset portions to the field, where the sew lines 162 are positioned. The convex portion 190 provides some contour to the exposed portion of the strip member 150" to reduce snagging and impact, as well as provide some aesthetic appeal.

[0086] In another example, joint structure 119'" is shown in Fig. 4B. As with joint structure 119 in Fig. 2A, the joint member 150'" includes a bridge 156 including a central region 155 that is flexibly and compressibly resilient for absorbing external forces, and in this example is a relatively thin member. Arms 152, 154 extend from the bridge 156 to form channel 158, and arms 157 and 159 extend oppositely from the bridge 156 to form channel 161. Channel 158 receives edge region 164, which is secured to arm 154 by a sewing line 162. Channel 161 receives peripheral edge region 165, which is secured to arm 159 by sewing line 162. Arm 152 and arm 157, along with the outer (left side in Fig. 4B) surface of the bridge 156 form a convex portion 169 having a planar central region 175 and curved ends 177. In this example, the peripheral edge region 164 is planar and in alignment with the field of the upper portion 136. Similarly, the peripheral edge region 165 is planar and in alignment with the field of the intermediate portion 140. Arm 152 and arm 157 are generally the same length as corresponding arms 154 and 159. Arms 152 and 156, together with the central region 155, form the convex portion 169, spaced away from the outer surface of the respective peripheral edge regions. The sewing line 162 for each moulded portion is underneath the convex portion 169, and in this example the planar region 175 extends beyond the sewing line, with curved ends 177 extending from the planar region 175 toward, and preferably engage, the outer surface of the upper and intermediate molded portions 136, 140. The convex portion 190 also provides some contour to the exposed portion of the strip member 150'" to reduce snagging and impact, as well as provide some aesthetic appeal. The strip-structure of the central region 155 of the joint member 150'" facilitates easier bending as it acts as a single-member living hinge and does not include the structure surrounding the hollow chamber as formed in the other examples of the bridge 156.

[0087] In another example, joint structure 119"" is shown in Fig. 4C as a direct connection between the adjacent edge regions 164 and 165 without a joint member 150"" positioned between terminal ends 190 and 192 of peripheral edge regions 164 and 165, respectively. In one example, the peripheral edge region 164 of a portion 136 includes a feature that mechanically interlocks with a corresponding feature on the peripheral edge region 165 of portion 140. The overlapping peripheral edge regions 164, 165 may then be additionally secured by stitching 162. In more detail, the terminal end 190 forms a tab 147 extending at an angle from the edge region 164 to form a substantially L-shaped rim. A channel 143 is formed in the peripheral edge region 165 spaced away from the terminal end 192. The channel extends outwardly (left side in Fig. 4C) to form a protruding rib. However, the channel may be reversed to extend internally to the luggage case so the channel is open to the outer surface of the luggage case if desired. The tab 147 is received in the channel 143 and engages a channel sidewall 145. A portion of the peripheral edge region 164 overlaps a portion of the peripheral edge region 165, which are secured together, for instance by a line of stitching 162, glue, adhesive, epoxy, and/or other mechanical or chemical fasteners. The tab 147 is held in engagement with the channel wall 143 to maintain the adjacent molded portions 136, 140 in alignment relative to one another, and to help relieve stress on the securement. This joint structure may not be as flexible or resilient as the other joint structures disclosed herein, but is strong and maintains alignment of the adjacent molded portions

[0088] In each of the examples 2A, 3A, 4A, 4B, and 4C, the inside of the luggage case may be on the right side of each figure, with the outside of the luggage case on the left side of the figure, and certain benefits and relative structure are described with that reference. Alternatively, the inside of the luggage case may be on the left side of each figure, with the outside of the luggage case on the right side of each figure.

[0089] In one example of the joint structure 119, it includes a resilient joint member 150 that receives and secures a peripheral edge region 164 of the first moulded hard portion 136, and receives and secures a peripheral edge region of the second moulded hard portion 138, without the need for the intermediate portion 140. This same structure eliminating the intermediate hard portion 134 applies to the second shell 120. It also applies to the embodiment where the molded portions 172, 174, 176, 178 extend longitudinally, and may meet together to be joined by a joint structure 119 without the need for an intermediate moulded portion.

[0090] In some examples, the joint structure includes a resilient bridge portion 155 from which opposing channels 158, 161 extend to receive a respective peripheral edge regions 164, 165 of adjacent moulded hard portions 136, 140. Each channel 158, 161 may be configured by a pair of spaced-apart arms 152 and 154, or 157 and 159, extending from the bridge portion 155. The outer portion of the joint member 150 on the outside of the luggage case 100 may, in one example, include a side surface formed by the central portion 156 of the bridge portion 155, one leg 152 of one channel 158 and one leg 157 of the opposing channel 161. The outer portion of the resilient joint member 150 may have a convex portion for a smooth outer contour.

[0091] With reference to Figs. 2A, 3A, 4A, and 4B, the resilient joint or strip member 150 shown in each figure has common features described below. The width of the channels 158 and 161 may accommodate the peripheral edge regions of the respective moulded portions having differing widths. Since the strip or joint member 150 may be flexible and resilient, the excess space in the channels may be taken up by the arms 152,154 flexing into contact with both surfaces of the moulded portion received in the channel 158, 161 when secured to the respective peripheral edge portions received therein. The shape, length or thickness of the arms 152 and 154, or arms 157 and 159, may be the same or different. Although the joint structures 119, 119', 119", 119"', 119"" are shown in Figs. 2A, 3A, and 4A-C with convex or protruding portions oriented towards the outer surface of the luggage article 100, any convex or protruding joint portions may alternatively be oriented towards the inner surface of the luggage article 100. Joining moulded hard portions, for example 130, 132, 134, 136, 138, 140 or 172, 174 with a resilient strip members 150 may make assembly of the luggage article 100 easier because moulded hard portions 130, 132, 134, 136, 138, 140 of different thicknesses can be received by the same resilient strip member 150. Any combination of the examples of the joint member 150 of the joint structure may be used in forming a single luggage shell.

[0092] It should be noted that all directional and/or dimensional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, front, back, rear, forward, backward, rearward, inner, outer, inward, outward, vertical, horizontal, clockwise, counterclockwise, length, width, height, depth, and relative orientation) are only used for identification purposes to aid the reader's understanding of the implementations of the disclosed invention(s), and do not create limitations, particularly as to the position, orientation, use relative size or geometry of the invention(s) unless specifically set forth in the claims.

[0093] Connection references (e.g., attached, coupled, connected, joined, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, connection references do not necessarily infer that two elements are directly connected and in a fixed relation to each other.

[0094] In some instances, components are described with reference to "ends" having a particular characteristic and/or being connected with another part. However, those skilled in the art will recognize that the disclosed invention(s) is not limited to components that terminate immediately beyond their points of connection with other parts. Thus, the term "end" should be interpreted broadly, in a manner that includes areas adjacent, rearward, forward of, or otherwise near the terminus of a particular element, link, component, part, member or the like. In methodologies directly or indirectly set forth herein, various steps and operations are described in one possible order of operation, but those skilled in the art will recognize that steps and operations may be rearranged, replaced, or eliminated without necessarily departing from the spirit and scope of the present invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made that are within the scope of the appended claims.

Claims

1. A luggage article (100) comprising:

a shell (120, 122);

another shell (120, 122) separable along a split line (118) and pivotally joined to the shell to define a storage volume;

the luggage article (100) characterized by:

at least the shell including:

a first moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178);

a second moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178) positioned at a region of the first shell that is distal from the first moulded hard portion;

at least one joint structure (119, 119', 119", 119"', 119""); and

a third moulded hard portion (134,140, 179, 181) positioned at least partially between the first moulded hard portion and the second moulded hard portion and fixedly joined to the first moulded hard portion by a joint structure (119, 119', 119", 119"', 119"") and the third moulded hard portion (134, 140, 179, 181) joined to the second moulded hard portion by a joint structure (119, 119', 119", 119"', 119"") to form at least part of an integrated external shell.

2. The luggage article of claim 1, wherein:

the first molded hard portion (130, 136)is an upper hard portion;

the second molded hard portion (132, 138) is a lower hard portion; and

the third moulded hard portion (134, 140) is an intermediate hard portion.

3. The luggage article (100) of claim 1, wherein:

the first molded hard portion is a side hard portion (172, 174, 176, 178);

the second molded hard portion is an opposing side hard portion (172, 174, 176, 178); and

the third moulded hard portion is an intermediate hard portion (179, 181) positioned between the first molded hard portion (172, 174, 176, 178) and the second molded hard portion (172, 174, 176, 178).

4. The luggage article of any of the preceding claims wherein:

the first molded hard portion includes at least a part of one of a top panel (108) and/or a bottom panel (110) and/or a side panel (112, 114).

5. The luggage article (100) of any of the preceding claims wherein:

the second molded hard portion includes at least a part of one of a top panel (108) and/or a bottom panel (110) and/or a side panel (112, 114).

6. The luggage article (100) of any of the preceding claims wherein:

the third moulded hard portion includes at least part of one of a top panel (108) and/or a bottom panel (110) and/or a side panel (112, 114).

7. The luggage article (100) of any of the preceding claims wherein:

the first hard portion or the second hard portion includes a corner region (116) and/or a corner edge (117).

8. The luggage article (100) of any of the preceding claims wherein:

one of the at least one joint structures (119, 119', 119", 119"', 119"") intersects the split line (118).

9. The luggage article of any of the preceding claims wherein the other shell (120, 122) comprises:

a fourth moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178);

a fifth moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178)positioned at a region of the second shell that is distal from the fourth moulded hard portion;

at least one joint structure (119, 119', 119", 119"', 119""); and

a sixth moulded hard portion (134, 140, 179, 181) positioned between the fourth moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178) and the fifth moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178) and fixedly joined to the fourth (130, 132, 136, 138, 172, 174, 176, 178) moulded hard portion by a joint structure (119, 119', 119", 119"', 119"") the sixth moulded hard portion (134, 140, 179, 181) joined to the fifth moulded hard portion (130, 132, 136, 138, 172, 174, 176, 178) by a joint structure (119, 119', 119", 119"', 119"") to form at least a hard portion of an integrated external shell.

10. The luggage article (100) of any of the preceding claims, wherein the joint structure (119, 119', 119", 119'") is a resilient joint member (150, 150', 150", 150'") and is positioned between and secured to peripheral edge regions (164, 165) of adjacent moulded hard portions (130,132,134,136,138,140,172,174,176,178).

11. The luggage article (100) of any of the preceding claims, wherein the first moulded hard portion (130, 136) and the second moulded hard portion (132,138) comprise at least in part a material independently selected from acrylonitrile-butadiene-styrene ("ABS") plastic, polycarbonate plastic, and ABS/polycarbonate plastic blend; or the first moulded hard portion (130,136) and the second moulded portion (132,138) are the same material.

12. The luggage article (100) of any of the preceding claims, wherein the third moulded hard portion (134, 140) is made of a different material, or is thinner, than the first moulded hard portion (130, 136) and/or the second moulded hard portion (132,138).

13. The luggage article (100) of any of claims 1 to 8, wherein any one or more of a thickness, a density, a hardness, or a stiffness property(ies) of the first moulded hard portion (136, 138) and/or the second molded hard portion (136, 138) is greater than the same property or properties of the third moulded hard portion (140).

14. The luggage article (100) of any of the preceding claims wherein each moulded hard portion (130, 132, 134, 136, 138, 140) further comprises a peripheral edge (164, 165) and wherein:

the peripheral edge (164, 165) of a moulded hard portion (130, 132, 134, 136, 138, 140, 172, 174, 176, 178) corresponds to or matches the peripheral edge (164, 165) of an adjacent moulded hard portion (130, 132, 134, 136, 138, 140, 172, 174, 176, 178); and

the joint member (150, 150', 150", 150"") includes a central portion and opposing channels (158, 161), each of the opposing channels securely receiving a respective peripheral edge (164, 165) to form at least part of an integrated shell (120, 122).

15. The luggage article (100) of any of the preceding claims, wherein
the article includes a top panel (108), bottom panel (110), and two side panels (112, 114),
the first shell comprises a front panel (104),
the second shell comprises a rear panel (106),
each of the front panel (104) and rear panel (106) is positioned between the top panel (108) and the bottom panel (110) and horizontally between the side panels (112, 114), and each moulded hard portion extends between at least two adjacent panels.

Drawing