US5132166A
Expired / Lapsed
US
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Semirigid luggage shell and method for its production
Assignee: Gates Formed Fibre Products Inc
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Filing: 1990-12-03
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Granted: 1992-07-21
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Expires: 2010-12-03
Abstract
Abstract A resilient, low modulus, semirigid shell for use as a component of an article of luggage. The shell comprises a first nonwoven batt of thermoplastic resin fibers and an exterior material attached to the first nonwoven batt. The first batt and exterior material are thermally formed to a predetermined shape. The shell may also include one or more additional component layers selected from a second nonwoven, fibrous batt, a layer of backing material, a water impermeable film, and a lining material. In manufacturing the shell, the exterior material is attached to a first portion of a substrate material which is comprised of the nonwoven batt of thermoplastic resin fibers. A second portion of the substrate material is secured to an apparatus for thermal forming and the exterior material and substrate material are thermally formed to a resilient, low modulus, semirigid shell having a predetermined configuration.
Inventors
- 👤 Ronald W. Adams
- 👤 Gerald J. Smith
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 08:45
CPC Classifications
A; A45; A45C; A45C7/00; A45C7/0018; A45C7/0045; A45C5/00; A45C5/02; B; B29; B29C; B29C70/00; B29C70/04; B29C70/06; B29C70/08; B29C70/28; B29C70/30; B29C70/34; B29C70/345; B29K; B29K2105/00; B29K2105/06; B29K2105/08; B29K2105/0854; B29L; B29L2009/00; B29L2031/00; B29L2031/7418; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T428/00; Y10T428/23; Y10T428/24; Y10T428/24033; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/24099; Y10T428/24107; Y10T428/24628; Y10T428/24636; Y10T428/24802; Y10T428/2481; Y10T428/24818; Y10T428/24942; Y10T428/249921; Y10T428/249953; Y10T428/249976; Y10T428/29; Y10T428/2913; Y10T428/2915; Y10T442/00; Y10T442/30; Y10T442/3707; Y10T442/3724; Y10T442/3732; Y10T442/374; Y10T442/60; Y10T442/659; Y10T442/666; Y10T442/667; Y10T442/668
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
140 words
A resilient, low modulus, semirigid shell for use as a component of an article of luggage comprising: a first nonwoven batt comprised of interengaged and consolidated first fibers and second thermoplastic resin fibers having different melting points, said second thermoplastic fibers having a melting point sufficiently lower than that of said first fibers so as to soften during thermal forming and reharden upon subsequent cooling to form a plurality of bonds with said first fibers, and being present in an effective amount to form said bonds yet provide said low modulus upon thermoforming, said batt defining a first and a second face; and an exterior material attached to said first face of said first nonwoven batt, said first nonwoven batt and said exterior material being thermally formed to a deformable shell configuration having low modulus to provide shape retentive memory.
Claim 2
Dependent Claim
140 words
A resilient, low modulus, semirigid shell for use as a component of an article of luggage comprising: a first nonwoven batt comprised of interengaged and consolidated first fibers and second thermoplastic resin fibers having different melting points, said second thermoplastic fibers having a melting point sufficiently lower than that of said first fibers so as to soften during thermal forming and reharden upon subsequent cooling to form a plurality of bonds with said first fibers, and being present in an effective amount to form said bonds yet provide said low modulus upon thermoforming, said batt defining a first and a second face; and an exterior material attached to said first face of said first nonwoven batt, said first nonwoven batt and said exterior material being thermally formed to a deformable shell configuration having low modulus to provide shape retentive memory.
Claim 3
Dependent Claim
41 words
The shell of claim 1 wherein said first nonwoven batt is comprised of at least one type of thermoplastic resin fibers selected from the group consisting of fibers of polyethylene, polypropylene, polyester, nylons, polyphenylene sulfides, polyether sulfones, polyether-ether ketones, and polybenzimidazoles.
Claim 4
Dependent Claim
30 words
The shell of claim 1 wherein said first nonwoven batt is further comprised of fibers selected from the group consisting of rayon, cellulosic materials, carbon, aramids, glass, and thermoset plastics.
Claim 5
Dependent Claim
41 words
The shell of claim 1 further comprising: a second nonwoven, fibrous bat interposed and attached to said first nonwoven batt and said exterior material and being thermally formed with said first nonwoven batt and said exterior material to said shell configuration.
Claim 6
Dependent Claim
47 words
The shell of claim 4 wherein said second nonwoven, fibrous batt is comprised of at least one type of thermoplastic resin fibers interengaged and consolidated by needlepunching, selected from the group consisting of fibers of polyethylene, polypropylene, polyester, nylons, polyphenylene sulfides, polyether sulfones, polyether-ether ketones, and polybenzimidazoles.
Claim 7
Dependent Claim
30 words
The shell of claim 4 wherein said second nonwoven, fibrous batt is comprised of fibers selected from the group consisting of rayon, cellulosic materials, carbon, aramids, glass, and thermoset plastics.
Claim 8
Dependent Claim
21 words
The shell of claim 4 wherein said second nonwoven, fibrous batt is attached to said first nonwoven batt by an adhesive.
Claim 9
Dependent Claim
22 words
The shell of claim 4 wherein said second nonwoven fibrous batt is attached to said first nonwoven batt by an fusion bonding.
Claim 10
Dependent Claim
20 words
The shell of claim 4 wherein said second nonwoven fibrous batt is attached to said first nonwoven batt by needlepunching.
Claim 11
Dependent Claim
38 words
The shell of claim 9 wherein said second nonwoven, fibrous batt is comprised of interengaged and consolidated thermoplastic resin fibers having a higher temperature softening point than said portion of thermoplastic resin fibers of said first nonwoven batt.
Claim 12
Dependent Claim
36 words
The shell of claim 4 wherein said exterior material is a polymer and said shell further comprises: a layer of nonwoven material interposed between and attached to said exterior material and said second nonwoven, fibrous batt.
Claim 13
Dependent Claim
12 words
The shell of claim 11 wherein said exterior material is a vinyl.
Claim 14
Dependent Claim
47 words
The shell of claim 4 herein said exterior material is a woven cloth and said shell further comprises: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said exterior material and said second nonwoven, fibrous batt.
Claim 15
Dependent Claim
21 words
The shell of claim 13 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 16
Dependent Claim
17 words
The shell of claim 13 wherein said water impermeable film is a linear low density polyethylene film.
Claim 17
Dependent Claim
37 words
The shell of claim 4 further comprising: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said first nonwoven batt and said second nonwoven, fibrous batt.
Claim 18
Dependent Claim
21 words
The shell of claim 16 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 19
Dependent Claim
17 words
The shell of claim 16 wherein said water impermeable film is a linear low density polyethylene film.
Claim 20
Dependent Claim
41 words
The shell of claim 1 further comprising: a closed cell foam material interposed and attached to said first nonwoven batt and said exterior material and being thermally formed with said first nonwoven batt and said exterior material to said shell configuration.
Claim 21
Dependent Claim
39 words
The shell of claim 1 further comprising: a lining material secured to said second face of said first nonwoven batt, said lining material selected from the group consisting of a nonwoven fabric, a knit fabric, and a woven fabric.
Claim 22
Dependent Claim
35 words
The shell of claim 20 further comprising: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said lining material and said first nonwoven batt.
Claim 23
Dependent Claim
21 words
The shell of claim 21 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 24
Dependent Claim
17 words
The shell of claim 21 wherein said water impermeable film is a linear low density polyethylene film.
Claim 25
Dependent Claim
147 words
In an article of luggage having at least one shell, the improvement comprising: a resilient, low modulus, semirigid shell comprised of a first nonwoven batt defining a first and a second face and an exterior material attached to said first face of said first nonwoven batt, said first nonwoven batt comprised of interengaged and consolidated first fibers and second thermoplastic resin fibers having different melting points, said second thermoplastic fibers having a melting point sufficiently lower than that of said first fibers so as to soften during thermal forming and reharden upon subsequent cooling to form a plurality of bonds with said first fibers, said second fibers being present in an effective amount to form said bonds yet provide said low modulus, and said first nonwoven batt and said exterior material being thermally formed to a deformable shell configuration having low modulus to provide shape retentive memory.
Claim 26
Dependent Claim
147 words
In an article of luggage having at least one shell, the improvement comprising: a resilient, low modulus, semirigid shell comprised of a first nonwoven batt defining a first and a second face and an exterior material attached to said first face of said first nonwoven batt, said first nonwoven batt comprised of interengaged and consolidated first fibers and second thermoplastic resin fibers having different melting points, said second thermoplastic fibers having a melting point sufficiently lower than that of said first fibers so as to soften during thermal forming and reharden upon subsequent cooling to form a plurality of bonds with said first fibers, said second fibers being present in an effective amount to form said bonds yet provide said low modulus, and said first nonwoven batt and said exterior material being thermally formed to a deformable shell configuration having low modulus to provide shape retentive memory.
Claim 27
Dependent Claim
41 words
The improvement of claim 24 wherein said first nonwoven batt is comprised of at least one type of thermoplastic resin fibers selected from the group consisting of fibers of polyethylene, polypropylene, polyester, nylons, polyphenylene sulfides, polyether sulfones, polyether-ether ketones, and polybenzimidazoles.
Claim 28
Dependent Claim
30 words
The improvement of claim 24 wherein said first nonwoven batt is further comprised of fibers selected from the group consisting of rayon, cellulosic materials, carbon, aramids, glass and thermoset plastics.
Claim 29
Dependent Claim
48 words
The improvement of claim 24 wherein said resilient, low modulus, semirigid shell further comprises: a second nonwoven, fibrous batt interposed and attached to said first nonwoven batt and said exterior material and being thermally formed with said first nonwoven batt and said exterior material to said shell configuration.
Claim 30
Dependent Claim
47 words
The improvement of claim 27 wherein said second nonwoven, fibrous batt is comprised of at least one type of thermoplastic resin fibers interengaged and consolidated by needlepunching, selected from the group consisting of fibers of polyethylene, polypropylene, polyester, nylons, polyphenylene sulfides, polyether sulfones, polyether-ether ketones, and polybenzimidazoles.
Claim 31
Dependent Claim
30 words
The improvement of claim 27 wherein said second nonwoven, fibrous batt is comprised of fibers selected from the group consisting of rayon, cellulosic materials, carbon, aramids, glass, and thermoset plastics.
Claim 32
Dependent Claim
21 words
The improvement of claim 27 wherein said second nonwoven, fibrous batt is attached to said first nonwoven batt by an adhesive.
Claim 33
Dependent Claim
22 words
The improvement of claim 27 wherein said second nonwoven fibrous batt is attached to said first nonwoven batt by an fusion bonding.
Claim 34
Dependent Claim
20 words
The improvement of claim 27 wherein said second nonwoven fibrous batt is attached to said first nonwoven batt by needlepunching.
Claim 35
Dependent Claim
36 words
The improvement of claim 32 wherein said second nonwoven, fibrous batt is comprised of interengaged and consolidated thermoplastic fibers having a higher temperature softening point than said portion of thermoplastic resin fibers of said nonwoven batt.
Claim 36
Dependent Claim
40 words
The improvement of claim 27 wherein said exterior material is a polymer and said resilient, low modulus, semirigid shell further comprises: a layer of nonwoven material interposed between and attached to said exterior material and said second nonwoven, fibrous batt.
Claim 37
Dependent Claim
12 words
The improvement of claim 34 wherein said exterior material is a vinyl.
Claim 38
Dependent Claim
51 words
The improvement of claim 27 wherein said exterior material is a woven cloth and said resilient, low modulus, semirigid shell further comprises: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said exterior material and said second nonwoven, fibrous batt.
Claim 39
Dependent Claim
21 words
The improvement of claim 36 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 40
Dependent Claim
17 words
The improvement of claim 36 wherein said water impermeable film is a linear low density polyethylene film.
Claim 41
Dependent Claim
44 words
The improvement of claim 27 wherein said resilient, low modulus, semirigid shell further comprises: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said first nonwoven batt and said second nonwoven, fibrous batt.
Claim 42
Dependent Claim
21 words
The improvement of claim 39 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 43
Dependent Claim
17 words
The improvement of claim 39 wherein said water impermeable film is a linear low density polyethylene film.
Claim 44
Dependent Claim
48 words
The improvement of claim 24 wherein said resilient, low modulus, semirigid shell further comprises: a closed cell foam material interposed and attached to said first nonwoven batt and said exterior material and being thermally formed with said first nonwoven batt and said exterior material to said shell configuration.
Claim 45
Dependent Claim
46 words
The improvement of claim 24 wherein said resilient, low modulus, semirigid shell further comprises: a lining material secured to said second face of said first nonwoven batt, said lining material selected from the group consisting of a nonwoven fabric, a knit fabric, and a woven fabric.
Claim 46
Dependent Claim
42 words
The improvement of claim 43 wherein said resilient, low modulus, semirigid shell further comprises: a water impermeable film of a polymer which is flexible, durable, and resilient at ambient temperature interposed and attached to said lining material and said first nonwoven batt.
Claim 47
Dependent Claim
21 words
The improvement of claim 44 wherein said polymer is selected from the group consisting of natural rubber, synthetic rubber, and thermoplastics.
Claim 48
Dependent Claim
17 words
The improvement of claim 44 wherein said water impermeable film is a linear low density polyethylene film.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-07-21 | 1996-01-20 | 1996-07-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-07-21 | 2000-01-20 | 2000-07-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-07-21 | 2004-01-20 | 2004-07-21 | $7700.00 | Window Closed / Lapsed |