Flat packing suitcase system

Abstract

An improved design for a rolling suitcase having a retractable handle assembly is disclosed. The design includes a multi-piece molded shell having opposing side and end walls and a bottom wall, which together form a packing area. The telescoping tubes of the handle are located outside the packing area to maximize the packing area, and also to provide a flat bottom surface to minimize wrinkling of packed articles. The wheel skids are moved to the outer corners of the suitcase to minimize intrusion into the packing area. The tubes are made from fiber reinforced polymer for enhanced strength, and are concealed from view by a covering envelope. The handle assembly and wheel skids attach to the shell in a manner that enhances the structural strength and rigidity of the suitcase. Wear points on the handle assembly are provided with removable wear members made from abrasion-resistant material.

1 . A bag assembly, comprising:
 a shell member having first and second side walls, first and second end walls, and a bottom;   a handle assembly connected to the shell member, the handle assembly having a telescoping tubular assembly comprising a fiber-reinforced polymer material; and   a wheel skid assembly having a pair of wheels, the wheel skid assembly connected to the shell member;   wherein the shell member defines a packing space defined by the side walls, the end walls, and the bottom, and the telescoping tubular assembly is disposed outside of said packing space;   and wherein the handle assembly, wheel skid assembly and telescoping tubular member impart a strength and rigidity to the suitcase assembly over that attributable to the multi-piece shell member alone.   
   
   
       2 . The bag assembly of  claim 1 , further comprising a cover disposed over an exterior surface of the bottom wall of the shell member, the cover concealing the telescoping tubular member, wherein filler material is positioned between the cover member, the exterior surface of the bottom, and the telescoping tubular assembly to support the bottom and to provide shape to the covering member; and wherein the cover does not extend beyond a rearward extension of the wheels. 
   
   
       3 . The bag assembly of  claim 2 , wherein the filler material comprises a pre-molded foam. 
   
   
       4 . The bag assembly of  claim 1 , wherein the handle assembly engages a portion of the bottom wall adjacent to the first end wall, the handle assembly further comprising a bearing element; wherein when the suitcase assembly is placed on a substantially flat surface so that the suitcase assembly is supported by the wheels and the handle assembly, the bearing element is configured to contact the substantially flat surface to protect the handle assembly from abrasion; and wherein the bearing element is made from a material that is different from the material of the remainder of the handle assembly. 
   
   
       5 . The bag assembly of  claim 4 , wherein the bearing element is releasably connectable to the remainder of the handle assembly to allow replacement of the bearing element without replacing the handle assembly. 
   
   
       6 . The bag assembly of  claim 4 , wherein the bearing element has a greater resistance to abrasion than the portion of the handle assembly to which it is connected. 
   
   
       7 . The bag assembly of  claim 1 , wherein the telescoping tubular assembly comprises a plurality of individual tubes each having an oval cross-section. 
   
   
       8 . The bag assembly of  claim 7 , wherein the plurality of individual tubes are made from a fiber reinforced polymer resin. 
   
   
       9 . The bag assembly of  claim 1 , wherein the shell is a multipiece shell having first and second side walls and first and second end walls with cooperating structures that enable the walls to be snapped together. 
   
   
       10 . The bag assembly of  claim 1 , wherein a portion of the handle assembly cooperates with a portion of the first end wall to engage an outer surface of the telescoping tubular assembly. 
   
   
       11 . The bag assembly of  claim 1 , wherein the telescoping tubular member engages a cooperating surface on the second end wall to thereby impart strength and rigidity to the shell member. 
   
   
       12 . The bag assembly of  claim 1 , wherein the wheel skid assembly comprises at least two wheel skids attached to opposite corners of the shell member. 
   
   
       13 . A carrying bag, comprising:
 a shell member having first and second side walls and first and second end walls;   a handle assembly connected to the first end wall, the handle assembly further having a telescoping tubular assembly connected to the first end wall via a recess in the first end wall, the telescoping tubular assembly connected to the second end wall via a projection in the end wall that receives the telescoping tubular assembly; and   first and second wheel assemblies connected to the second end wall;   wherein the shell member comprises a packing space defined by the first and second side walls and the first and second end walls;   wherein the telescoping tubular assembly comprises a glass-reinforced plastic material, and is disposed outside of said packing space; and   wherein the handle assembly has at least one removable wear insert comprising a material having a higher resistance to abrasion than the portion of the handle assembly to which the removable wear insert connects.   
   
   
       14 . The bag assembly of  claim 13 , further comprising a cover disposed over an exterior surface of the bottom wall of the shell member, the cover concealing the telescoping tubular assembly, wherein filler material is positioned between the cover member, the exterior surface of the bottom, and the telescoping tubular member to support the bottom and to provide shape to the covering member; and wherein a rearward extension of the cover does not extend beyond a rearward extension of the first and second wheel assemblies. 
   
   
       15 . The bag assembly of  claim 14 , wherein the filler material comprises a pre-molded foam. 
   
   
       16 . The bag assembly of  claim 13 , wherein the telescoping tubular assembly comprises a plurality of individual tubes each having an oval cross-section. 
   
   
       17 . The bag assembly of  claim 16 , wherein the plurality of individual tubes are made from a fiber reinforced polymer resin. 
   
   
       18 . The bag assembly of  claim 13 , wherein the first and second side walls and first and second end walls have cooperating structures that enable the walls to be snapped together. 
   
   
       19 . The bag assembly of  claim 13 , wherein the wheel skid assembly comprises a pair of individual wheel skids attached to opposite corners of the shell member. 
   
   
       20 . A bag assembly, comprising:
 a shell assembly comprising first and second end walls and first and second side walls, the shell assembly having a packing space defined by the first and second end walls and first and second side walls;   a handle assembly comprising a telescoping tubular assembly having an outer tubular member with first and second ends, the first end of the outer telescoping tubular assembly connected to the first end wall and the second end of the telescoping tubular assembly connected to the second end wall, the telescoping tubular member further being disposed outside of said packing space; and   a tube cover overlying said telescoping tubular member, the tube cover connected to at least one of said first and second side walls; and   a foam insert disposed around said telescoping tubular member within said tube cover;   wherein a surface of the foam insert forms a bottom wall of said bag assembly.