Motorcycle saddlebag

Abstract

A motorcycle saddlebag is formed of a plurality of panels joined by structural adhesives. The saddlebag includes an outer panel, an inner panel, a lid, and a hinge. Some embodiments may also include a bottom panel. The lid is coupled to the outer panel by the hinge. The inner panel includes flanges extending around at least some of its perimeter edges. The outer panel is generally C-shaped shaped and receives the inner panel such that the flanges engage inner surfaces of the outer panel. Structural adhesives bond the flanges to the inner surfaces of the outer panel such that the outer and inner panel (and, in some embodiments, the bottom panel) cooperate to define a storage chamber. In some embodiments, portions of the outer panel extend beyond the inner panel and may be trimmed after bonding of the inner and outer panels to customize an inner contour of the saddlebag for different motorcycle applications.

1 . A motorcycle saddlebag comprising:
 a substantially U-shaped first panel including a generally forwardly-facing front portion, a generally outwardly-facing side portion, and a generally rearwardly-facing rear portion, the first panel including a substantially continuous outer surface extending along the front portion, the side portion, and the rear portion, and a substantially continuous inner surface opposite the outer surface and extending along the front portion, the side portion, and the rear portion; and   a substantially L-shaped second panel joined to the first panel, the second panel including a back wall and a bottom wall, the back wall defining on one end a generally forwardly-facing flange and on an opposite end a generally rearwardly-facing flange, the bottom wall defining a generally outwardly-facing flange, the forwardly-facing flange, the rearwardly-facing flange, and the outwardly facing flange each matingly engaging with the inner surface of the first panel for joining of the second panel to the first panel by way of structural adhesive.   
     
     
         2 . The motorcycle saddlebag of  claim 1 , wherein the outwardly facing flange blends smoothly into the forwardly-facing flange and the rearwardly-facing flange such that the forwardly-facing flange, the rearwardly-facing flange, and the outwardly-facing flange cooperate to define a substantially continuous and smoothly contoured engagement surface for matingly engaging with the inner surface of the first panel. 
     
     
         3 . The motorcycle saddlebag of  claim 2 , wherein substantially the entire engagement surface matingly engages the inner surface of the first panel. 
     
     
         4 . The motorcycle saddlebag of  claim 1 , wherein the front portion extends generally inwardly beyond the forwardly-facing flange, wherein the rear portion extends generally inwardly beyond the rearwardly-facing flange, and wherein the side portion extends generally downwardly beyond the outwardly-facing flange. 
     
     
         5 . The motorcycle saddlebag of  claim 1 , wherein the back wall includes at least a portion that is substantially perpendicular to at least a portion of the bottom wall. 
     
     
         6 . The motorcycle saddlebag of  claim 1 , wherein the back wall includes a substantially planar back panel and a generally U-shaped dished portion that is recessed relative to the back panel. 
     
     
         7 . The motorcycle saddlebag of  claim 6 , wherein the forwardly-facing flange and the rearwardly-facing flange are both oriented substantially perpendicular to the back panel. 
     
     
         8 . The motorcycle saddlebag of  claim 1 , wherein the first panel and the second panel together define a storage cavity, the saddlebag further comprising a lid pivotally coupled to one of the first panel and the second panel. 
     
     
         9 . The motorcycle saddlebag of  claim 1 , wherein the first and second panels are formed by at least one of thermoforming and injection molding. 
     
     
         10 . A motorcycle saddlebag comprising:
 an outer panel including a forward portion, a rearward portion, and a side portion, the forward and rearward portions each curving and smoothly transitioning into the side portion, the forward portion defining a forward edge, the rearward portion defining a rearward edge, and the forward portion the rearward portion and the side portion cooperating to define a lower edge, the first panel including an inner surface at least partially bounded by the forward edge, the rearward edge, and the lower edge;   an inner panel received by the outer panel and including a back wall and a bottom wall, at least a portion of the back wall extending substantially perpendicular to at least a portion of the bottom wall, the back and bottom walls cooperating to define a single smoothly contoured engagement surface that matingly engages the inner surface of the outer panel and that extends along and engages the forward portion, the side portion, and the rearward portion; and   structural adhesive between the inner surface and the engagement surface for joining the inner panel to the outer panel.   
     
     
         11 . The motorcycle saddlebag of  claim 10 , wherein the back wall defines a generally forwardly-facing flange that defines a first portion of the engagement surface and a generally rearwardly-facing flange that defines a second portion of the engagement surface, and wherein the bottom wall defines a generally outwardly-facing flange that defines a third portion of the engagement surface. 
     
     
         12 . The motorcycle saddlebag of  claim 10 , wherein substantially the entire engagement surface matingly engages the inner surface of the outer panel. 
     
     
         13 . The motorcycle saddlebag of  claim 10 , wherein the forward portion extends inwardly and downwardly beyond the engagement surface, the rearward portion extends inwardly and downwardly beyond the engagement surface, and the side portion extends downwardly beyond the engagement surface. 
     
     
         14 . The motorcycle saddlebag of  claim 10 , wherein the outer panel and the inner panel together define a storage cavity, the saddlebag further comprising a lid pivotally coupled to one of the outer panel and the inner panel. 
     
     
         15 . The motorcycle saddlebag of  claim 10 , wherein the outer panel and the inner panel are formed by at least one of thermoforming and injection molding. 
     
     
         16 . A method of making a motorcycle saddlebag, the method comprising:
 forming a generally U-shaped outer panel including a forward portion, a side portion, and a rearward portion, the forward portion, the side portion, and the rearward portion together defining a curved inner surface;   forming a generally L-shaped inner panel including a back wall and a bottom wall, the back wall defining a generally forwardly-facing flange and a generally rearwardly-facing flange, and the bottom wall defining a generally outwardly-facing flange, the forwardly-facing flange, the rearwardly-facing flange, and the outwardly-facing flange together defining an engagement surface;   applying structural adhesive to at least one of the inner surface and the engagement surface; and, after applying structural adhesive,   engaging the engagement surface with the inner surface to thereby couple the inner panel to the outer panel, including engaging the forwardly-facing flange with the inner surface at the forward portion, engaging the rearwardly-facing flange with the inner surface at the rearward portion, and engaging the outwardly-facing flange with the inner surface at the side portion.   
     
     
         17 . The method of  claim 16 , wherein forming the generally L-shaped inner panel includes at least one of thermoforming and injection molding. 
     
     
         18 . The method of  claim 16 , wherein forming the generally U-shaped outer panel includes at least one of thermoforming and injection molding. 
     
     
         19 . The method of  claim 16 , wherein the engagement surface is a substantially continuous and smoothly contoured surface, and wherein engaging the engagement surface with the inner surface includes engaging substantially the entire engagement surface with the inner surface. 
     
     
         20 . The method of  claim 16 , further comprising after engaging the engagement surface with the inner surface to thereby couple the inner panel to the outer panel, trimming outer edges of the outer panel to change an outer contour of the motorcycle saddlebag.