Virtually Seamless and Shape-Retaining Bag with a Flexible and Soft Material Exterior

Abstract

A virtually seamless, flexible, and shape-retaining bag and a method of manufacturing such a bag is disclosed. The bag is formed from two complementary three-dimensional custom shaped halves of molded flexible foam. A single and continuous piece of material, fabric, or textile is bonded or otherwise joined over the exterior of each half. The entire outer material covering each half is free of seams, stitching, or other joining of two separate pieces material. The complementary and exposed edges of the two halves are joined about a hinge and fastener, whereby opening the fastener allows the two halves to separate about the hinge, and closing the fastener secures the first half to the complementary second half of the bag.

I claim: 
     
         1 . A method for manufacturing a bag, the method comprising:
 producing a first molded core of flexible foam comprising an exterior with a first three-dimensional (“3D”) shape that protrudes outwards with a plurality of contours from a first edge by forming the flexible foam of the first molded core between a first cavity mold and a first core mold with one or more of a first amount of pressure or a first amount of heat to the first cavity mold and the first core mold, wherein the first cavity mold and the first core mold have the first 3D shape;   preforming a first continuous section of material in the first 3D shape based on a gradually stretching of the first continuous section of the material;   bonding the first continuous section of the material seamlessly and without stitching to the exterior of the first molded core with application of one or more of a second amount of pressure or a second amount of heat;   producing a second molded core of flexible foam comprising an exterior with a second 3D shape that protrudes outwards with a plurality of contours from a second edge by forming the flexible foam of the second molded core between a second cavity mold and a second core mold with one or more of the first amount of pressure or the first amount of heat to the second cavity mold and the second core mold, wherein the second cavity mold and the second core mold have the second 3D shape;   preforming a second continuous section of material in the second 3D shape based on a gradually stretching of the second continuous section of the material;   bonding the second continuous section of the material seamlessly and without stitching to the exterior of the second molded core with application of one or more of the second amount of pressure or the second amount of heat; and   bonding a fastener to an interior of the first molded core along a length of the first edge, and to an interior of the second molded core along a complementary length of the second edge, wherein the fastener is free of stitching.   
     
     
         2 . The method of  claim 1  further comprising:
 applying an adhesive to edges of the first continuous section of the material; 
 extending the edges of the first continuous section of the material over and around the first edge to the interior of the first molded core; 
 joining the edges of the first continuous section of the material to the interior of the first molded core; 
 applying an adhesive to edges of the second continuous section of the material; 
 extending the edges of the second continuous section of the material over and around the second edge to the interior of the second molded core; and 
 joining the edges of the second continuous section of the material to the interior of the second molded core. 
 
     
     
         3 . The method of  claim 1 ,
 wherein bonding the first continuous section of the material comprises applying an adhesive to one or more of a backside of the first continuous section of the material or to the exterior of the first molded core prior to the application of the second amount of pressure or the second amount of heat; and   wherein bonding the second continuous section of the material comprises applying an adhesive to one or more of a backside of the second continuous section of the material or to the exterior of the second molded core prior to the application of the second amount of pressure or the second amount of heat.   
     
     
         4 . The method of  claim 1 ,
 wherein the first amount of pressure or the first amount of heat is greater than the second amount of pressure or the second amount of heat and is sufficient to alter a shape of the flexible foam of the first molded core; and   wherein bonding the first continuous section of the material comprises activating an adhesive between the first continuous section of the material and the first molded core and smoothing wrinkles from the first continuous section of the material when bonding to the first molded core with the application of the second amount of pressure or the second amount of heat.   
     
     
         5 . The method of  claim 1  further comprising:
 cutting the first continuous section of the material to a size of the first molded core prior to said preforming the first continuous section of the material; and 
 cutting the second continuous section of the material to a size of the second molded core prior to said preforming of the second continuous section of the material. 
 
     
     
         6 . The method of  claim 1  further comprising:
 trimming excess amounts of the first continuous section of the material after said bonding of the first continuous section of the material; and 
 trimming excess amounts of the second continuous section of the material after said bonding of the second continuous section of the material. 
 
     
     
         7 . The method of  claim 1 , wherein the first molded core forms a first half of the bag and the second molded core forms and a second half of the bag. 
     
     
         8 . The method of  claim 7 , wherein the first 3D shape of the first molded core is a copy of the second 3D shape of the second molded core. 
     
     
         9 . The method of  claim 7 , wherein the first 3D shape of the first molded core is different than the second 3D shape of the second molded core. 
     
     
         10 . The method of  claim 1  further comprising:
 bonding a liner free of stitching and seams to the interior of the first molded core, wherein the liner is a of a different material than the first continuous section of the material. 
 
     
     
         11 . The method of  claim 10 , wherein bonding the first continuous section of the material comprises:
 folding edges of the first continuous section of the material around the first edge to the interior of the first molded core and over a first section of the liner; and   joining the edges of the first continuous section of the material over the first section of the liner without stitching using an adhesive.   
     
     
         12 . The method of  claim 1  further comprising:
 placing a protective layer over the first continuous section of the material prior to said bonding of the first continuous section of the material; and 
 wherein bonding the first continuous section of the material comprises applying one or more of the second amount of pressure or the second amount of heat to the protective layer, and 
 wherein the protective layer protects the first continuous section of the material from one or more of heat, tearing, or disfiguration resulting from the application of the second amount of pressure or the second amount of heat. 
 
     
     
         13 . The method of  claim 1 , wherein bonding the first continuous section of the material comprises:
 activating a pressing cylinder of a molding machine that places the first amount of pressure or the first amount of heat to the first cavity mold and the first core mold for a particular duration of time.   
     
     
         14 . The method of  claim 1  further comprising:
 folding edges of the first continuous section of the material around the first edge to the interior of the first molded core after bonding the first continuous section of the material to the exterior of the first molded core; and 
 bonding the edges of the first continuous section of the material to the interior of the first molded core by applying and retaining a third amount of pressure or a third amount of heat for a duration of time. 
 
     
     
         15 . The method of  claim 1  further comprising:
 coating the first continuous section of the material with a waterproofing liquid or film. 
 
     
     
         16 . The method of  claim 1 , wherein the fastener secures the length of the first edge to the complementary length of the second edge when fastened, and releases the length of the first edge from the complementary length of the second edge when unfastened, and wherein the length is less than a full length of either the first edge or the second edge. 
     
     
         17 . The method of  claim 16 , wherein the fastener is a zipper with material about either side of the zipper, wherein the material about a left side of the zipper is joined about the length of the first edge, and the material about a right side of the zipper is joined about the complementary length of the second edge. 
     
     
         18 . The method of  claim 1  further comprising:
 attaching a hinge to the interior of the first molded core and the second molded core about a different second length of the first edge and the second edge than the length at which the fastener is bonded to the interior of the first molded core and the second molded core, wherein the first molded core rotates or stretches away from the second molded core about the second length of the hinge when the fastener is unfastened.