Backpack and Frame Structure for a Backpack

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a nonprovisional of, and claims priority to, U.S. Provisional Application No. 63/613,027, filed Dec. 20, 2023, the entire disclosure of which is incorporated by reference herein.

TECHNICAL FIELD

This disclosure relates to backpacks configured to hold weights for exercise purposes and/or cargo for transportation, and more specifically to backpacks that engage with a rigid structural frame for wearing by the user.

BACKGROUND

A wide variety of backpacks are available for various uses and purposes. Certain backpacks are designed for rugged use and/or carrying heavy loads over long distances, such as military use, hiking, camping, or holding weights for physical training exercise. Such backpacks may use a rigid structural frame made from metal and/or rigid plastics, including fiber-reinforced plastics (“FRP”), to provide structural support for a more flexible shell or body, which may be made from fabric or other such materials. One well-known example is a military-style field pack or rucksack designed for use with an All-purpose Lightweight Individual Carrying Equipment (“ALICE”) set, of which numerous variations have been created for various recreational and other non-military uses. Backpacks of this type are often bulky in size and appearance, and may have parts of the rigid frame exposed or other features that are detrimental to user comfort. Specifically, a traditional ALICE pack uses a frame that is externally connected to the pack. Because a frame must be externally connected to the pack, it can be uncomfortable for the user to wear against their back. Furthermore, traditional ALICE packs typically have minimal padding that includes only padded shoulder straps and a kidney pad. Thus, a need exists for a rugged, frame-supported backpack that provides a compact size, with improved comfort, storage, and aesthetics, and pairs with an efficient frame.

The present disclosure is provided to address these needs and other needs in existing backpacks. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

BRIEF SUMMARY

A backpack assembly and a method of assembling a backpack assembly is provided, the backpack assembly includes a pack, and when combined with a frame assembly, forms a frame-supported backpack with storage for items to be carried by a user. The backpack assembly may also include shoulder straps and handles to allow the user to carry the backpack assembly.

Aspects of the disclosure relate to a pack that includes an outer shell defining an inner cavity having two compartments, a frame compartment and a cargo compartment, separated by an inner panel. In one aspect, the pack includes an inner closure to open and close the inner panel, releasably separating the two compartments. The frame compartment is configured to removably hold and enclose the frame assembly and the cargo compartment is configured to removably hold one or more articles.

The frame assembly has a front side configured to face the user's body and includes a frame and pads connected to the frame. The frame is generally formed as a rigid structure, including a base and an upright portion extending upward from the base. The upright portion includes rigid frame members extending both vertically and horizontally to define a rigid shape and structure for the frame. The base is also generally formed of rigid frame members connected together.

In one aspect, the frame assembly has a lower back pad and an upper back pad connected to the frame. The lower back pad is connected to the bottom of the frame as to provide cushioning to the user's lower back. The upper back pad is formed as a sleeve that extends over the top of the frame assembly and includes a cushioning part and a wrap part that loop around the frame assembly.

In another aspect, the outer shell of the pack has a hole extending into the frame compartment, and the frame assembly includes a bracket connected to the frame. A shoulder strap, having a bottom end connected to the outer shell, may extend through the hole and connect to the bracket, thereby connected the shoulder strap directly to the frame. In another aspect, there are two shoulder straps connected to the backpack assembly.

In still another aspect, the pack includes a second opening and a second outer closure configured for selectively opening and closing the second opening to provide access to the frame compartment.

Other features and advantages of the disclosure will be apparent from the following description taken in conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To allow for a more full understanding of the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of one embodiment of a backpack assembly according to aspects of the disclosure;

FIG. 2 is a front perspective view of one embodiment of a frame assembly of the backpack assembly of FIG. 1, according to aspects of the disclosure;

FIG. 3 is a rear perspective view of the frame assembly of FIG. 2;

FIG. 4 is a rear view of the frame assembly of FIG. 2;

FIG. 5 is a front view of the frame assembly of FIG. 2;

FIG. 6 is a side view of the frame assembly of FIG. 2;

FIG. 7 is a rear perspective view of the frame assembly of FIG. 2, with an upper back pad removed;

FIG. 8 is a partial rear perspective view of the frame assembly of FIG. 2;

FIG. 9 is a rear perspective view of the backpack assembly of FIG. 1, with both inner and outer closures open;

FIG. 10 is a side perspective view of one embodiment of a pack of the backpack assembly of FIG. 1 according to aspects of the disclosure;

FIG. 11 is a rear perspective view of the backpack assembly of FIG. 1, with the inner closure closed and the outer closure open;

FIG. 12 is a rear perspective view of the backpack assembly of FIG. 1, with the inner closure closed and the outer closure open, and an outer shell of the pack pulled back to show internal detail;

FIG. 13 is a rear perspective view of the backpack assembly of FIG. 1, with the inner closure closed and the outer closure open, and with an internal pocket shown opened;

FIG. 14 is a front view of the backpack assembly of FIG. 1;

FIG. 15 is a schematic side view of the backpack assembly of FIG. 1, showing the frame assembly, with the pack and shoulder straps shown schematically; and

FIG. 16 is a schematic side view of another embodiment of a backpack assembly according to aspects of the disclosure, showing the frame assembly, with the pack and shoulder straps shown schematically, and a second outer closure in a closed position.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail example embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.

Referring now to the drawings, FIGS. 1-15 illustrate an embodiment of a backpack assembly 10 configured to be carried by a user and generally including a frame assembly 20 and a pack 50 that removably encloses the frame assembly 20 when the backpack assembly 10 is assembled. The backpack assembly 10 may also include one or more shoulder straps 80 and one or more handles 81 configured for engagement by the user to carry the backpack assembly 10.

The frame assembly 20 has a front side 21 configured to face the user's body and a rear side 22 opposite the front side 21 and includes a frame 23 and one or more pads connected to the frame 23. The frame assembly 20 in FIGS. 1-15 has a lower back pad 30 connected to the frame 23 proximate to a bottom 32 of the frame 23 and an upper back pad 31 connected to the frame 23 proximate to a top 33 of the frame 23. Other pad arrangements may be used in other embodiments. The frame 23 is generally formed as a rigid structure that has greater strength and rigidity than the structural material(s) of the pads 30, 31 and the structural material(s) of the pack 50.

The frame 23 includes an upright portion 25 and may also include a base 24 at or near the bottom 32 of the frame 23, with the upright portion 25 extending upward from the base 24 to the top 33 of the frame 23. The upright portion 25 provides a rigid structure that extends both vertically and horizontally. In the embodiment of FIGS. 1-15, the upright portion 25 is formed of a plurality of rigid frame members connected to each other to define a rigid shape and structure for the frame 23. The frame members may be formed from any rigid structural material, such as metals (including alloys and composites), plastics (including composites such as FRP), and other rigid materials, or combinations thereof. The frame members of the upright portion 25 in FIGS. 1-15 include two vertical frame members 27 and a horizontal frame member 28 forming an outer frame 29 and a plurality of cross-members including a horizontal cross-member 34 extending across the middle of the outer frame 29 and a vertical cross-member 35 extending across the middle of the frame 29. The horizontal cross-member 34 is are connected to the vertical frame members 27, and the vertical cross-member 35 is connected to the horizontal frame member 28, the horizontal cross-member 34, and the base 24. The vertical frame members 27 are generally vertical and are bent forward toward the top 33, such that the outer frame 29 has a bent portion 41 at the top 33 that is bent forward toward the front 21 of the frame assembly 20. The horizontal frame member 28 forms the top of the frame 23 in this embodiment. The horizontal cross-member 34 is a C-shaped member that is bent to extend forward at the ends to connect to the outer frame 29. The vertical cross-member 35 is a curved member that curves forward at the top portion and extends generally vertically from the horizontal cross-member 34 to the base 24. The frame assembly 20 also has two brackets 47 connected to the frame 23 at the horizontal frame member 28, for connection to the shoulder straps 80 as disclosed herein.

The connections between the frame members may be integral connections (i.e., being formed of a single piece), permanent connections such as welding, brazing, adhesives or other bonding materials, another integral joining technique, or permanent fasteners, and/or non-permanent connections formed by various fastening structures, or combinations thereof. In the embodiment of FIGS. 1-15, the outer frame 29 is formed as a single, integral piece that is bent into shape, and the outer frame 29 is connected to the cross-members 34, 35 and the base 24 by fasteners. The cross-members 34, 35 are connected to the base 24 and to each other by interlocking connecting members (e.g., a peg received in a hole), which may be reinforced by welding, bonding, etc.

The base 24 is also generally formed of rigid frame members connected together, and may be formed of any material discussed with respect to the frame members of the upright portion 25 and may be connected using any connection technique discussed herein. In one embodiment, the base 24 and the upright portion 25 are both formed of metal, and the base 24 is connected to the upright portion 25 by fasteners. The base 24 in FIGS. 1-15 includes a horizontal cross-member 38 that extends across the bottom of the outer frame 29, two forwardly-extending arms 39 extending forward from the outer frame 29, and two braces 37 extending upward and rearward from the arms 39 to the vertical frame members 27 of the outer frame 29. In the embodiment of FIGS. 1-15, the horizontal cross-member 38 and the arms 39 are formed of a single, integral piece that is bent into shape, and the braces 37 are connected to the outer frame 29 and the arms 39 by fasteners. The base 24 in FIGS. 1-15 also has an indented front 26 on the front side 21 to provide support and comfort for the user's back, which is formed by an angled cross-member 36 extending between the arms 39. The arms 39 also have rings 40 for connection of the lower back pad 30.

The lower back pad 30 includes a compressible cushioning material such as foam, rubber, etc., to provide cushioning to the lower back of the user when the backpack assembly 10 is worn. The lower back pad 30 in FIGS. 1-15 is a horizontally extending pad that is connected to the bottom 32 of the frame 23 at or near the longitudinal ends of the lower back pad 30. As seen in FIGS. 7-8, the lower back pad 30 has a cushioning part 48 that includes the compressible cushioning material within a fabric shell and a reinforcing part 42 that is formed from a low-stretch fabric material (e.g., nylon), with a strap 43 connected to the reinforcing part 42 to connect the lower back pad 30 to the frame 23. The reinforcing part 42 in FIGS. 7-8 forms a portion of the strap 43, and the strap 43 has a releasable buckle and a tensioning mechanism to ensure the lower back pad 30 is tightly connected to the frame 23.

The upper back pad 31 is formed as a sleeve that extends over at least part of the top 33 of the frame assembly 20 and includes a cushioning part 44 with a compressible cushioning material as disclosed herein positioned on the front 21 of the frame assembly 20 and a wrap part 45 that wraps around the rear 22 of the frame assembly 20 to form a loop. A portion of the frame 23 is inserted into the loop between the cushioning part 44 and the wrap part 45, and the upper back pad 31 further has a top opening 46 to permit access to the brackets 47 at the top 33 of the frame assembly 20.

The pack 50 generally includes an outer shell 51 that defines an inner cavity 52 having a frame compartment 53 that holds the frame assembly 20 when the backpack assembly 10 is assembled, and a cargo compartment 54 that is configured to hold one or more items of cargo, such as weights for training, equipment, food/drinks, or other articles. The outer shell 51 has an outer closure 55 permitting reclosable access to the inner cavity 52 through a rear opening 62, which is embodied as a zipper in the pack 50 of FIGS. 1-15. Other types of releasable and/or reclosable closures may be used in other embodiments, such as drawstrings or releasable connectors such as hook-and-loop connections, buckles, snaps, buttons, straps, etc. The outer shell 51 has a front wall 56 that may be provided with padding containing a compressible cushioning material, a bottom wall 57 that may include some rigid reinforcement, a side wall 58 extending around the sides and top of the outer shell 51, and a flap 59 that can be moved to open and close the rear opening 62 using the outer closure 55. The components of the outer shell 51 may be made from a fabric material, such as a low-stretch fabric material (e.g., nylon), and the front wall 56 may be made from a different material than the rest of the outer shell 51, having a lower-friction surface. The flap 59 in the embodiment of FIGS. 1-15 is connected to the bottom wall 57 along a fixed end and is releasably connected to the side wall 58 by the outer closure 55 in the form of a zipper that runs upward along both sides and across the top of the outer shell 51, extending along the side wall 58 in an inverted U-shape. The pack 50 also includes an inner panel 60 within the inner cavity 52 that separates the frame compartment 53 from the cargo compartment 54. The inner panel 60 may include a protective member, such as a rigid reinforcement and/or a cushioning material that is included in an internal pocket in one embodiment. The internal and external walls, panels, and other fabric structures of the pack 50 are connected by stitching in the embodiment of FIGS. 1-15.

The frame compartment 53 holds the entire frame assembly 20, such that the outer shell 51 completely encloses the frame assembly 20, and the outer shell 51 and the inner panel 60 combine to enclose the frame assembly 20 within the frame compartment 53. The frame compartment 53 is accessible from outside the pack 50 to permit the frame assembly 20 to be inserted into and removed from the pack 50, and the pack 50 may include a closure to provide reclosable access to the frame compartment 53 for this purpose. In the embodiment of FIGS. 1-15, the pack 50 includes an inner closure 61 that reclosably secures the inner panel 60 to an inner surface within the outer shell 51 to releasably separate the frame compartment 53 from the cargo compartment 54. In this configuration, opening the outer closure 55 and the flap 59 provides access to the cargo compartment 54, but the frame compartment 53 remains closed by the inner panel 60 and the inner closure 61. By releasing the inner closure 61, the frame compartment 53 becomes accessible through the rear opening 62. The inner closure 61 is a zipper with an inverted U-shaped configuration similar to the outer closure 55. Additionally, the pack 50 in FIGS. 1-15 includes an inner pocket wall 63 connected to an inner surface of the outer shell 51 and further defining the frame compartment 53. The inner pocket wall 63 in this embodiment is connected to the inner surface of the front wall 56 and/or the side wall 58 of the outer shell 51 and shaped similarly to the side wall 58, extending from the bottom wall 57 upward along both sides and across the top of the outer shell 51. In this configuration, the frame compartment 53 is defined by inner surfaces of the front wall 56 and the bottom wall 57 of the outer shell 51, as well as the inner pocket wall 63 and the inner panel 60. The inner closure 61 releasably connects the inner panel 60 to the inner pocket wall 63 around the sides and top of the inner cavity 52. It is understood that the inner panel 60 may not be a complete wall between the frame compartment 53 and the cargo compartment 54 in one embodiment, such as by the inner panel 60 having one or more gaps and/or a mesh structure, and the frame assembly 20 is still considered to be contained within the frame compartment 53 in such an embodiment.

In another embodiment, shown in FIG. 16, the pack 50 includes a second outer opening 68, which provides external access to the frame compartment 53 that is separate from the rear opening 62. The pack 50 may also include a second outer closure 69 for selectively opening and closing the second outer opening 68. The second outer opening 68 and the second outer closure 69 are illustrated as being located in the side wall 58 of the outer shell 51, along at least one side of the side wall 58. It is understood that the second outer opening 68 and the second outer closure 69 may defined in any portion of the outer shell 51, including any portion of the side wall 58, any portion of the front wall 56, or along the juncture between the front wall 56 and the side wall 58. In one embodiment, the second outer opening 68 and the second outer closure 69 may extend along both sides of the side wall 58 and across the top or the bottom of the side wall 58. In another embodiment,. The inner panel 60 may be fixed in place in such a configuration, and the inner closure 61 may not be present, as the frame compartment may be accessed through the second outer opening 68 instead. The pack 50 in this embodiment may include any features of the pack 50 of FIGS. 1-15 described herein, and the pack 50 in FIG. 16 is otherwise similar to the pack 50 of FIGS. 1-15 disclosed herein. Such similar features of the pack 50 in FIG. 16 are not described in detail herein for the sake of brevity.

The cargo compartment 54 is configured to hold one or more items of cargo, as disclosed herein, and the pack 50 may include one or more internal securing structures to secure certain items within the cargo compartment 54. For example, the pack 50 in FIGS. 1-15 has pockets 64 connected to the rear surface of the inner panel 60 and to the front surface of the flap 59 to securely hold one or more items. The pockets 64 may be closed by flaps, zippers, and similar closures in some embodiments. Other securing structures may be used in other embodiments, such as straps or flaps that limit movement of items within the cargo compartment 54.

The backpack assembly 10 may be provided with one or more shoulder straps 80 that are connected to the frame assembly 20 and/or the pack 50 and configured to be worn over the shoulders of a user, to place the backpack assembly 10 on the user's back. In the embodiment of FIGS. 1-15, the backpack assembly 10 has two shoulder straps 80 that are connected at their bottom ends to the outer shell 51 of the pack 50, e.g., by stitching, and are connected at their top ends to the frame 23. The shoulder straps 80 in this embodiment have connecting straps 82 at the top end that extend through holes 65 in the front wall 56 of the outer shell 51 and into the frame compartment 53 to connect to the frame 23, as shown in FIG. 14. The frame 23 in FIGS. 1-15 has brackets 47 at the top 33, and the connecting straps 82 loop through the brackets 47 and back out of the holes 65 to connect to brackets or clips 66, thereby creating an adjustable-length connecting structure. The shoulder straps 80 may also include other length adjustment mechanisms, padding, MOLLE strips or other attachment points, and other known accessories.

The backpack assembly 10 may also be provided with handles 81, attachment points, and other engagement structures for engagement by the user and/or equipment. For example, the backpack assembly 10 of FIGS. 1-15 has handles 81 connected to the side wall 58 of the outer shell 51 at the top and both sides of the outer shell 51 and MOLLE strips connected to the side wall 58 of the outer shell 51 on both sides of the outer shell 51 and on the outer side of the flap 59.

Assembly of the backpack assembly 10 may be accomplished by opening the outer closure 55 and the inner closure 61 to provide access to the frame compartment 53, after which the frame assembly 20 (including the lower back pad 30 and the upper back pad 31) can be inserted into the frame compartment 53. In this position, the base 24 of the frame 23 is placed against the bottom wall 57 of the outer shell 51 and the upright portion 25 extends around the inside of the periphery of the inner pocket wall 63, providing the inner pocket wall 63 and the side wall 58 of the outer shell 51 with shape stability. The shoulder straps 80 may be threaded through the holes 65 and connected to the brackets 47 of the frame assembly 20 prior to, during, or after insertion of the frame assembly 20 into the frame compartment 53. The inner panel 60 is then positioned to cover the frame compartment 53, and the inner closure 61 is closed to secure the frame assembly 20 into the frame compartment 53. Any desired items may then be inserted into the cargo compartment 54, or such insertion may be reserved for a later time. Example items 67 are shown schematically in FIG. 15. The flap 59 is then positioned to cover the cargo compartment 54, and the outer closure 55 is closed to close the cargo compartment 54 and the entire inner cavity 52. After closure, the backpack assembly 10 is ready for use by inserting the user's arms and shoulders through the shoulder straps 80 (including appropriate adjustment) and carrying. In this assembled configuration, the frame assembly 20, including the frame 23, the lower back pad 30, and the upper back pad 31, are all enclosed within the inner cavity 52 and within the frame compartment 53 thereof. Thus, in this configuration, no portion of the frame assembly 20 directly engages the user, and the frame 23 is also spaced from

Various embodiments of backpack assemblies, packs, frames, and other components thereof have been described herein, which include various components and features. In other embodiments, the backpack assembly may be provided with any combination of such components and features. It is also understood that in other embodiments, the various devices, components, and features of the backpack assembly described herein may be constructed with similar structural and functional elements having different configurations, including different ornamental appearances.

Several alternative embodiments and examples have been described and illustrated herein. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. The terms “top,” “bottom,” “front,” “back,” “side,” “rear,” and the like, as used herein, are intended for illustrative purposes only and do not limit the embodiments in any way. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention, unless explicitly specified by the claims. When used in description of a method or process, the term “providing” (or variations thereof) as used herein means generally making an article available for further actions, and does not imply that the entity “providing” the article manufactured, assembled, or otherwise produced the article. The term “approximately” as used herein implies a variation of up to 10% of the nominal value modified by such term, or up to 10% of a midpoint value of a range modified by such term. “Integral joining technique,” as used herein, means a technique for joining two pieces so that the two pieces effectively become a single, integral piece, including, but not limited to, irreversible joining techniques such as welding, brazing, soldering, or the like, where separation of the joined pieces cannot be accomplished without structural damage thereto. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claims.