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Support skeleton for a juvenile transport product and methodSupport skeleton for a juvenile transport product and method description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070145799, Support skeleton for a juvenile transport product and method. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION [0001] This invention relates generally to a juvenile transport product system, and more particularly to a support skeleton for a juvenile product system that includes an infant carrier of improved construction that is optionally mountable, for example, to a stroller and/or a stay-in-the-car base. The system includes several features that collectively provide a juvenile product system with enhanced comfort and safety features. While the particular exemplary embodiment disclosed in this application is of an infant carrier, the inventive features of the system have application in other juvenile seating and transportation products, such as child safety seats, booster seats, strollers, and carriages. [0002] Infant carriers typically include an impact polymer shell and a shock absorbing component interior. Conventional infant carriers are relatively heavy, contain fragile shock attenuating component parts, and are awkward to carry. Prior art juvenile seats such as infant carriers often include an impact polymer shell and a shock-absorbing component interior. This structure has been used for many years to provide a reasonable compromise among strength, durability, economy and weight considerations. [0003] The present application discloses a novel method of fabricating an infant carrier by injection-molding the infant carrier body out of foam with a load-bearing skeleton embedded within the foam. The resulting structure is a rigid, lightweight body that meets and exceeds all applicable safety standards for such juvenile seating products. [0004] Since the foam body of the novel infant carrier disclosed herein is not outwardly attractive in appearance and is not by itself durable enough for everyday use, a cover or shell is provided to both protect and decorate the foam body of the infant carrier. However, the disadvantage of using a hard plastic shell of the type typically used on prior art infant carriers is that such a hard plastic shell would add an unacceptable amount of weight to the infant carrier, when one of the objects of the invention is to provide a carrier that is as light as possible. [0005] Another disadvantage of the hard plastic shell found on prior art carriers is that it is difficult to apply decoration to its surface. Typically, decoration is accomplished by coloring the plastic compound used to form the shell, painting the outside of the shell, or by applying decalcomanias. Multicolored plastic shells are more expensive, do not provide as many design options, and may be easily scratched and soiled, thereby detracting from the attractiveness of the shell. Painted shells can also be easily scratched and soiled through normal use, quickly becoming unattractive with an undesirable worn look. Even when new, paint of the type typically used gives the shell a rather lusterless, unattractive appearance. Similarly, decalcomanias may peel off or be scratched, also resulting an a worn, unattractive appearance. [0006] The present invention relates to an improved infant carrier construction that provides an infant carrier suitable for use as an automotive safety restraint and having reduced weight and improved aesthetics as compared to conventional infant carriers. The invention is therefore directed to a comfortable, lightweight, protective infant carrier preferably made from a process of insert molding. The infant carrier includes a skeleton, or insert portion, made of a substantially rigid material that is embedded into the central portion of the infant carrier to act as the load bearing, structural component. The skeleton also serves several other functions including functioning as a hard point for securing attachments to the infant carrier, such as adjustment mechanisms, carrying handles and the like. In addition, the skeleton can include cavities or protrusions for coupling the retention system of the infant carrier to the stay-in-the-car base or stroller. In another embodiment of the invention, the skeleton forms one component of a built-in belt lock off used to prevent belt slippage when the infant carrier is used without the base. [0007] The skeleton is embedded within a shock attenuating, lightweight molded material that may be a suitable open or closed-cell foam. The lightweight molded material can replace other shock attenuating components while being contoured to better fit the seat occupant for improved comfort. A shell is provided for covering the exterior of the infant carrier for improved aesthetics and durability. SUMMARY OF THE INVENTION [0008] Therefore, it is an object of the invention to provide a skeleton for an improved infant carrier that provides enhanced safety features. [0009] It is another object of this invention to provide a skeleton for an infant carrier that is substantially rigid and capable of withstanding substantial loading. [0010] It is yet another object of the invention is to provide an infant carrier that weighs less than conventional infant carriers. [0011] It is a further object of the invention is to provide an infant carrier with improved comfort and aesthetic features. [0012] It is another object of the invention to provide an infant carrier that is economical to produce and convenient to use. [0013] It is another object of the invention to provide an infant carrier that easily attaches to and detaches from another structure such as a seat base or stroller. [0014] It is another object of the invention to provide an infant carrier with an external shell that protects the underlying components of the carrier. [0015] It is another object of the invention to provide an infant carrier that is resists soiling and is easy to clean. [0016] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a juvenile transport product, comprising a load-bearing support skeleton for rigidly supporting the juvenile transport product in a predetermined configuration, and a foam body molded to the skeleton and supported thereby. The foam body preferably has a shape generally corresponding to the shape of the juvenile transport product. A protective cover shell is adhered to the foam body to protect the foam against damage from wear and impacts. [0017] According to one preferred embodiment of the invention, the support skeleton is formed of an openwork structure defined by integrally-formed support members and weight-reducing voids. [0018] According to another preferred embodiment of the invention, the support skeleton is formed from a material selected from the group consisting of carbon fibers, plastics, resins and combinations of carbon fibers, plastics and resins. [0019] According to yet another preferred embodiment of the invention, the support skeleton comprises first and second side components and an intermediate component adapted to be secured between the first and second side components to form a unitary skeleton. [0020] According to yet another preferred embodiment of the invention, the juvenile transport product comprises an infant carrier, and the support skeleton comprises first and second infant carrier side components and an intermediate seat component adapted to be secured between the first and second side components to form a unitary infant carrier skeleton. [0021] According to yet another preferred embodiment of the invention, the juvenile transport product comprises an infant carrier, and the support skeleton comprises an integrally-formed, unitary infant carrier skeleton. [0022] According to yet another preferred embodiment of the invention, the body comprises foam selected from the group consisting of open cell foam and closed cell foam. Continue reading about Support skeleton for a juvenile transport product and method... 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