Synthetic rubber wallet and related methods of manufacture

Abstract

A wallet comprises first and second panels formed of a synthetic rubber material such as neoprene. The first and second panels are stitched together at their edges to form a container having dimensions suiting to receiving cards, such as credit cards or business cards. An opening is formed across a longitudinal direction of the second panel to allow cards to be inserted to and removed from the wallet.

1 . A wallet, comprising:
 a first panel formed of a synthetic rubber material and having a transverse length and a longitudinal length greater than the transverse length;   a second panel formed of a synthetic rubber material and having a transverse length and longitudinal length substantially the same as the first panel, the second panel having outer edges attached to outer edges of the first panel; and   a slit formed in the second panel along its longitudinal length to create an opening allowing items to be securely inserted between the first and second panels.   
     
     
         2 . The wallet of  claim 1 , wherein the edges of the first panel are attached to the edges of the second panel by sewing. 
     
     
         3 . The wallet of  claim 1 , further comprising a loop attached to the outer edges of the first and second panels. 
     
     
         4 . The wallet of  claim 1 , wherein the longitudinal length of the first and second panels is within a range of about 90-110 mm, and the transverse length of the first and second panels is within a range of about 75-85 mm. 
     
     
         5 . The wallet of  claim 1 , wherein the first and second panels each have rounded corners extending about 15-20 mm from straight edge portions of the first and second panels. 
     
     
         6 . The wallet of  claim 1 , wherein the synthetic rubber material is neoprene. 
     
     
         7 . The wallet of  claim 1 , further comprising a design pattern imprinted in the first or second panel by melting. 
     
     
         8 . The wallet of  claim 1 , wherein the slit has heat-treated inner edges. 
     
     
         9 . The wallet of  claim 2 , wherein the sewn edges of the first and second panels are turned inside the opening of the wallet. 
     
     
         10 . A method of forming a wallet, comprising:
 attaching a rectangular shaped first panel formed of a synthetic rubber material to a rectangular shaped second panel formed of a synthetic rubber material; and   forming a slit along a longitudinal length of the second panel to create an opening allowing items to be securely inserted between the first and second panels.   
     
     
         11 . The method of  claim 10 , wherein attaching the first panel to the second panel comprises sewing the outer edges of the first panel to the outer edges of the second panel. 
     
     
         12 . The method of  claim 11 , wherein the sewing is performed by an automated sewing machine based on pre-programmed sewing instructions. 
     
     
         13 . The method of  claim 11 , further comprising:
 reconfiguring the attached first and second panels such that the sewn outer edges are located inside the opening.   
     
     
         14 . The method of  claim 10 , wherein the synthetic rubber material is neoprene. 
     
     
         15 . The method of  claim 10 , further comprising:
 inserting the wallet inside a shipping envelope using an automated packaging machine.   
     
     
         16 . A method of forming a wallet, comprising:
 feeding first and second sheets of synthetic rubber material through a tensioning apparatus to an automated sewing machine;   operating the sewing machine to attach a portion of the first and second sheets together with a rectangular stitching pattern defining a wallet outline;   cutting the first and second sheets along the wallet outline to create a rectangular pouch comprising first and second panels sewn together by the rectangular stitching; and   forming a slit along a lengthwise direction of the second panel.   
     
     
         17 . The method of  claim 16 , wherein the synthetic rubber material is neoprene. 
     
     
         18 . The method of  claim 16 , wherein cutting the first and second sheets comprises applying laser light to the first and second sheets along the wallet outline. 
     
     
         19 . The method of  claim 16 , further comprising:
 inserting the rectangular pouch with the slit into a shipping envelope using an automated packaging machine.   
     
     
         20 . The method of  claim 16 , wherein the rectangular pouch has a longitudinal length within a range of about 90-110 mm and a transverse length within a range of about 75-85 mm, and rounded corners; and
 wherein the slit is located at a distance of about 20-30 mm from a longitudinal edge of the rectangular pouch.