Note: Descriptions are shown in the official language in which they were submitted.
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PROTECTIVE CASE AND METHODS OF MAKING
CROSS-REFERENCE TO RELATED APPLICATIONS
1100011 The present application claims foreign priority under 35 U.S.C. 5
119(e) to
commonly owned and co-pending U.S. Provisional Application No. 61/698,563,
which was filed on
September 7, 2012, the subject matter of which is incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to cases designed to
protect sensitive items
from damage and/or to provide an exterior surface that is comfortable to
touch.
BACKGROUND
[0003] Numerous different types of electronic devices currently exist for
communication,
entertainment and other purposes. These include cell phones, MP3 players,
video players,
smartphones, communication devices, such as walkie-talkies, navigation
devices, such as GPS
devices, and other types of electronic devices, such as various types of
computers, including laptop
computers, hand-held computers, ultra-mobile computers and tablet computers.
These devices often
include touch screens, interactive panels including, but not limited to,
capacitive coupled interfaces,
keyboards, scroll wheels, tilt switches, push button switches, and other
interactive controls. Due to
the sensitive nature of these electronic devices, it is desirable to provide
protection for these devices.
SUMMARY
[0004] Disclosed herein, in one embodiment, is a protective case. The
protective case
comprises a cover having a back portion and a sidewall connected to the back
portion. The cover
includes interconnected support members defined by a plurality of receiving
apertures disposed in
predetermined areas, and has a predetermined thickness. The case also includes
a liner having a
back portion and a sidewall connected to the back portion. The cover and liner
each have a
predetermined thickness. The case also includes a cushion insert with raised
impact regions
disposed adjacent to first recessed impact regions. The raised impact regions
are disposed in
predetermined areas corresponding to the plurality of receiving apertures, and
have a predetermined
thickness greater than the thickness of the cover. The cushion insert is
disposed between the cover
and the liner, such that the plurality of interconnected support members
engage with the first
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recessed impact regions, and the raised impact regions engage with the
plurality of receiving
apertures, such that the raised impact regions extend above the outer surface
of the cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the Figures, the features and advantages of the
present disclosure
will be apparent from the following more particular description of exemplary
embodiments, as
illustrated in the accompanying drawings, in which like reference characters
refer to the same parts
throughout the different views. The drawings are not necessarily to scale,
emphasis instead being
placed upon illustrating the principles of the disclosure.
[0006] FIG. 1 is a perspective front view of an exemplary protective case
according to the
present disclosure, in an assembled configuration;
[0007] FIG. 2 is perspective back view of the cover of the protective
case shown in FIG. 1;
[0008] FIG. 3 is a side view of the protective case shown in FIG. 1;
[0009] FIG. 4 is an exploded perspective view of the protective case
shown in FIG. 1;
[0010] FIG. 5 is a partial perspective cross-sectional view of the
protective case shown in
FIG. 1, through line 5-5;
[0011] FIG. 6 is an exploded view of the cross-section shown in FIG. 5;
[0012] FIG. 7A is a cross-section of one embodiment of the cushion insert
shown in FIG.
4, which is not drawn to scale;
[0013] FIG. 7B is a cross-section of another embodiment of the cushion
insert shown in
FIG. 4, which is not drawn to scale;
[0014] FIG. 8 is a perspective front view of another exemplary protective
case according to
the present disclosure, in an assembled configuration and mounted on a cell
phone;
[0015] FIG. 9 is a perspective back view of the protective case shown in
FIG. 8;
[0016] FIG. 10 is an exploded perspective view of the protective case
shown in FIG. 8;
[0017] FIG. 11 is an exploded cross-sectional view of the protective case
shown in FIG. 8;
[0018] FIG. 12 is an exploded perspective view of one section of the
protective case shown
in FIG. 8;
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[0019] FIG. 13 is an exploded perspective view of one section of the
protective case shown
in FIG. 8;
[0020] FIG. 14 is an exploded perspective view of the two sections of
shown in shown in
FIGS. 12 and 13, each in an assembled configuration;
[0021] FIG. 15 is a cross-section of screen protector and liner of the
protective case shown
in FIG. 8, mounted on a cell phone;
[0022] FIG. 16 is a cross-section of the cover and liner of the
protective case shown in FIG.
8, in an assembled configuration;
[0023] FIG. 17 is a cross-section of the protective case shown in FIG. 8;
[0024] FIG. 18 is a front view of another embodiment of a protective case
according to the
present disclosure;
[0025] FIG. 19 is an interior view of the protective case shown in FIG.
18;
[0026] FIG. 20 is a side view of the protective case shown in FIG. 8; and
[0027] FIG. 21 is a cross-sectional view of the protective case shown in
FIG. 18.
DETAILED DESCRIPTION
[0028] The present disclosure is directed to protective impact absorbing
and cushioning
structures designed to protect sensitive items from damage. The present
structures can conform to
the contours of the items to be protected, and provide an exterior surface
that is comfortable to
touch. The present structures include, in some embodiments, both raised and
recessed impact
regions of various shapes, sizes, configurations and thicknesses. Various
materials can be used for
the raised impact regions, as will be described below.
[0029] The improved cases of the present disclosure comprise
interconnected but separable
case sections that substantially conform to the outer surface of the item to
be protected. The case
can be designed to have specific functional characteristics such as, for
example, targeted impact
protection on case edges and corners. By combining specific shapes, sizes,
configurations, contours
and orientations of raised and recessed impact regions, the case can be
adapted for any type of
product that requires protection, in addition to those mentioned above.
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[0030] For example, the present cases can be adapted into sleeves or
cases that correspond
to the shape and size of an electronic device, such as a laptop computer or a
tablet device, such that
they conform to the exterior of the case. As such, the case can be formed in
shapes that would
conform at least in part to the outer surface of the encased product. The
cases described herein also
may be adapted for luggage, athletic protective gear, and the like.
[0031] The protective cases can provide lightweight and flexible impact-
resistant protection,
and can be aesthetically pleasing, more durable and lower in cost than other
cases. For ease of
discussion, the term "flexible," as used herein, means the ability of the pad
to move by bending,
twisting, flexing and/or stretching, and the like. The construction of the
present cases is rugged,
durable, and able to withstand the temperatures, detergents and mechanical
action used in industrial
and/or commercial laundering, unlike other cases, which may degrade under such
harsh conditions.
[0032] FIGS. 1-7, when taken together, show one exemplary embodiment of
the present
disclosure, which is directed to a protective case 10 for an electronic device
(not illustrated), such as
a media device or cell phone. Although described herein with reference to a
protective case for an
electronic device, as noted above, the protective case may be adapted to any
product that requires
protection or that is designed to provide protection. For ease of reference,
in all of the
embodiments disclosed herein, the electronic device will be referred to
hereinafter as a cell phone.
[0033] Case 10 is shown in an assembled configuration in FIG. 1, and in
an exploded view
in FIG. 4. As shown, case 10 comprises a cover 12, a cushion insert 30, and a
liner 40, which may be
interconnected when assembled, as shown in FIG. 1, but are otherwise separable
from one another,
as shown in FIG. 4. In the present embodiment, cover 12, cushion insert 30 and
liner 40 are each
single, unitary parts, but if desired, each may be formed as two or more
separable but interlocking
parts that can be assembled together and/or onto the surfaces of the cell
phone.
[0034] Cover 12 may be constructed to conform to the exterior surface of
at least a portion
of the cushion insert 30. Cover 12 comprises a back section 14 and a sidewall
16 extending upwardly
from the back section 14. Each of the back section 14 and sidewall 16 comprise
opposing inner
surfaces 14a, 16a and outer surfaces 14b, 16b respectively.
[0035] One or both of the back section 14 and sidewall 16 comprises a
plurality of receiving
apertures 22 extending from the inner surfaces 14a, 16a to the outer surface
14b, 16b, to define a
plurality of interconnected support members 24 disposed between the receiving
apertures 22.
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[0036] The cover 12 may be formed of a substantially rigid, semi-rigid
and/or flexible
material, and has a size and configuration corresponding to the cell phone.
When rigid or semi-
rigid, it may be desirable for the cover 12 to comprise two or more separable
but interlocking parts
that can be assembled onto the front and rear surfaces of the cell phone. The
cover 12 can be made
from a material that is capable of stretching sufficiently to allow the
electronic device to slide into
the front opening 20 of the cover 12 while maintaining the form-fitting shape
of the cover 12.
Suitable materials include, but are not limited to, a variety of thermoset
materials, such as synthetic
rubber, silicon, urethane and other materials. The density and elasticity of
the cover 12, as well as
the pre-forming of the cover 12 to fit the shape of electronic device, allows
the material of the cover
12 to both stretch and recover so that the cushion cover fits tightly on the
electronic device. In the
present embodiment, cover 12 is a unitary pre-formed elastomeric material that
is flexible and
capable of stretching sufficiently to allow the electronic device to slide
easily into and be removed
from case 10. The cover 12 has sufficient elasticity to stretch over the
electronic device, and to
recover so that the cover fits snugly over the cushion insert and on the
electronic device, such that
the case 10 conforms to the electronic device. The cover 12 can be formed
using a variety of
techniques and processes suitable for processing the foregoing materials,
which are known in the art.
[0037] In the present embodiment, cover 12 has a predetermined thickness
T1 that is
selected to be less than the thickest section of the cushion insert T2, as
will be described below. In
the present embodiment, the thickness T1 ranges from about 0.050" to about
0.090", more
particularly about 0.060" to about 0.080", more particularly still about
0.075".
[0038] The liner 40 may be constructed to conform to the interior surface
of at least a
portion of cover 12 and cushion insert 30. The liner comprises a back section
44, a sidewall 46
extending upwardly from the back section 44, and a bezel 48 extending
outwardly from the sidewall
46 to define the front opening 20.
[0039] The liner 40 may be formed of a substantially flexible material,
and has a size and
configuration corresponding to the cell phone. The liner 40 can be made from
any of the materials
described above with reference to the cover 12, provided the material is
capable of stretching
sufficiently to allow the electronic device to slide into the front opening 20
of the liner 40 while
maintaining the form-fitting shape of the liner 40. In the present embodiment,
liner 40 is unitary,
and can comprise an elastomeric material as described above with reference to
the cover 12, which is
flexible and capable of stretching sufficiently to allow the electronic device
to slide easily into and be
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removed from liner 40. The liner 40 has sufficient elasticity to stretch over
the electronic device,
and to recover so that the cover fits snugly over the cushion insert and on
the electronic device,
such that the liner 40 and therefore the case 10 conforms to the electronic
device. The density and
elasticity of the liner 40, as well as the pre-forming of the liner 40 to fit
the shape of electronic
device, allows the material of the liner 40 to both stretch and recover so
that the cushion cover fits
tightly on the electronic device. The liner 40 can be formed using a variety
of techniques and
processes suitable for processing the foregoing materials, which are known in
the art.
[0040] The cushion insert 30 may be constructed to conform to at least a
portion of the
outer surface of the liner. The cushion insert 30 may be formed from a variety
of materials, such
that it has a size and configuration corresponding to a portion of the inner
surface of the cover and
a portion of the outer surface of the liner, and a thickness that allows it to
fit between the inner
surface of the cover and the outer surface of the liner 40.
[0041] FIG. 7 shows an exemplary embodiment of cushion insert 30, which
comprises
spaced apart top and bottom surfaces 30a,b and a plurality of raised impact
regions 32 disposed
adjacent to first recessed impact regions 34. The raised impact regions 32 are
defined in and extend
upwardly from the top surface 30a, and are disposed in predetermined areas
corresponding to the
plurality of receiving apertures 22 and having a width 1,1, which may vary as
desired, and a
predetermined thickness T2 that is selected to be greater than the thickness
T1 of the cover 12. In
the present embodiment, the width 1,1 of the raised impact regions 32 is about
0.200" to about
0.400", more particularly about 0.250" to about 0.350", and more particularly
still about 0.305"; and
the thickness T2 ranges from about 0.150" to about 0.350", more particularly
about 0.200" to about
0.300", more particularly still about 0.240".
[0042] Raised impact regions 32 are spaced apart from one another by first
recessed impact
regions 34. First recessed impact regions 34 have a width 1,2, which may vary
as desired, and a
predetermined thickness T3, which is selected to be less than the thickness T2
of the raised impact
regions 32. In the present embodiment, the width 1,2 of the first recessed
regions 34 is about
0.100" to about 0.200", more particularly about 0.130" to about 0.170", and
more particularly still
about 0.150"; and the thickness T3 ranges from about 0.025" to about 0.045",
more particularly
about 0.030" to about 0.040", and more particularly still about 0.035".
[0043] The cushion insert 30 also may comprise one or more second recessed
impact
regions (not illustrated) that correspond to the contours, edges and/or
corners of the cell phone, to
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facilitate bending and/or flexing of the cushion insert 30 into the contours,
edges and/or corners of
cover 12. When present, the second recessed impact regions 36 have a width
1,3, which may vary as
desired, and a predetermined thickness T4, which is selected to be less than
the thickness 7'3 of the
first recessed impact regions 36. In the present embodiment, the width 1,3 of
the second recessed
regions 36 is about 0.080" to about 0.200", more particularly about 0.100" to
about 0.170", and
more particularly still about 0.132"; and the thickness T3 ranges from about
0.010" to about 0.030",
more particularly about 0.015" to about 0.025", and more particularly still
about 0.020". When
assembled, the raised impact regions 32 protrude or extend above the outer
surface of cushion insert
30 by a distance D1, as shown in FIG. 5.
[0044] All of the foregoing thicknesses, widths, distances and spacings
may vary, as desired.
[0045] In the present embodiment, the raised impact regions 32 comprise
an upper surface
32a and sidewalls 32b extending downwardly therefrom. The raised impact
regions 32 may have
any thickness sufficient to provide a protective or comfortable effect, by
protruding above the
exterior surface of the cover 12. Thus, for certain functional advantages, the
thickness of the raised
impact regions 32 may be designed to protrude above the outer surface of the
case, when in an
assembled configuration. For example, in the present exemplary cell phone
device case 10, when
assembled, the raised impact regions 32 may protrude or extend above the outer
surface 12a of the
cover 12 by about 1/16 inch to about 1/2 inch. If desired or needed, and as
shown in the present
embodiment, the cushion insert 30 also can comprise raised impact regions 32
designed to protrude
through the sidewall or the bezel to protect the edges and/or screen from an
impact.
[0046] The raised impact regions 32 may have any shape or configuration
as is desired to
achieve the functional advantage of impact protection, or the aesthetic design
intended to appeal to
a consumer. The size, shape, quantity, configuration and location of the
raised impact regions may
be varied as desired in order to achieve the foregoing objectives. For
aesthetic purposes, the color
of the cover and cushion insert may be the same or different, and also may
include text and/or
graphics.
[0047] Each of the cover 12, liner 40 and insert 30 may comprises one or
more raised keys
28 that correspond in shape, size and location to the size, shape and location
of smaller functional
keys or ports (also not illustrated herein) to which access may be limited due
to the thickness of the
case, to allow the user to maintain functional access without removing the
case from the electronic
device. Examples of such smaller functional keys include, but are not limited
to, power and volume
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keys. Raised keys 28 should not be confused with the raised impact regions 32,
which are intended
to absorb impacts.
[0048] Similarly, each of the cover 12, liner 40 and insert 30 may
comprise one or more
functional apertures 26 or holes that correspond in shape, size and location
to the size, shape and
location of various functional keys, ports, devices or other items that may be
included on the
electronic device (none of which are illustrated herein), to keep such items
free of obstruction.
Examples of such functional keys include, but are not limited to, charging
ports, speakers, auxiliary
ports, power keys, camera lenses, and the like.
[0049] The cushion insert 30 also optionally may comprise one or more
perforations (not
illustrated) formed in the second recessed impact regions, or elsewhere as
desired, to facilitate ease
and conformance of the cushion insert 30 between the cover 12 and liner 40.
[0050] To assemble the case, the cushion insert 30 may be inserted into
cover 12 such that
the raised impact regions 32 are aligned with the receiving apertures 22 such
that the raised impact
regions 32 are received into and extend at least partially therethrough the
corresponding receiving
apertures 22, and a portion of the raised impact regions 32 extends above the
upper surface 12a of
the cover 12.
[0051] When assembled, the raised impact regions 32 protrude from the
corresponding
receiving apertures 22 on the cover 12, and the first recessed impact regions
34 between the raised
impact regions 32 are disposed underneath the support members 24, between the
raised impact
regions 32. The protruding raised impact regions 32 function at least to
protect the cover and
electronic device from impact, and the first and second recessed impact
regions 34 disposed
underneath the cover 12 also absorb energy through the material disposed
between the device and
the cover. Thus, the case 10 provides impact resistance and energy absorption,
as a result of the
externally exposed raised impact regions 32 and portions of the cushion insert
30 that are disposed
underneath the cover 12, adjacent to the electronic device. Although
illustrated herein with receiving
apertures 22 adapted to receive raised impact regions 32 therein, cover 12
also can be formed to
comprise recessed regions 38, rather than apertures, to receive the raised
impact regions 32 therein.
[0052] FIGS. 8-17, when taken together, show another exemplary embodiment
of a
protective case 100 according to the present disclosure. As in the previous
embodiment, although
described herein with reference to a protective case for an electronic device,
the protective case may
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be adapted to any product that requires protection or that is designed to
provide protection. For
ease of reference, the electronic device will be referred to hereinafter as a
cell phone.
[0053] As shown, case 100 comprises a cover 12', a cushion insert 30, and
a liner 40', which
may be interconnected when assembled, but are otherwise separable from one
another. In the
present embodiment, cover 12', cushion insert 30, and liner 40', are each
single, unitary parts, but if
desired, each may be formed as two or more separable but interlocking parts
that can be assembled
together and/or onto the surfaces of the cell phone.
[0054] Cushion insert 30 has the same construction as in the previous
embodiments.
[0055] Liner 40' may be constructed to conform to the interior surface of
at least a portion
of cover 12' and cushion insert 30. The liner 40' comprises a back section 44,
a sidewall 46
extending upwardly from the back section 44, and a bezel 48 extending
outwardly from the sidewall
46 to define the front opening 20.
[0056] Cover 12' comprises a back section 14, sidewalls 16 extending
upwardly from the
back section 14, and one or more retaining arms 70 extending inwardly from one
or more of the
sidewalls 16. Each of the back section 14 and sidewall 16 comprise opposing
inner surfaces 14a, 16a
and outer surfaces 14b, 16b respectively.
[0057] When assembled, the retaining arms 70 assist in retaining the
bezel 48 and liner
against the cell phone when the cell phone is disposed in the protective case.
[0058] FIGS. 18-21, when taken together, show another exemplary
embodiment of a
protective case 200 according to the present disclosure.
[0059] As shown, case 200 comprises a cover 12 and a cushion insert 30,
and an optional
liner 40 (not illustrated). In the present embodiment, cover 12, cushion
insert 30 and optional liner
40 are each single, unitary parts, but if desired, each may be formed as two
or more separable but
interlocking parts that can be assembled together and/or onto the surfaces of
the cell phone.
Cushion insert includes receiving apertures 22 in which raised impact regions
32 have been disposed,
to provide improved protection on the front or screen side of the cell phone.
The raised impact
regions can comprise part of a cushion insert 30 that conforms to the interior
of the cover, as in
previous embodiments, or they can be individual regions that are disposed in
the receiving apertures.
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[0060] Optionally, in any of the foregoing embodiments, two or more of
the cover, liner
and inserts may be co-molded, welded, bonded or adhered together using a
variety of techniques.
[0061] The thickness of cushion insert 30 may be varied as desired, but
it is desirable for the
thickness to be sufficient to protect the device from impact, while remaining
thin enough to
minimize the total weight of the case
[0062] Various other materials and layers may be used to form the
cushioning inserts, as
described in commonly-owned and co-pending U.S. Application No. 13/447, 093,
which was filed
on April 13, 2012, and is incorporated herein by reference in its entirety.
Other materials for and
methods of making materials that are useful for the cushion inserts are
disclosed in commonly
owned and co-pending U.S. Patent Application Nos. 13/208,229, filed on August
11, 2011; and
13/271,594, filed on October 12, 2011, each of which is incorporated herein by
reference in its
entirety. One desirable construction for the cushion inserts 30 includes a
cushioning layer disposed
between opposing upper and lower layers, and optional fabric layer, as
described in the foregoing
applications.
[0063] In addition to the foregoing, suitable materials for the foregoing
layers and the
adhesive (if used) are disclosed in the afore-mentioned patent applications,
and in U.S. Publication
Nos. US 2008/0034614 and US 2009/0255625, which also disclose techniques for
manufacturing
the present cushion inserts; each of the foregoing publications is
incorporated herein by reference in
its entirety. The molds for the present pads are designed to allow layers to
be compressed together
under conditions sufficient to minimize or eliminate the foam in the recessed
impact regions, for
certain embodiments, while allowing the layers to bond together.
[0064] Advantages of the present improved cases include, but are not
limited to, improved
impact protection, particularly on case edges and corners, lighter weight,
improved aesthetics, lower
manufacturing costs, and less abrasion to the encased article. The improved
cases of the present
disclosure comprise separable inner and outer interconnected parts that
substantially conform to the
outer surface of an article to be protected. The protective cases can be
adapted for any type of
product that requires protection, in addition to those mentioned above.
[0065] Compounds are described using standard nomenclature. For example,
any position
not substituted by an indicated group is understood to have its valency filled
by a bond as indicated,
or a hydrogen atom A dash ("-") that is not between two letters or symbols is
used to indicate a
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point of attachment for a substituent. For example, - CHO is attached through
carbon of the
carbonyl group. Unless defined otherwise herein, all percentages herein mean
weight percent
("wt.%"). Furthermore, all ranges disclosed herein are inclusive and
combinable (e.g., ranges of "up
to about 25 weight percent (wt.%), with about 5 wt.% to about 20 wt.% desired,
and about 10 wt.%
to about 15 wt.% more desired," are inclusive of the endpoints and all
intermediate values of the
ranges, e.g., "about 5 wt.% to about 25 wt.%, about 5 wt.% to about 15 wt.%",
etc.). The notation
means that the indicated measurement may be from an amount that is minus 10 A
to an
amount that is plus 10% of the stated value.
[0066] Finally, unless defined otherwise, technical and scientific terms
used herein have the
same meaning as is commonly understood by one of skill in the art to which
this disclosure belongs.
[0067] While the disclosure has been described with reference to an
exemplary
embodiment, it will be understood by those skilled in the art that various
changes may be made and
equivalents may be substituted for elements thereof without departing from the
scope of the
disclosure. In addition, many modifications may be made to adapt a particular
situation or material
to the teachings of the disclosure without departing from the essential scope
thereof. Therefore, it is
intended that the disclosure not be limited to the particular embodiment
disclosed as the best mode
contemplated for carrying out this disclosure, but that the disclosure will
include all embodiments
falling within the scope of any appended claims.
[0068] What is claimed is:
