FLEXIBLE IMPACT PROTECTIVE CASES, METHODS OF MAKING AND METHODS OF USING

TECHNICAL FIELD

The disclosure relates to flexible impact protective cases and methods of making

BACKGROUND

Protective cases for sensitive equipment, devices or instruments are usually designed with padding on the interior or exterior, or both. Many times the padding is formed of continuous sheets of protective materials, such as neoprenes, foams and/or laminated materials, and the like. Such cases often do not offer sufficient protection from impact, vibration, and the like. Protection for the devices may be improved by using thicker materials, but increasing the thickness may not be desirable due to the added bulk or weight. Moreover, increased weight and bulk may be undesirable for streamlined electronic devices, for which users usually pay a premium in order to obtain slim and/or lightweight products.

Many electronic devices have a screen interface used to display information to users, so it is necessary to expose the screen during use. However, screen interfaces are known to be delicate, tending to break easily when dropped or otherwise impacted.

Portable electronic devices, such as laptop computers, or medical equipment, also have screen interfaces, and to protect the screen interface, such devices often include a hinged protective cover that provides some protection from dropping or impact, when not in-use. However, many cell phones, media devices, and tablet-style computers or netbooks do not include such covers. Therefore, a screen or edge impact can easily cause severe damage to the screen and/or device. In addition, some devices, such as iPad devices, are very thin and delicate, which exacerbates their ability to withstand an impact. As a result, many companies now manufacture covers, cases and shells that can be purchased separately from the devices, which tends to fall into a few different categories.

One type of case is a rigid plastic shell, which may include internal or external padding, such as rubber or silicone. Although the rigid shells offer some protection, there are some disadvantages. First, the shells are made for specific device sizes and configurations, and therefore cannot be used for “next-generation” devices, such as when a device is upgraded or changed. Also, a store must stock multiple stock-keeping units (“SKU(s)”) to accommodate the range of devices of even a like kind. Another disadvantage is that such rigid shells, even with some soft added elements, may not protect well against a drop of the face or open screen. Even devices that include a protective bezel do not absorb energy, unless made very thick, so a drop on the screen side may result in a broken screen. Another type of case is a soft “skin,” generally made of rubber, silicone or other thermoplastic elastomeric (“TPE”) material. Like rigid plastic shells, skins are made for specific device sizes and configurations, and therefore cannot be used for “next-generation” devices. Other disadvantages are that they are generally thin, and therefore provide only minor impact protection and mostly scratch protection. They also may not be able to protect the device from a significant drop on the screen side, from corner or edge drops, and they offer no torsional protection if the devices bends or twists on impact.

Another type of case is a portfolio-style case, to which the electronic devices may be attached using clips, elastic bands or other features. However, these types of cases do not provide screen side impact protection, and generally offer little impact protection.

There is a need for an improved case for sensitive equipment, devices or instruments, which is lightweight, flexible and provides improved impact protection, particularly for exposed screen or “in-use” devices, and which is not specific to one device size, but instead can accommodate a range of device sizes.

SUMMARY

The present disclosure is directed to, in one embodiment, a protective case for a device. The case comprises a flexible structural panel comprising a panel interior surface and a panel exterior surface. One of the structural panel interior and exterior surfaces comprises an extensible material, and one of the structural panel interior and exterior surfaces comprises a non-extensible material. At least one flexible retaining device is disposed on the panel interior surface. The at least one flexible retaining device comprises a layer of a rate dependent material disposed between an extensible inner material layer and an non-extensible outer material layer.

Some embodiments comprise a cover defining an inner cover surface, an outer cover surface, and opposing first and second cover edges, the cover being interconnected to the structural panel at the first edge. In some embodiments, the cover can comprise an optional protective element. Some embodiments can comprise fastening devices to maintain the cover in a closed position, and to position the case as an easel.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent from the following more particular description of exemplary embodiments of the disclosure, 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.

FIG. 1 is a front perspective view of one embodiment of a single-panel protective case according to the present disclosure;

FIG. 2 is a front view of the protective case shown in FIG. 1;

FIG. 3 is a back view of the protective case shown in FIG. 1;

FIG. 4 is a top view of one embodiment of a molded panel that can be used to form the case shown in FIG. 1;

FIG. 5 is a cross-sectional view of the sheet shown in FIG. 4, through line 5-5, showing the thickness of the stitching channel;

FIG. 6 is a cross-sectional view of the sheet shown in FIG. 4, through line 5-5, showing the width of the stitching channel;

FIG. 7 is a perspective view of one of the corner-retaining devices shown on the protective case of FIG. 1;

FIG. 8 is a cross-sectional view of the corner-retaining device shown in FIG. 7, through line 8-8;

FIG. 9 is a cross-sectional view of the corner-retaining device shown in FIG. 7, through line 9-9;

FIG. 10 is a front perspective view of the protective case shown in FIG. 1, showing an electronic device retained in the case by the corner-retaining devices;

FIG. 11 is a cut-away side view of the protective case and device shown in FIG. 10, showing the curvature of the case, and the open space between the interior surface of the case and the back surface of the electronic device;

FIG. 12 is a front perspective view of another embodiment of a one-sided protective case according to the present disclosure;

FIG. 13 is a front view of the protective case shown in FIG. 12;

FIG. 14 is a back view of the protective case shown in FIG. 12;

FIG. 15 shows a perspective view of another embodiment of a portfolio-style case according to the present disclosure, shown in a closed position;

FIG. 16 is a perspective view of the portfolio-style case shown in FIG. 15, in an open position;

FIG. 17 is a front perspective view of the protective case shown in FIG. 16, showing an electronic device retained in the case by the corner-retaining devices;

FIG. 18 is an exterior, open view of the another embodiment of a protective case according the present disclosure;

FIG. 19 is an interior, open view of the case shown in FIG. 18;

FIG. 20 is a front perspective view of the case shown in FIG. 18, in a closed configuration;

FIG. 21 is a front perspective view of the case shown in FIG. 18, in a closed configuration;

FIG. 22 is a front view of the protective case shown in FIG. 18;

FIG. 23 is a back view of the protective case shown in FIG. 18;

FIG. 24 is a front perspective view of the case shown in FIG. 21, in an “in-use” configuration;

FIG. 25 is a perspective view of the case shown in FIG. 30, in use on a user's thigh;

FIG. 26 is a perspective view of the case shown in FIG. 21, in an easel configuration;

FIG. 27 is a perspective view of another embodiment of a protective case according to the present disclosure, with a magnetic closure;

FIG. 28 is a perspective view of the protective case shown in FIG. 327 in an open position, showing the exterior surface;

FIG. 29 is a perspective view of the protective case shown in FIG. 27 in an open position, showing the interior surface;

FIG. 30 is a cross-section of the cover portion of the protective case shown in FIG. 27, through line 30-30;

FIG. 31 shows a perspective view of another embodiment of a case according of the present disclosure, which is a sleeve-style case, shown in a closed position;

FIG. 32 shows an expanded schematic side view of the zipper attachment and formation of the interior bumper of the case in FIG. 31; and

FIG. 33 shows an expanded cross-section side view of a device disposed the case shown in FIG. 31, showing the device resting in the bumper.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present disclosure is directed to a protective case that allows full access to the device while the device is in the case and in-use, as well as protection for impacts to the front, back and sides of a device. Thus, the present case provides improved protection for devices with screen interfaces, as are found in many electronic and medical devices.

The present cases are lightweight, flexible and provide improved impact protection, particularly for exposed screen or “in-use” devices. The present cases protect the corner and edges of devices, as well as provide torsional protection against the device twisting or bending upon impact. In addition, due to the flexible construction of the case, it is not specific to one device size, but instead may accommodate a range of device sizes. The case is also comfortable to hold and carry, due to its flexibility. The case may also be used in a kneeboard or other body attachment with comfort, due to its flexibility.

The present case has the further advantage of being capable of accommodating a range of device shapes. Therefore, the cases can be designed and used for any type of sensitive device or item that may need protection, such as musical instruments, wine and liquor bottles, crystal, and the like.

The present cases and methods of making provide improved impact protection, lighter weight, reduced bulk, improved aesthetics, reduced manufacturing costs, improved fit, and less abrasion to the contained article. Moreover, in some instances, the cases can be hygienic, as they may be designed so as to be able to be washed and to also withstand the high temperatures and caustic chemicals used in commercial-grade laundering.

FIGS. 1-11, when taken together, show one embodiment of an exemplary protective case 10 according to the present disclosure. As shown, case 10 comprises a perimeter “P” and opposing front and back sides 12,14, each with corresponding front and back surfaces 12a, 14a. A retaining device 30 is disposed in each corner of the panel 20 (hereinafter “corner-retaining device(s) 30). In the present embodiment, the retaining devices 30 each have a substantially triangular shape, and are positioned in the corners of the case 10. However, those of ordinary skill in the art will recognize that it is not necessary for the retaining devices to have a triangular shape, and that any quantity, shape, location and/or configuration of retaining devices may be selected, and that the retaining devices may be positioned elsewhere. For example, an alternative configuration for the retaining device 30 may comprise a single retaining device shaped like a bezel (not illustrated) extending around case 10, extending inwardly from the perimeter by a width sufficient to retain a device in the case. Another alternative may comprise disposing one or more retaining devices 30 on the sides, such as on each of the four sides, or at multiple points along the sides, or a combination of corners and sides. The retaining devices may be positioned in order to grip the device, while providing access to, and not obscuring, the ports, controls, and screen area.

In addition, and an optional binding 40 may be disposed around the case 10, for functional and aesthetics reasons.

Case 10 also may comprise a plurality of access ports to provide access to various functional devices on the device and/or to external devices, such as battery chargers, audio ports, camera lenses, and the like. The access ports may be disposed in any location, as desired, to correspond with the location of such features as found on commercial electronic devices. In the present embodiment, case 10 comprises an audio port 50 that extends through one of the corner-retaining devices 30, and a camera port 60 that extends through the panel 20. Camera port 60 is disposed on a planar, raised pad 65 formed in the case, which is adapted to press against the backside of the device when in use. If desired, the camera port 60 may comprise a film (not illustrated) integrated into the port, to minimize or eliminate debris from entering the port. Also if desired, pad 65 may comprise a recessed region (not illustrated) disposed around the camera port 65, for receiving the film, which can be attached to the pad by, for example, welding, and the like. If a film is used, is may be desirable to use a non-yellowing optical film that can withstand laundering.

Alternatively, or in addition to, the case edges, including the binding can be flexed in order to expose and provide access to the various functional devices. This is an important feature, because the edges of the case (with or without binding) comprise the rate dependent foam, which leaves the edges of the device fully protected when in use, but also capable of being bent or folded in order to easily to accommodate, for example, the charge cable, etc.

Panel 20 may be formed from a variety of materials. Suitable materials and methods of making the panels are disclosed in U.S. Publication Nos. 2007/0261274, 2008/003614, 2009/0255625, the subject matter of which is incorporated herein by reference in its entirety. The foregoing applications describe methods that can be used to mold the panels and retaining devices, and the molds for the panels and retaining devices can be designed to compress the layers together under conditions sufficient to minimize or eliminate the foam in the channels, while allowing the layers to bond together, either with a chemical or thermal bond, or both.

In some embodiments, panel 20 may comprise a structural material, and additionally may comprise one or more layers of a variety of materials with different aesthetic and functional characteristics, and which may be varied as needed or desired for a particular application or design.

“Structural material,” as used herein, means any material having sufficient structural integrity to be formed into predetermined shapes, sufficient strength to weight ratio to provide structure to the case, and that is capable of withstanding the environment in which it is intended to be used.

The structural material may comprise a variety of materials such as, but not limited to, polymeric materials, including foamed polymeric materials, composite materials, and the like. In one exemplary embodiment, the structural material can comprise a rate dependent material. Examples of rate dependent materials include, but are not limited to, d3O and Poron XRD. One exemplary structural material is a rate dependent foam available from Rogers Corporation under the product name Poron XRD®. In the present exemplary embodiment, the Poron XRD® foam density may range from between about 1 and about 40 pounds per cubic foot (“pcf”), more particularly from about 5 to about 30 pcf, more particularly from about 1 to about 25 pcf, and more particularly still from about 15 to about 25 pd.

The structural material may be combined or co-molded with other materials including, but not limited to, synthetic and/or non-synthetic materials including, but not limited to, paper, fabric, metal, metallized plastic, plastic film, metal foil, and/or the like, as well as composites, laminates thereof, and/or combinations comprising at least one of the foregoing. Other suitable materials include, bur are not limited to, fabrics, leather, vinyl, composites, laminates thereof, and/or combinations comprising at least one of the foregoing. If fabric is used, it may be synthetic or non-synthetic, knit, woven, non-woven, laminates thereof, and combinations comprising at least one of the foregoing. Any of the foregoing materials may be laminated and/or may comprise a coating on one or both surfaces, to impart desirable functional or aesthetic characteristics, such as water repellency, and the like.

When the panel or portions of the panel requires stretch, then use of a material with elongation may be desirable. Therefore, in some embodiments, it may be desirable to combine or co-mold the structural material with materials than are extensible, because the extensible materials can improve the flexing of the case, as well as impart other desirable characteristics, such as water repellency, air or water permeability, increased surface tension, which may be desirable when non-slip characteristics are desired. For example, when greater air permeability is desired, it the extensible materials may be mesh. “Extensible material,” as used herein, means any formable material that is capable of regaining its original shape or position after bending, stretching, compression, or other deformation, and that is capable of withstanding the methods used to form the material and the case, and that is capable of withstanding the environment in which it is intended to be used.

Other examples of suitable extensible materials include, but are not limited to, any extensible substrate comprising a TPE film and/or coating, composites thereof, laminates thereof, and combinations thereof. Polyester and polyether thermoplastic polyurethane (“TPU”) have been found suitable to be used alone, or in laminated form. One exemplary material is a Polyester thermoplastic polyurethane (“TPU”) made by Bayer and sold under the name PS5400. Suitable film thicknesses range from about 1 milli-inch (“mil(s)”) to about 15 mils, more particularly between about 2 mils to about 10 mils, and even more particularly from about 3 mils to about 7 mils. However, when increased durability is desired, film thicknesses may be increased to, for example, 15-60 mils, limited only by the characteristics and performance of the film after molding. When used in laminated form, it may be possible to decrease film thicknesses, as laminating the film to a substrate may enhance strength and abrasion characteristics. When laminated to an extensible substrate (such as a circular knit or Lycra fabric), TPE film thicknesses of about 1 mil or less could readily be used in some applications.

Other examples of suitable extensible materials include, but are not limited to, synthetic and non-synthetic knit, woven and non-woven fabrics, composites thereof, laminates thereof, and combinations thereof. Examples of suitable fabrics include those comprising fibers such as elastane, which is also known under the product names of Spandex, Lycra and Dorlastan which, when included in fabrics, either by wrapping the elastane fiber with a non-elastic thread (either natural or synthetic) or using pure elastane threads worked or woven into fabrics made from other fibers, may provides varying degrees of elasticity, depending on the percentage included in the fabric, which depends on the type of fabric and the end use. For example, about 2% may be sufficient to allow a garment to retains its shape, whereas compression applications, such as athletic wear, undergarments and sportswear may comprise up to about 40% elastane, or more, if desired.

Other examples of suitable extensible materials include the foregoing synthetic and non-synthetic knit, woven and non-woven fabrics, composites thereof, laminates thereof, and combinations thereof, including those comprising a TPE film and/or coating, composites thereof, laminates thereof, and combinations thereof.

When the panel or portions of the panel require more rigidity or tension, it may be desirable to combine the structural material with non-extensible materials, or materials with relatively low stretch. Examples of non-extensible materials include, but are not limited to, nonwoven materials, including nonwoven fabrics, leather, woven materials, such as ballistic fabrics, and the like. Examples of such materials include, but are not limited to, reinforced and un-reinforced polyester, nylon, rayon, polyamides (such as aramids and para-aramids), and the like, and combinations thereof. Examples may include Cordura, Kevlar, Twaron, Spectra, Zylon, ripstop weaves thereof, and combinations thereof. One suitable ballistic material is a woven 1680 denier ballistic

Nylon sold by RockyWoods, 418 8^thStreet SE, Loveland, Colo., which has a weight of approximately 12 ounces per square yard (oz/yd²), a polyurethane coating of approximately 1-1.25 oz/yd²on one side for water resistance, and a durable water repellent (“DWR”) finish on the opposite side. Other suitable materials include 1050 ballistic nylon and Cordura, both with and without the polyurethane coating and/or DWR, which are available from Rockywoods and Brookwood Roll Goods Group, 275 Putnam Road Wauregan, Conn. It may be desirable for the polyurethane coating on these fabrics to be heavier such as 2.0 oz/yd²or more, which may provide greater moisture resistance or durability. In addition, a laminate of TPE on these fabrics may further enhance the water resistance.

In one embodiment, panel 20 may comprise a layer of a structural material (hereinafter “structural layer”) and a layer of extensible material (hereinafter “extensible layer”) disposed adjacent to the structural layer. In this embodiment, it maybe desirable for the inside 12a of the case to be formed from an extensible material that “grips” the electronic device, when it is disposed in the case.

In another embodiment, panel 20 may comprise a structural layer disposed between opposing extensible layers. In this embodiment, it maybe desirable for the inside 12a and outside 14a of the case to be formed from an extensible material that “grips” the electronic device, when it is disposed in the case, and also grips the surface on which the device may rest, or be held, during use.

The corner-retaining devices 30 may comprise any of the materials used for panel 20, as described above. It maybe desirable for the thumbprint side of the retaining device to be formed from a material that “grips” the electronic device, when it is disposed in the case. Therefore, the corner pieces may comprise a TPU or other film or material that has some “grip” properties, on the surface of the retaining device that faces the device. TPU has been found suitable for gripping a variety of devices, but a silicone or any TPE or possible certain fabrics or leather could also have such grip properties. One exemplary material is a Polyester TPU made by Bayer and sold under the name PS5400. Other Polyether TPU could easily be used or any TPU or TPE would also be good choices. Suitable film thicknesses range from about 1 milli-inch (“mil(s)”) to about 15 mils, more particularly between about 2 mils to about 10 mils, and even more particularly from about 3 mils to about 7 mils.

The optional binding 40 may comprise any of the materials used for panel 20, as described above. However, in may be desirable to bind the edge with the ballistic Nylon or Cordura with DWR, or with any other highly abrasion resistant and stain or water resistant material, to provide durability and water resistance.

One exemplary panel 20 is shown in FIGS. 4-6, when taken together. In the present embodiment, the composite panel 20 is sized to be larger than the device to be protected, in order to have edge protection that extends beyond the perimeter of the device. As shown, panel 20 comprises a molded multilayer construction, comprising a structural layer disposed between a non-extensible inner layer 12 and an extensible outer layer 14.

In many embodiments, the panel may be molded with “medallions,” or areas of greater and lesser thickness, as described in the applications mentioned above, but it is not necessary to do so. However, inclusion of regions of very thin or “near zero” foam thickness may improve the flex of the case, and improve durability by minimizing or preventing delamination of the foam. The near-zero regions also allow flex, which may be helpful, as noted when the part is sewn under tension so that it may accommodate a range of device sizes. Such regions also allow for sealing out moisture or dirt from areas completely surrounded by near zero foam thickness, as closed cell structures prevent or minimize the migration of moisture or dirt therethrough. These near zero areas also allow for areas to be readily heat sealed as the near zero areas can be welded more easily without any cell structure that absorbs or interferes with heat for welding. As noted this may be helpful in sealing film or other clear materials over a camera hole or for edge sealing the panels into a more water resistant structure. A near zero area around the edge perimeter may create a more durable structure for laundering.

Panel 20 also comprises an optional channel 22 spaced apart from and extending around the entire perimeter 24 of the sheet. If the retaining devices and/or optional binding are to be attached by stitching, then it may be advantageous to include such a channel. The channel 22 defines a bumper portion 26 adjacent to the perimeter, which may be encapsulated in a binding material, as discussed previously. The channel 22 has a width W₁and a thickness T₁, and the bumper 26 has a thickness T₂and a width W₂. Those of skill in the art will recognize that any thickness or width may be selected, as desired. For example, width W₁may be selected to be sufficient to accommodate a stitching tool, and to be thin enough to stitch, while still being sufficiently thick to minimize or prevent defects from the stitching operation. For example, a thickness T₁of about 0.030″ and a bumper thickness T₂of about 0.125″ have been found suitable, such that when stitched together with the corner-retaining devices 30, a larger bumper can be formed.

In the present embodiment, panel 20 and corner-retaining devices 30 are stitched together along the stitching lines, forming a supportive and protective edge, or bumper, for an electronic device disposed in the case.

FIG. 7-9 show an expanded perspective view of one exemplary corner-retaining device 30, which also comprises an optional channel 22 spaced apart from and extending around two sides 30a,b. If the retaining devices and/or optional binding are to be attached to the panel by stitching, then it may be advantageous to include such a channel. The channel 22 defines a bumper portion 26 adjacent to the edges 30a,b of the device 30. The channel 22 has a width W₁and a thickness T₁, and the bumper 26 has a thickness T₂and a width W₂. Those of skill in the art will recognize that any thickness or width may be selected, as desired. For example, width W_imay be selected to be sufficient to accommodate a stitching tool, and to be thin enough to stitch, while still being sufficiently thick to minimize or prevent defects from the stitching operation. For example, the same thicknesses and widths as used for panel 20 have been found suitable.

The corner-retaining devices 30 have a sufficient thickness to be able to protect the device, particularly when it includes a screen interface, from an impact. The retaining devices may have a thickness ranging from about 0.040″ to about 0.500″, more particularly about 0.100″ to about 0.350″, and more particularly about 0.150″ to about 0.300″.

Corner-retaining device 30 also comprises a notch 34, for stress relief during assembly and use, and a recessed region 38. In the present embodiment, the recessed region 38 has a concave or thumbprint-like shape, which assists with insertion of a device into the case 10. The presence of the recessed region also maximizes the exposure of the device and/or screen surface when the device is positioned in the case, which is advantageous for accessing functional keys that would otherwise be hidden under the retaining device 30. Increasing or decreasing the thickness for the device may vary the exposure of the device and screen underneath the retaining device 30. For example, the exposure of the device may be increased by increasing the thickness T₃of the device in region 31, which allows the recessed region to be further spaced from the device, when in use.

The corner may be contoured as shown for aesthetics and to provide access for a finger to remove and insert the device. Maximizing the thickness toward the sewn edge of the corner may assist with keeping the device from sliding too far to a corner or edge. Having film wrap the entire piece, as shown in the figures, may be desirable. The recessed region in the corner-retaining device allows for a greater thickness in the corner where needed for protection, but the flexibility to insert the device and access under the corner retainer to touch the full area of the screen. The recessed regions in the corner-retaining devices are not necessary, but may be advantageous, in some instances, because they allow the dimensions, including the thickness, of the corner-retaining device to be maximized. As the dimensions of the corner-retaining device increase, particularly the thickness of the regions closest to the sewn edges, the ability of the retaining devices to “lock” the device into the case, increases, and provide the ability to accommodate a wide a range of device sizes. The thicker regions of the corner-retaining device may compress to accommodate gripping different sizes of devices within a reasonable range.

Those of ordinary skill in the art will recognize that the channel, bumper, recessed region and notch may be any size, shape and/or configuration desired or needed to allow ease of attachment of the retaining device 30 to the panel 20. In addition, it may be desirable to include additional notches in the retaining device, to provide additional flex during assembly and use.

The result of the corners of molded foam locking in the device, the molded panel and the bound foam sewing flange edge is a case that is capable of protecting the device from almost any type or direction of drop. The lateral movement of the device is limited because it is secured by the corner-retaining devices. The corner-retaining devices absorb impact from a drop on the screen-side, because the thickness spaces the screen from the impact surface. The back of the molded panel also absorbs energy. The recessed areas of the corner-retaining devices are raised above the screen in that area, and while thinner, they also provide added protection as they have the capability to absorb energy in flexing of those areas during impacts.

The construction of case 10 involves attaching the retaining devices 30 to a substantially rectangular composite panel 20. Retaining devices 30 may be attached to panel 20 using a variety of techniques including, but not limited to, stitching, gluing, welding, or a combination of the foregoing. In some embodiments, the retaining devices 30 may be attached to panel 20 under tension, such that panel 20 has a concave shape. When assembled, the retaining devices 30 are disposed so that the “gripping” surface is disposed adjacent to the iPad. The use of a relatively non-extensible material such as a Cordura or a Ballistic Nylon fabric or other non-extensible material for the composite panel when sewn into this concave shape has a unique synergistic effect of creating torsional or twisting protection for a delicate device. In use, the device is inserted into the concave non-extensible structure under fairly significant tension and presses against the corner retainers. As a result, the device itself is given added torsional stability by the strength of the non-extensible fabric structure, and is restrained from flexing forward toward the open screen by the tension of the non-extensible panel. Thus, the flexible case structure provides surprising torsional or twist protection during impact. The foam thickness in the corner-retaining devices allows different dimensioned devices to be tightly gripped.

The optional binding 40 may be disposed around the circumference of the panel 20, such that it extends slightly beyond the channels on panel 20 and corner-retaining devices 30. The optional binding 40 may be attached using a variety of techniques including, but not limited to, stitching, gluing, welding, or a combination of the foregoing.

In this embodiment, it maybe desirable for the inside 12a be formed from an extensible material that “grips” the electronic device, when it is disposed in the case, and for the outside 14a of the case to be formed from a non-extensible material that can provide improved abrasion resistance and/or high strength and/or sliding characteristics for the intended application. If the ballistic fabric is not capable of being co-molded with the panel 20, then it could be attached to the outer surface using a variety of attachment techniques including, but not limited to, sewing, gluing, welding, and the like.

In the present embodiment, which includes optional binding 40, the binding is attached by stitching. Accordingly, the panel 20 and retaining device 30 construction each include a stitching channel, and the binding is disposed around the circumference of the panel, and folded over the edge of the panel, after the retaining devices have been attached to the panel. The binding is then sewn to the panel at the stitching lines, through all of the layers.

FIGS. 10-11, when taken together, shows perspective and cross-sectional views of an electronic device 70 (hereinafter “device 70”) disposed in case 10, such that the charging plug on device 70 is exposed to the corresponding audio port 50 on case 10, and the camera lens on the back of device 70 is exposed to the corresponding audio port 50. As shown, device 70 is disposed in case 10 such that the corner-retaining devices 30 are disposed over the corresponding corners of device 70. The retaining devices 30, in combination with the inner surface of the case 10, “grip” or retain the device 70 within the case 10. In the present embodiment, corner-retaining devices 30 are under tension, such that panel 20 is forced into a concave shape, as shown in FIG. 11. As a result of the concave shape of panel 20, a spacer region “S” is formed between the back surface of device 70 and the front surface of case 10. The space S is advantageous because it provides heat dissipation, space for storage, and it minimizes or prevents sound waves emanating from the speaker, from being muffled or suppressed. This case as described may be used as is or placed within a sleeve for transport and full screen protection.

FIGS. 12-14, when taken together, show another embodiment of an exemplary protective case 100 according to the present disclosure. In the present embodiment, panel 20 comprises a molded multilayer construction, comprising a structural layer disposed between a non-extensible inner layer 12 and an extensible outer layer 14. Therefore, in the present embodiment, the surfaces of the case and the corner-retaining devices that contact the device, when inserted into the case, have “gripping” surfaces, to help retain the device in the case.

In the present embodiment, the case may be constructed such that the corner-retaining devices 30 are under tension, as in the previous embodiment, to force panel into a concave shape, as shown in FIG. 11. The case may be used as is or placed within a sleeve for transport and full screen protection.

FIGS. 15-17, when taken together, show one embodiment of an exemplary protective portfolio-style case 200 according to the present disclosure. The portfolio configuration offers screen protection during transport but may not be needed for in field use. The same materials and construction methods use in previous embodiments may be used to construct the present case.

As shown, case 200 comprises a retaining panel 202 and a cover panel 204, each of which comprise an optional binding 40 at the outer edge. In the present embodiment, cover panel 204 may be attached to panel 202 using various attachment methods. In the present embodiment, panels 202, 204 are the same size and shape, and are attached to one another along one edge by stitching, or by an intermediate device, such as a hinge (not illustrated).

In the present embodiment, panel 202 is identical in construction to case 100, comprising a perimeter “P” and opposing front and back sides 12,14, each with corresponding front and back surfaces 12a, 14a, and a retaining device 30 is disposed in each corner of the panel 20 (hereinafter “corner-retaining device(s) 30). As in other embodiments disclosed herein, the retaining devices 30 each have a substantially triangular shape, and are positioned in the corners of the case 10.

As shown, case 200 comprises a zipper closure 25, but other types of closures may be used, such as hook and loop tape, a waterproof and/or gas resistant zipper, a plastic zipper (e.g., Zip-Loc-style), pillow flap type closures, or any other closure method. The zipper closure 25 may be attached to the outer edge of the panels by stitching adjacent to the zipper teeth, along the stitching lines, and the panel at the closure end is sufficient thickness to minimize or prevent defects from the stitching operation, and is sufficient to provide protection in the zipper area. The portfolio case utilizes a zippered edge, but the top may be attached using other fasteners including, but not limited to, a belt, Velcro, magnets clips, and the like.

The case may be constructed by sewing, but in the case of more water resistance being desired, the sewing could be replaced by heat sealing, gluing or welding of any kind

If desired, cover panel 204 may comprise a liner 23, which may be attached to the interior surface of panel 204, for example, by stitching. Cover panel 204 also comprises a pocket 25, formed from the same material as the liner 23. If desired, panel 204 may comprise additional pockets or receptacles may be included for papers, writing instruments, cell phones, chargers, and the like.

Case 200 may include an optional insert (not illustrated) disposed between the liner and panel 204, which may comprise any rigid material or a composite structure that involves a rigid material or by itself is sufficiently rigid, preferably a relatively light-weight, rigid, impact-resistant plastic such as polycarbonate, acrylonitrile butadiene styrene (“ABS”), polyvinyl chloride (“PCV”), polypropylene (“PP”), laminates thereof, composites thereof, and combinations thereof

An optional binding 40 may be disposed around the circumference of the panels, such that it extends slightly beyond the stitching channels on the panels and corner-retaining devices.

Those of ordinary skill in the art will recognize that any lightweight, rigid, impact-resistant material may be used as the rigid support structure for the case. Optionally, the rigid material in the case may be designed to be larger in length and width than the electronic device stored in the device case, to provide even further edge impact protection for the edges of the device.

FIG. 17 shows a perspective view of a device 70 disposed in case 200, such that the charging plug on device 70 is exposed to the corresponding audio port 50 on case 10. As shown, device 70 is disposed in case 10 such that the corner-retaining devices 30 are disposed over the corresponding corners of device 70. The retaining devices 30, in combination with the inner surface of the case 10, “grip” or retain the device 70 within the case 10.

FIGS. 18-23, when taken together, show one embodiment of an exemplary protective “in-use” style case 400 according to the present disclosure. The in-use style case offers screen protection during transport, and may be configured in a variety of ways, including for use as a kneeboard. The same materials and construction methods use in previous embodiments may be used to construct the present case.

As shown, case 400 comprises a retaining panel 402 and a cover panel 404, each of which comprise an optional binding 40 at the outer edge. In the present embodiment, cover panel 404 is attached to panel 402 by an intermediate hinge device 90. As shown, cover panel 404 comprises three (3) fold lines 410.

Cover panel 402 also may comprise an optional liner (not illustrated), which may be attached to the interior surface of panel 402, for example, by stitching. If desired, panel 402 also may comprise additional pockets or receptacles may be included for papers, writing instruments, cell phones, chargers, and the like.

Cover panel 402 also may comprise at least one optional protective element 420. The protective element 420 may be co-molded with the liner material, or formed separately and attached to the liner using a variety of techniques such as sewing, gluing, welding, and the like. The present embodiment comprises a single rectangular protective element 420 extending between opposing edges of panel 402, which is stitched to the liner between two of the fold lines 410.

Case 400 also may include one or more optional inserts (not illustrated). In the present embodiment, panel 402 comprises three optional inserts (not illustrated) disposed in pockets (not illustrated) created by stitching the liner along fold lines 410. The optional inserts may comprise any relatively lightweight, rigid, impact-resistant material, as described above.

In the present embodiment, panel 402 is identical in construction to case 100, comprising a perimeter “P” and opposing front and back sides 12,14, each with corresponding front and back surfaces 12a, 14a, and a retaining device 30 is disposed in each corner of the panel 20 (hereinafter “corner-retaining device(s) 30). As in other embodiments disclosed herein, the retaining devices 30 each have a substantially triangular shape, and are positioned in the corners of the case 10.

In the present embodiment, the present case may comprise at least one fastener, to maintain the cover in a close position, when not in use. For example, case 400 comprises two interconnectable fastening devices 75, 77, used to close the case. In use, when closed, the buckles pinch the two edges together. Fastener 75 comprises webbing 75s attached to opposing exterior surfaces of the case, with corresponding quick-release buckle style fasteners 75a,b attached to the ends of the webbing 75s. Similarly, fastener 77 comprises webbing 77s attached to opposing exterior surfaces of the case, with corresponding quick-release style fasteners 77a,b attached to the ends of the webbing 77s. In the present embodiment, the webbing is attached to the case body by stitching, but those of ordinary skill in the art will recognize that a variety of other attachment methods may be used. The present case comprises a buckled closure, but those of ordinary skill in the art will recognize that a variety of other closures can be used in place of, or in addition to, the buckle closure, such as a zipper, Velcro, magnets, clips, and the like.

FIG. 24 shows a perspective view of case 400 in an in-use configuration, such that the exterior surfaces face inwardly, and with a device 70 disposed in the case. As shown, device 70 is disposed in case 40 such that the corner-retaining devices 30 are disposed over the corresponding corners of device 70. The retaining devices 30, in combination with the inner surface of the case 10, “grip” or retain the device 70 within the case 10.

Those of ordinary skill in the art will recognize that the present in-use case can be attached to a variety of support members as desired, such as user's arm, leg, thigh, luggage, backpacks, medical instruments, kitchen handles (e.g., for cook's ease of use), and the like.

FIG. 25 shows a perspective view of case 400 in an in-use kneeboard configuration, attached to a user's thigh. In use as a kneeboard, the exterior surface of the case is disposed adjacent to the user's thigh, and depending on the outer material, can “grip” the user's thigh. Similarly, the webbing 75 may be elasticized, which also may assist in gripping the case to the thigh/support. It is a unique aspect of the present cases, that the exterior surface of the case is sufficiently flexible to comfortably wrap a user's thigh, arm, etc., while still providing full device protection. This is achieved through the use of the exterior surface with longitudinal supports and longitudinal optional protective elements that allow wrapping of an arm or thigh etc., but when used as a cover still can offer appropriate screen protection.

As shown in FIG. 26, panel 404 may be folded along fold lines 410 to form an easel configuration.

FIGS. 27-30, when taken together, show another embodiment of an exemplary protective in-use style case 500 according to the present disclosure, with a magnetic closure and retractable carrying handle 560. The same materials and construction methods use in previous embodiments may be used to construct the present case, including the retractable handle 560.

As shown, case 500 comprises a retaining panel 502 and a cover 504, each of which comprise an optional binding 40 at the outer edge. In the present embodiment, cover 504 is attached to panel 502 by an intermediate hinge device 90.

In the present embodiment, retaining panel 502 is similar in construction to case 100, comprising a perimeter “P” and opposing front and back sides 12,14, each with corresponding front and back surfaces 12a, 14a, and a retaining device 30 disposed in each corner. As in other embodiments disclosed herein, the retaining devices 30 each have a substantially triangular shape, and are positioned in the corners of the case 500.

As shown, cover 504 comprises an opposing cover panel 506 and liner panel 508. In the present embodiment, cover panel 504 comprises four (4) pockets defined by at least partially stitching the cover panel 506 and liner panel 508 together from the opposing short edges of the cover panel, along fold lines 510.

Cover panel 504 also may include one or more optional inserts to provide stability to the cover. Prior to attaching the optional binding, four (4) optional inserts 520 are disposed in the pockets. The optional inserts may comprise any relatively lightweight, rigid, impact-resistant material, as described above, such as polycarbonate.

Cover panel 504 also may comprise at least one optional protective element, to provide impact resistance for the front side of a device disposed in the case. The present embodiment comprises two (2) rectangular protective elements 530 extending between opposing short edges of the cover 504. The protective elements may be formed from a variety of materials, and may be may be co-molded with the liner material, or formed separately and attached to the liner panel 508 using a variety of techniques such as sewing, gluing, welding, and the like. In the present embodiment, the protective elements 530 are the same material as the corner retaining devices and panels, and are stitched to the liner panel 508 between the fold lines 510.

In the present embodiment, the present case may comprise at least one fastener, to maintain the cover in a closed position, when not in use. For example, case 500 comprises an optional magnetic fastener, which comprises a tab 530 extending from the retaining panel 502. Two magnets M₁, M₂(shown in phantom) are disposed in the tab 530, which allow the case to be closed using the magnetic closure. Two additional and optional magnets M₃, M₄(shown in phantom) are disposed in the cover panel 504, which allow the cover to be folded into an easel configuration, with the magnets retaining the case in the easel configuration. Tab 540 can comprise a variety of materials, including the same material as the cover panel, described above. In the present embodiment, the magnets M are stitched into place, but any technique can be used to maintain the position of the magnets.

FIGS. 31-33, when taken together, show another exemplary sleeve-style case 600 according to the present disclosure.

Case 600 can be constructed from, for example, two (2) panels 20 that are mirror images of one another, and can be attached together. As shown, two panels 20 are stitched together along the stitching lines with the outer surfaces 14a facing one another. As shown, case 600 comprises a zipper closure 25 as in previous embodiments, but other types of closures may be used, as described above.

After stitching the panels 20 together and attaching the zipper 25, the case is inverted, such that the edges are positioned adjacent to one another and form a supportive interior bumper 610, with a channel 620 adapted to suspend a device (not illustrated) within the case 600.

Those of ordinary skill in the art will recognize that a combination of the foregoing materials and techniques can be used to make protective cases for a variety of devices that need to be protected, while maintaining unobstructed screen access, both in dry or wet environments, including underwater environments. The ability to withstand commercial laundering also applies to other dirty environments including, but not limited to, muddy areas, chemical exposure, hospitals, military, and the like. Those of ordinary skill in the art will also recognize that the foregoing these techniques can be modified and/or combined with other features to be used for protection of other items.

The cases disclosed herein can comprise one or more of the following advantages: 1) they provide lightweight impact resistance; 2) the cases are flexible, and can accommodate devices of different dimensions, in contrast to other types of cases, which are designed specifically for one type of device; 3) improved economics as a result of the methods of making the panels and retaining devices; 4) the ability to provide a single-panel, lightweight, “in-use” case with screen protection; 5) the ability to provide a protective cover for an “in-use” case, with the linear protective medallion on the inside cover; 6) folding cover provides easel configuration; 7) the clip on strap extenders provide a knee board for in-use applications; 8) the clip extenders provide a knee strap which, when combined with the flexible panel, allow the case to be strapped to a user's limb, unlike rigid portfolios 9) the flexible panel allows the case to be attached to display poles, etc., such an oven panel (for cook's ease of use); 10) the cover provides a place for embroidering or embossing e.g., for corporate logos, and the like; 11) clip extenders form handle or connect to accessory pouch etc.; 12) additional components and/or accessories may be attached to the case using successive clip attachments (e.g., an accessory pouch, a flexible keyboard, a flexible solar panel, Velcro handle, etc.; 13) the extender straps may be elastic or rigid and are adjustable in length.

It should be noted that the terms “first,” “second,” and the like herein do not denote any order or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Similarly, it is noted that the terms “bottom” and “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. In addition, the modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity).

Compounds are described herein 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 point of attachment for a substituent. For example, —CHO is attached through the 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 “+/−10% means that the indicated measurement may be from an amount that is minus 10% to an amount that is plus 10% of the stated value.

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.

While the disclosure has been described with reference to exemplary embodiments, 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 the appended claims.

	Number	Date	Country
Parent	13271594	Oct 2011	US
Child	13532412		US

FLEXIBLE IMPACT PROTECTIVE CASES, METHODS OF MAKING AND METHODS OF USING

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CPC

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Abstract

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CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)

Continuation in Parts (1)