Patent Application
20140069825
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.
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.
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 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.
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.
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.
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.
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.
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.
Case 10 is shown in an assembled configuration in
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.
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.
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.
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″.
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.
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 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.
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.
Raised impact regions 32 are spaced apart from one another by first recessed impact regions 34. First recessed impact regions 34 have a width W2, 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 W2 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″.
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 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 W3, which may vary as desired, and a predetermined thickness T4, which is selected to be less than the thickness T3 of the first recessed impact regions 36. In the present embodiment, the width W3 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
All of the foregoing thicknesses, widths, distances and spacings may vary, as desired.
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 ½ 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.
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.
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 keys. Raised keys 28 should not be confused with the raised impact regions 32, which are intended to absorb impacts.
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.
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.
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.
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.
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.
Cushion insert 30 has the same construction as in the previous embodiments.
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.
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.
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.
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.
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.
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
Various other materials and layers may be used to form the cushioning inserts, as described in commonly-owned and co-pending U.S. application Ser. No. 13/447,093, which was filed on Apr. 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 Ser. No. 13/208,229, filed on Aug. 11, 2011; and Ser. No. 13/271,594, filed on Oct. 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.
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.
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.
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 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 “+/−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 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.
The present application claims foreign priority under 35 U.S.C. §119(e) to commonly owned and co-pending U.S. Provisional Application No. 61/698,563, which was filed on Sep. 7, 2012, the subject matter of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61698563 | Sep 2012 | US |
