U.S. patent application number 10/581764 was filed with the patent office on 2007-07-12 for impact-resistant case with sealable opening.
Invention is credited to Robert J. Cleereman, Joseph A. Langmaid, Jeffrey D. Wenzel.
Application Number | 20070158220 10/581764 |
Document ID | / |
Family ID | 34794299 |
Filed Date | 2007-07-12 |
United States Patent
Application |
20070158220 |
Kind Code |
A1 |
Cleereman; Robert J. ; et
al. |
July 12, 2007 |
Impact-resistant case with sealable opening
Abstract
The present invention is a cost effective impact-absorbing
insert which combines multiple functionality with parts
consolidation and ease of customization that allows wide
application anywhere tailored impact protection is desired. The
impact-absorbing insert of the present invention mates with a user
defined enclosure to produce a protective case for any fragile
articles that are used in a portable environment, for example
portable electronic devices such as cameras (35 mm and digital),
instrumentation, tools, PDAs, web tablets, hand held computers,
cell phones, pagers, gaming devices, electronic music players,
voice recorders, global positioning systems (GPS), and the
like.
Inventors: |
Cleereman; Robert J.;
(Midland, MI) ; Langmaid; Joseph A.; (Caro,
MI) ; Wenzel; Jeffrey D.; (Saginaw, MI) |
Correspondence
Address: |
THE DOW CHEMICAL COMPANY
INTELLECTUAL PROPERTY SECTION,
P. O. BOX 1967
MIDLAND
MI
48641-1967
US
|
Family ID: |
34794299 |
Appl. No.: |
10/581764 |
Filed: |
December 15, 2004 |
PCT Filed: |
December 15, 2004 |
PCT NO: |
PCT/US04/42278 |
371 Date: |
June 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60534624 |
Jan 7, 2004 |
|
|
|
Current U.S.
Class: |
206/320 |
Current CPC
Class: |
A45C 11/00 20130101;
H05K 5/0004 20130101; A45C 2011/001 20130101; A45C 11/38 20130101;
G06F 1/1626 20130101; A45C 2011/002 20130101; H04M 1/18 20130101;
G06F 2200/1633 20130101 |
Class at
Publication: |
206/320 |
International
Class: |
B65D 85/00 20060101
B65D085/00 |
Claims
1. An impact-absorbing insert for a protective case designed for
containing and protecting a fragile article wherein the insert
comprises one or more impact-absorbing portion and one or more
tethered plug for insertion into an access tunnel contained in a
mating user defined enclosure, wherein said access tunnel provides
access to features of the article without opening the protective
case.
2. A protective case for a fragile article comprising the
impact-absorbing insert and user defined enclosure of claim 1
wherein the protective case provides impact protection and, when
the access tunnel is plugged, a water tight and dust tight seal for
the fragile article.
3. The impact-absorbing insert of claim 1 wherein the fragile
article is a portable electronic device.
4. The impact-absorbing insert of claim 3 wherein the portable
electronic device is a 35 mm camera, digital camera,
instrumentation, a tool, a personal data assistant, a web tablet, a
cell phone, a hand held computer, a pager, a gaming device, an
electronic music player, a voice recorder, a global positioning
system.
5. The protective case of claim 2 wherein the fragile article is a
portable electronic device.
6. The protective case of claim 5 wherein the portable electronic
device is a 35 mm camera, digital camera, instrumentation, a tool,
a personal data assistant, a web tablet, a cell phone, a hand held
computer, a pager, a gaming device, an electronic music player, a
voice recorder, a global positioning system.
7. The impact-absorbing insert of claim 1 further comprises an
integral energy absorbing web and rib feature that compresses or
deforms to absorb impact loading, a molded-in button, a rib, an
aesthetics feature, an engagement rib, an interference tolerance to
enable positive fit and function for the life of the article, or
combinations thereof.
8. The protective case of claim 2 containing a portable electronic
device passes the MIL-STD-81 OF, Table 516.5-VI Transit Drop Test
at a minimum height of 24 inches.
9. The impact-absorbing insert of claim 1 comprises a molded
elastomeric material, having a hardness between about Shore 40 A
and about Shore 65 D.
10. The Impact-absorbing insert of claim 1 comprising thermoplastic
polyurethane.
11. A method to retain the impact-absorbing insert of claim 1 in a
user defined enclosure by designing attachment features which
produce a tight fit between the impact-absorbing insert with the
user defined enclosure.
12. The method of claim 11 wherein the design features comprise
molded fingers and mating grooves, wherein the fingers are on the
impact-absorbing insert and the grooves are on the user defined
enclosure, the fingers are on the user defined enclosure and the
grooves are on the impact-absorbing insert, or a combination
thereof.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an impact-resistant case
with a sealable opening, in particularly to a dust and watertight
seal.
BACKGROUND OF THE INVENTION
[0002] Electronic enclosures and housings are basically cases
designed to provide protection for product contents. Aesthetics,
ergonomics, weight, decoration, and additional functionality are
provided as well since the case is usually the basis of human
interface to the product. This interface may be sensory (visual)
only, or it may be the basis for product use--e.g. the user holds
onto the package to use the product. For example, a portable drill
where the case is also the tool housing and the housing is what the
operator holds to use the tool. Consequently, the case is a
multifunctional product in its own right and the design is the
result of fulfilling all the necessary functional requirements.
[0003] Recent developments in portable electronics has resulted in
the need for ruggedized supplemental cases for electronic products,
such as web tablets, cell phones, video and still cameras, palm
computers, etc. These specialized secondary enclosures allow
products designed for office use to be usable in the outdoors under
adverse conditions. There are numerous hazards for which a
protective case may be required, two primary ones being impact
(drop) and environmental (water and/or dust). Challenges arise when
the protection functionality is combined with aesthetics or
ergonomics.
[0004] Traditionally, a shipping case is designed to be energy
absorbent. If energy absorbency is the only requirement, many low
cost options exist since generally the larger the case, the easier
it is to design it to be energy absorbent. For example, foam cubes
can be placed in a corrugated box between the fragile contents and
the box (case) and these blocks will provide a high degree of
impact protection. However, this approach yields a large and bulky
package. If in addition to impact resistance, the case needs to
provide the "user interface", this approach is typically much
larger than is practical and, on a sensory basis, it will appear as
large, unwieldy, and even ugly. As a user interface enclosure, it's
totally impractical. Consequently, user preferred supplemental
enclosures are intensively designed to minimize size, bulk, weight,
and optimize ergonomics.
[0005] Most portable electronic devices have features that require
access while contained in a supplemental enclosure, for example, a
protective case. For example, Personal Data Assistants (PDAs) have
removable memory cards, batteries, synch cables, and/or power
cables. However, under typical operating conditions, it may be
desirable to use or access these features without removing the
product from its protective case. In addition to the energy
absorbing requirement, incorporating a functional requirement, such
as access, traditionally has resulted in increasing the number of
parts, the complexity to design and the cost to manufacture a
protective case. When size, weight, protection, aesthetics,
ergonomics, user access and/or more are all required, the
protective case might end up with as much or more engineering as
the basic product itself. The conventional approach to this problem
has been to tailor the design of the protective case for portable
electronic device, unfortunately, this approach is time consuming
and expensive.
[0006] An alternative, cost effective, approach to provide a
protective case for portable electronic devices having multiple
functions, such as impact-absorbing and internal access, is
needed.
SUMMARY OF THE INVENTION
[0007] The present invention is a cost effective impact-absorbing
insert which combines multiple functionality with parts
consolidation and ease of customization that allows wide
application anywhere tailored impact protection is desired. The
impact-absorbing insert of the present invention mates with a user
defined enclosure to produce a protective case for any fragile
article that is used in a portable environment, for example
portable electronic devices such as cameras (35 mm and digital),
instrumentation, tools, PDAs, web tablets, hand held computers,
cell phones, a pagers, gaming devices, electronic music players,
voice recorders, global positioning systems (GPS), and the
like.
[0008] It is further objective of the invention to reduce part
count and to improve ease of use of the impact-absorbing
insert.
[0009] It is a still another objective of the invention to provide
versatility by designing an impact-absorbing insert which can fit
into one or more different user defined enclosures. This reduces
the level of complex engineering necessary for each product while
allowing sophisticated design of the energy absorbing features in
the insert alone.
[0010] In one embodiment, the present invention is an
impact-absorbing insert for a protective case designed for
containing and protecting a fragile article wherein the insert
comprises one or more impact-absorbing portion and one or more
tethered plug for insertion into an access tunnel contained in a
mating user defined enclosure, wherein said access tunnel provides
access to features of the article without opening the protective
case.
[0011] In another embodiment, the present invention is a protective
case for a fragile article comprising the impact-absorbing insert
of the present invention and a user defined enclosure wherein the
protective case provides impact protection and, when the access
tunnel is plugged, a water tight and dust tight seal for the
fragile article.
[0012] In another embodiment, the impact-absorbing insert comprises
a molded polymeric material, preferably a low hardness, highly
elastic polymeric material such as an elastomeric thermoplastic or
an elastomeric thermoset plastic, preferably thermoplastic
polyurethane.
[0013] Another embodiment of the invention is a method to retain
the impact-absorbing insert in a user defined enclosure by
designing attachment features which produce a tight fit between the
impact-absorbing insert with the user defined enclosure, for
example molded fingers on the impact-absorbing insert and grooves
on the user defined enclosure, fingers on the user defined
enclosure and grooves are on the impact-absorbing insert, or
combinations thereof.
[0014] In a further embodiment of the invention the
impact-absorbing portion of the impact-absorbing insert comprises
one or more of an integral energy absorbing web and rib feature
that compresses or deforms to absorb impact loading, molded-in
buttons, ribs, aesthetics features, engagement ribs, interference
tolerances to enable positive fit and function for the life of the
article, or combinations thereof.
[0015] It is still another embodiment of the invention to allow
easy manufacture of the insert by utilizing common injection
molding technology and tooling with open and shut operation.
[0016] Another embodiment of the invention is a protective case for
a portable electronic device comprising the impact-absorbing insert
of the invention inserted into a user defined enclosure which
demonstrates an impact improvement provided to the user defined
enclosure, and electronic product contained therein, sufficient to
pass MIL-STD-810F, Table 516.5-Vi Transit Drop Test at a minimum of
24 inches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an exploded perspective view from the inside of a
protective case for a portable electronic device comprising an
impact-absorbent insert and a mating user defined enclosure.
[0018] FIG. 2 is an exploded perspective view from the outside of a
protective case for a portable electronic device comprising an
impact-absorbent insert and a mating user defined enclosure.
[0019] FIG. 3 is an exploded perspective view of a web tablet with
its protective case comprising an impact-absorbent insert and a
mating user defined enclosure.
[0020] FIG. 4 is a perspective view of a protective case comprising
an impact-absorbent insert and a mating user defined enclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The impact-absorbing insert 1 as shown in FIG. 1 has an
outside surface 2 and an inside surface 3. Further, the
impact-absorbing insert has one or more impact-absorbing portions 4
and one or more tethered plugs 5. At least a portion of the outside
surface of the insert, for example the impact-absorbing section(s),
is designed to fit within the exterior surface 21 of a user defined
enclosure 20. The user defined enclosure comprises a top portion 22
and a bottom portion 23, each having an interior surface 24. The
user defined enclosure comprising the impact-absorbing insert
comprise a protective case 30 for a portable electronic device 40
(FIG. 4).
[0022] Preferably, the outside surface of the impact-absorbing
insert must fit tightly against the interior surface of the user
defined enclosure. Any means to hold the insert tightly against the
user defined enclosure is acceptable, for example, it can be held
by an adhesive, a fastener, a mechanical means, or combination
thereof. An example of a mechanical means is shown in FIG. 1. The
insert is held by fingers 25 which are molded into the interior
surface of the user defined enclosure which engage grooves 6 on the
outside surface of the insert. Alternatively, the grooves can be on
the interior surface of the user defined enclosure and the fingers
on the outside surface of the insert or each surface can have one
or more groove, one or more finger or any combination thereof.
[0023] When a portable electronic device is placed within the
protective case, it must fit tightly against the inside surface of
the impact-absorbing insert. The outside surface of the insert
preferably has integral ribs and standoff features 7 that (1)
provide clearance to prevent the portable electronic device from
contacting the interior surfaces of the user defined enclosure,
and/or the ground in a drop impact, and (2) absorb energy resulting
from such a drop. Further, the impact-absorbing insert may comprise
one or more molded-in button, rib, access tunnel, aesthetics
feature, tethered plug, engagement rib, or interference tolerance
to enable positive fit and function for the life of the product.
Such features are designed for specific functionality based on the
portable electronic device and end product needs.
[0024] Preferably, the impact-absorbing insert should have
sufficient structure to avoid collapse in an impact situation and
still be able to absorb the energy resulting from such a drop
without damage to the portable electronic device it serves to
protect. It is preferable that the insert has adequate flex fatigue
resistance so as to recover its original position after being
depressed when a drop or other impact occurs. It should be rigid
enough to maintain its position within the user defined enclosure
during normal use so as to minimize unwanted movement of the
portable electronic device within the user defined enclosure.
[0025] Preferably, the impact-absorbing insert must have good
solvent resistance and good long term creep properties so that it
will not sag or warp over time. Further, it is preferable that the
impact-absorbing insert have sufficient thermal resistance to
enable it to perform its function in a wide range of climate
conditions, preferably from --40.degree. F. (-40.degree. C.) to
120.degree. F. (49.degree. C.). The enclosed portable electronic
device may generate thermal issues as well and the impact-absorbing
insert must withstand these without distortion or lack of
performance.
[0026] As shown in FIG. 2, the tethered plug 5 is integral with the
impact-absorbing portions of the impact-absorbing insert. It
comprises a plug portion 9 and a tether portion 10. The plug
portion has an outside 11 and an inside surface 12. The tethered
plug is designed to initially pass through and then fit snugly back
into an opening or access tunnel 26 in the user defined enclosure.
The access tunnel allows access from the outside of the user
defined enclosure/protective case to the portable electronic device
located inside of the user defined enclosure/protective case
without the need to open the user defined enclosure/protective case
(for example to allow removal of a memory card, replace a battery,
attach/detach a synch cable, insert/remove an earphone jack,
insert/remove a power cable, etc.). The plug is designed to be
insertable and removable from the outside surface of the user
defined enclosure while remaining attached to the impact-absorbing
portion(s) of the insert, which is on the inside surface of the
user defined enclosure, by a tether that passes through the user
defined enclosure opening. When the plug is inserted into the
access tunnel, from the outside of the user defined enclosure, it
preferably forms a water tight and/or dust tight seal. The
impact-absorbing insert may have multiple tethered plugs for
sealing matching multiple access tunnels in the user defined
enclosure depending on the specific requirements of the portable
electronic device which is incased within the protective case.
[0027] Preferably the impact-absorbing insert is molded with a
nominal wall thickness equal to or greater than about 2 millimeter
(mm) with integral feature (impact-absorbing portion, tether, plug,
etc.) thicknesses preferably equal to or greater than about 1 mm,
more preferably equal to or greater than about 1.5 mm and most
preferably equal to or greater than about 2 mm. The maximum nominal
wall and integral feature thicknesses are only limited by what is
practical for the specific enclosure and portable electronic
device, but generally, they are equal to or less than about 25 mm,
preferably equal to or less than about 12 mm, and most preferably
equal to or less than about 6 mm.
[0028] The impact-absorbing insert can be made from any polymeric
material which can (1) be manufactured with the necessary geometric
design and (2) will hold its shape through time in a wide range of
environments when fitted into the user defined enclosure.
Preferably, the polymeric material is a thermoplastic or thermoset
elastomer. Suitable elastomers are described, for example, in
Billmeyer, F., Textbook of Polymer Science, lnterscience
Publishers, New York, N.Y. (1965) and in Kirk-Othmer Science of
Chemical Technology 4.sup.th Ed, John Wiley & Sons, New York,
N.Y. (1993).
[0029] The impact-absorbing insert can be made from any elastomeric
plastic, thermoplastic or thermoset with low modulus and high
elasticity. Preferably, the impact-absorbing insert is made from a
material having a hardness between about Shore 40 A to about Shore
65 D.
[0030] Preferably the insert is made from polyamide (PA);
polyurethane (PU); polyolefin (PO), such as polyethylene (PE), such
as low density polyethylene (LDPE), polypropylene (PP), ethylene
and vinyl acetate copolymer (EVA), ethylene and propylene copolymer
(EP), polyethylene and alpha-olefin co-polymer, such as ENGAGE .TM.
polyolefin elastomers available from The Dow Chemical Company,
thermoplastic polyolefin (TPO); polyvinyl chloride (PVC);
polyester; polysiloxane; and mixtures thereof. Preferably the
impact-absorbing insert is made from a thermoplastic polyurethane
(TPU), such as PELLETHANE .TM. 2102-75A polyurethane available from
The Dow Chemical Company.
[0031] The impact-absorbing insert of the present invention can be
made by any known molding process including injection molding,
transfer molding, reaction injection molding, or liquid injection
molding.
EXAMPLE
[0032] The following example serves to demonstrate an embodiment of
the invention but is not intended to limit the scope of the
invention.
[0033] PELLETHANE 2102-75A thermoplastic polyurethane resin is
injection molded into a designed geometry mold cavity in the shape
of an impact-absorbing insert measuring 218 mm.times.30 mm.times.37
mm with a nominal wall thickness of 2 mm. This design is the result
of combining the fit functionality between a portable electronic
device, a user defined enclosure having two access tunnels, and an
impact-absorbing insert with the energy absorbing features (ribs,
standoffs, and fingers) and two tethered plugs for the access
tunnels. All the geometry necessary for correct functionality is
designed into the part and transferred to the metal mold, which
reproduces the requisite geometry to all parts manufactured by it.
The manufacture of the part is such that each time the mold opens,
a complete, impact-absorbing insert is ejected. The
impact-absorbing insert contains the necessary impact absorption
features and tethered plugs all in one molded article.
[0034] The PELLETHANE 2102-75A TPU resin is dried at a temperature
between 80.degree. C. to 95.degree. C. and the molding conditions
are a melt temperature between 200.degree. C. to 215.degree. C.
with a mold temperature between 15.degree. C. to 60.degree. C. An
Engel 25 mm single screw injection molding machine is used.
[0035] The resulting impact insert is placed into a user defined
enclosure (also molded from PELLETHANE 2102-75A TPU resin) having a
top and bottom portion, such that the impact-absorbing insert is
placed in the top portion and mates with a recess in the top
portion of the protective user defined enclosure. A personal
electronic device, for example a web tablet, is placed in the
protective user defined enclosure and fits snuggly against the
impact-absorbing insert. The access tunnels in the user defined
enclosure line up with the access features of the electronic device
and when the tethered plugs on the impact-absorbing insert are
inserted into these access tunnels a water and dust tight seal is
formed.
[0036] The top portion of the user defined enclosure is mated with
the bottom portion of the user defined enclosure. The resulting
protective case provides the encased portable electronic device
water and dust resistance, impact protection, and access to
features within the user defined enclosure.
[0037] The protective case comprising a portable electronic device,
the user defined enclosure, and the impact-absorbing insert is
subjected to the MIL-STD-81 OF, Table 516.5-VI Transit Drop Test
and passes at a minimum of 24 inches.
[0038] Table 516.5-VI testing protocol is: [0039] To pass, the unit
must survive 26 drops at a specific height without damage (defined
as impaired functional use) to the portable electronic device.
[0040] Up to five units may be used to obtain the 26 drops. [0041]
Use five different units for each drop height (24 in. (70 cm), 30
in. (76 cm), 36 in. (91 cm), 42 in. (107 cm), 48 in. (122 cm),
etc.) [0042] The units are dropped onto concrete covered with two
layers of 0.5 inch plywood. [0043] Drop Sequence: [0044] 1. Drop on
each of the 6 faces 3 times (18 drops total). Evenly spread these
drops over 3 units. [0045] 2. Drop on each of the 4 corners 2 times
(8 drops total). [0046] 3. Repeat at next drop level if 26 passing
drops are achieved.
[0047] As can be seen by the preceding example, the present
invention provides a cost effective impact-absorbing insert which
combines multiple functionality with parts consolidation and ease
of customization that provides good impact protection to the
encased portable electronic device.
* * * * *