U.S. patent application number 13/271594 was filed with the patent office on 2012-04-19 for flexible impact protective cases and methods of making.
This patent application is currently assigned to G-FORM, LLC. Invention is credited to Thomas Cafaro, David Foster, Richard B. Fox, Ami Newsham, Daniel M. Wyner.
Application Number | 20120091025 13/271594 |
Document ID | / |
Family ID | 45933171 |
Filed Date | 2012-04-19 |
United States Patent
Application |
20120091025 |
Kind Code |
A1 |
Wyner; Daniel M. ; et
al. |
April 19, 2012 |
FLEXIBLE IMPACT PROTECTIVE CASES AND METHODS OF MAKING
Abstract
Disclosed herein are protective cases for sensitive devices,
including devices with screen interfaces, which cases provide
protection from front, back and edge impacts.
Inventors: |
Wyner; Daniel M.; (North
Scituate, RI) ; Fox; Richard B.; (Smithfield, RI)
; Cafaro; Thomas; (Foster, RI) ; Newsham; Ami;
(Providence, RI) ; Foster; David; (Swansea,
MA) |
Assignee: |
G-FORM, LLC
Providence
RI
|
Family ID: |
45933171 |
Appl. No.: |
13/271594 |
Filed: |
October 12, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61404906 |
Oct 12, 2010 |
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61412767 |
Nov 11, 2010 |
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61495371 |
Jun 9, 2011 |
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61520546 |
Jun 10, 2011 |
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61501140 |
Jun 24, 2011 |
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61571623 |
Jul 1, 2011 |
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61575363 |
Aug 19, 2011 |
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Current U.S.
Class: |
206/523 ;
206/521; 206/586 |
Current CPC
Class: |
A45C 2011/002 20130101;
A45C 13/008 20130101; A45C 2011/003 20130101; A45C 13/36 20130101;
A45F 2005/008 20130101; A45C 11/00 20130101; A45C 2013/025
20130101; A45C 13/02 20130101 |
Class at
Publication: |
206/523 ;
206/521; 206/586 |
International
Class: |
A45C 13/00 20060101
A45C013/00; B65D 85/30 20060101 B65D085/30; B65D 81/02 20060101
B65D081/02 |
Claims
1. A protective case for a device, comprising: a case body
comprising a closure; and at least one protective element disposed
on the case body, the at least one protective element comprising a
base layer, an intermediate layer of a rate dependent material, and
a surface layer; wherein the rate dependent material is
encapsulated by the base layer and the surface layer.
2. The protective case of claim 1, wherein the at least one
protective element is disposed on one or more surfaces selected
from the group consisting of an external surface of the case body,
an internal surface of the case body, and combinations thereof.
3. The protective case of claim 1, wherein the case body comprises
a base, a sidewall extending upwardly from the base, and at least
one sidewall protective element disposed against the sidewall.
4. The protective case of claim 1, wherein the case body comprises
four corners, and further comprising a corner protective element
disposed in the at least one corner.
5. The protective case of claim 3, wherein the case body comprises
a base, and further comprising a protective element disposed in the
base.
6. The protective case of claim 4, wherein the case body comprises
a base, and further comprising a protective element disposed in the
base.
7. The protective case of claim 1, wherein the protective element
comprises a flange, and wherein the rate dependent material in the
flange is encapsulated by the base layer and the outer layer.
8. The protective case of claim 1, wherein the protective element
comprises a flange, the flange is spaced apart from the protective
element by a channel, and the channel comprises the base layer and
the outer layer, and the base layer and the outer layer in the
channel are bonded together.
9. The protective case of claim 10, wherein a portion of the rate
dependent foam is disposed between the bonded base and outer layers
in the channel.
10. The protective case of claim 1, wherein the surface layer is
continuously bonded to the rate dependent material.
11. The protective case of claim 1, wherein the base layer is
continuously bonded to the rate dependent material.
12. The protective case of claim 1, wherein the surface layer and
the base layer are both continuously bonded to the rate dependent
material.
13. The protective case of claim 1, wherein one or more channels
are defined in the protective element.
14. The protective case of claim 1, wherein one or more grooves are
defined in the protective element.
15. The protective case of claim 1, wherein the rate dependent
material comprises a rate dependent foam.
16. The protective case of claim 1, wherein the rate dependent
material comprises a rate dependent polyurethane.
17. The protective case of claim 1, wherein the rate dependent
material comprises a polyurethane foam.
18. The protective case of claim 1, wherein each of the base layer
and the surface layer are selected from the group consisting of
film, fabric composites thereof, and combinations of the
foregoing.
19. The protective case of claim 6, wherein the film is a
thermoplastic elastomer.
20. The protective case of claim 18, wherein the thermoplastic
elastomer is a thermoplastic polyurethane.
21. The protective case of claim 19, wherein the thermoplastic
polyurethane is selected from aliphatic or aromatic polyether
polyurethane, aliphatic or aromatic polyester polyurethane, and
combinations of the foregoing.
22. The protective case of claim 18, wherein the film has a
thickness ranging from about 1 milli-inch ("mil") to about 15
mils.
23. The protective case of claim 18, wherein the film has a
thickness ranging from about 2 mils to about 10 mils
24. The protective case of claim 18, wherein the film has a
thickness ranging from about 3 mils to about 7 mils.
25. The protective case of claim 18, wherein the film has a
thickness of greater than about 10 mils to about 60 mils.
26. The protective case of claim 1, wherein the case body comprises
a woven nylon fabric or composite thereof.
27. The protective case of claim 1, wherein the case body comprises
an extensible material.
28. The protective case of claim 9, wherein the extensible material
comprises elastane.
29. The protective case of claim 10, wherein, when the case body is
disposed on an item comprising an outer surface, and the case body
conforms to the outer surface of the item.
30. A protective case for a device, comprising: a case body
comprising a closure, the case body comprising an extensible
material comprising elastane; and at least one protective element
disposed on the case body, the at least one protective element
comprising a base layer, an intermediate layer of a rate dependent
polyurethane foam, and a surface film of polyester polyurethane;
wherein the protective element comprises a flange spaced apart from
the protective element by a channel.
31. The protective case of claim 30, wherein the base layer and the
outer layer in the channel are bonded together.
32. The protective case of claim 30, wherein the base layer and the
outer layer in the channel are continuously bonded together.
33. The protective case of claim 30, wherein the rate dependent
rate dependent polyurethane foam is encapsulated by the base layer
and the surface layer.
34. The protective case of claim 32, wherein the base layer and the
outer layer in the channel are continuously bonded together.
35. The protective case of claim 30, wherein the base layer
comprise an extensible material comprising elastane.
36. A protective case for a device, comprising: a case body
comprising a closure, the case body comprising an extensible
material layer comprising elastane; and at least one protective
element disposed on the case body, the at least one protective
element comprising a cushioning region disposed between a surface
layer of polyester polyurethane and the extensible material layer;
wherein the protective element comprises a channel, and the
extensible layer and the surface layer in the channel are bonded
together.
36. The protective case of claim 35, further comprising a flange,
and wherein the flange is spaced apart from the cushioning region
by the channel.
37. The protective case of claim 35, wherein the extensible
material and the surface layer in the channel are continuously
bonded together.
38. The protective case of claim 35, wherein the rate dependent
polyurethane foam is encapsulated by the extensible layer and the
surface layer.
Description
CROSS REFERENCE TO RELATED CASES
[0001] Priority under 35 U.S.C. .sctn.119(e) is hereby claimed to
commonly-owned and co-pending U.S. Provisional Application No.
61/404,906, which was filed on Oct. 12, 2010; U.S. Provisional
Application No. 61/412,767, which was filed on Nov. 11, 2010; U.S.
Provisional Application No. 61/495,371 which was filed on Jun. 9,
2011; U.S. Provisional Application No. 61/520,546, which was filed
on Jun. 10, 2011; U.S. Provisional Application No. 61/501,140,
which was filed on Jun. 24, 2011; U.S. Provisional Application No.
61/571,623, which was filed on Jul. 1, 2011; and U.S. Provisional
Application No. 61/575,363, which was filed on Aug. 19, 2011. The
subject matter of each of the foregoing applications is
incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosure relates to flexible impact protective cases
and methods of making.
BACKGROUND
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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. Once again they are not generally
able to protect the device from a significant drop on the screen
side
[0008] 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.
[0009] There is a need for an improved case for sensitive
equipment, devices or instruments, which is lightweight 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
[0010] The present disclosure is directed, in one embodiment, to a
protective case for a device. The case can comprise a case body
comprising a closure, at least one protective element disposed on
the case body. The at least one protective element can comprise a
base layer, an intermediate layer of a rate dependent material, and
a surface layer.
[0011] The rate dependent material can be encapsulated by the base
layer and the surface layer. The at least one protective element
can be disposed on one or more surfaces selected from the group
consisting of an external surface of the case body, an internal
surface of the case body, and combinations thereof. The case body
can comprise a base, a sidewall extending upwardly from the base,
and at least one sidewall protective element disposed against the
sidewall.
[0012] The case body can comprise four corners, and further can
comprise a corner protective element disposed in the at least one
corner. The case body can comprise a base, and can further comprise
a protective element disposed in the base. The case body can
comprise a base, and can further comprise a protective element
disposed in the base. The protective element can comprise a flange,
and the rate dependent material in the flange can be encapsulated
by the base layer and the outer layer. The protective element can
comprise a flange, and the flange can be spaced apart from the
protective element by a channel.
[0013] The channel can comprise the base layer and the outer layer,
and the base layer and the outer layer in the channel can be bonded
together. A portion of the rate dependent foam is disposed between
the bonded base and outer layers in the channel. The surface layer
is continuously bonded to the rate dependent material. The base
layer is continuously bonded to the rate dependent material. The
surface layer and the base layer are both continuously bonded to
the rate dependent material. The surface layer can comprise a
thermoplastic polyurethane selected from aliphatic or aromatic
polyether polyurethane, aliphatic or aromatic polyester
polyurethane, and combinations of the foregoing.
[0014] The present disclosure is directed, in one embodiment, to a
protective case for a device. The case comprises a case body
comprising a closure, the case body comprising an extensible
material comprising elastane; at least one protective element
disposed on the case body, the at least one protective element
comprising a base layer, an intermediate layer of a rate dependent
polyurethane foam, and a surface film of polyester polyurethane;
wherein the protective element can comprise a flange spaced apart
from the protective element by a channel, and the channel the base
layer and the outer layer in the channel are bonded together. The
base layer and the outer layer in the channel can be continuously
bonded together. The rate dependent rate dependent polyurethane
foam can be encapsulated by the base layer and the surface layer.
The base layer and the outer layer in the channel can be
continuously bonded together. The base layer can comprise an
extensible material comprising elastane.
[0015] Another embodiment of the protective case comprises a case
body with a closure. The case body can comprise an extensible
material layer comprising elastane. At protective element can be
disposed on the case body, and the protective element can comprise
a cushioning region disposed between a surface layer of polyester
polyurethane and the extensible material layer. The protective
element can comprise a channel, and the extensible layer and the
surface layer in the channel can be bonded together. The case also
can comprise a flange, and the flange can be spaced apart from the
cushioning region by the channel. The extensible material and the
surface layer in the channel can be continuously bonded together.
The rate dependent polyurethane foam can be encapsulated by the
extensible layer and the surface layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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.
[0017] FIG. 1 is a front perspective view of one exemplary
embodiment of a protective case according to the present
disclosure, in a closed position;
[0018] FIG. 2 is a front view of the protective case shown in FIG.
1;
[0019] FIG. 3 is a perspective view of the protective case shown in
FIG. 1, in an open position;
[0020] FIG. 4 is a front perspective view of another exemplary
embodiment of a protective case according to the present
disclosure, in a closed position;
[0021] FIG. 5 is a front view of the protective case shown in FIG.
4;
[0022] FIG. 6 is a perspective view of the protective case shown in
FIG. 4, in an open position;
[0023] FIG. 7 is a front perspective view of another exemplary
embodiment of a protective case according to the present
disclosure, in an open position;
[0024] FIG. 8 is a perspective view of one protective element shown
in the protective case of FIG. 7;
[0025] FIG. 9 is a side view of the protective element shown in
FIG. 8;
[0026] FIG. 10 is a perspective view of a corner protective element
shown in the protective case of FIG. 7, in an unfolded
position;
[0027] FIG. 11 is a bottom view of the corner protective element
shown in the FIG. 10, in an unfolded position;
[0028] FIG. 12 is a perspective view of the corner protective
element shown in the FIG. 10, in an folded position; and
[0029] FIG. 13 is a top view of the corner protective element shown
in the FIG. 10, in an folded position; and
[0030] FIG. 14 is a cross-sectional view of the corner protective
element shown in FIG. 10.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0031] The present disclosure is directed to a protective case that
provides improved impact protection, particularly for devices with
screen interfaces, as are found in many electronic and medical
devices.
[0032] One aspect of the disclosure is a flexible protective case,
which is advantageous because it is capable of accommodating a
range of device shapes and sizes. 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.
[0033] 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.
[0034] Some embodiments comprise a film of polyester polyurethane,
which has unexpectedly improved the performance of the present
cases in certain harsh environments, such as during repeated
commercial laundering, and it is thought that the unexpected
performance is due to the continuous bonding of the materials,
particularly at the perimeter of the protective elements, and to
the encapsulation of the intermediate layer, as will be discussed
in detail below. As a result, the cases are hygienic, and are
capable of withstanding the high temperatures and caustic chemicals
used in commercial-grade laundering.
[0035] FIGS. 1-3, when taken together, show one embodiment of an
exemplary protective case 100 according to the present disclosure.
As shown, case 100 comprises a flexible, rectangular case body 12
with a front exterior surface 14, a back exterior surface (not
illustrated), an interior surface 15, a closed edge 16, and a
closure 18 that extends around three (3) edges of the case body 12.
Those of ordinary skill in the art will recognize that it is not
necessary for the case to have rectangular shape, and that it may
have any shape and/or configuration. Those of ordinary skill in the
art will recognize that a variety of types of closures including,
but not limited to, zippers, including waterproof, air resistant
and plastic ziplock-style zippers; pillow flap type enclosures;
envelope-style enclosures; hook and eye tape; magnets; clips; and
the like.
[0036] Case 100 comprises a protective element 20 disposed on one
or both of the front exterior surface 15 and back exterior
surfaces. Those of ordinary skill in the art will recognize that
any number of protective elements may be used, that the protective
element(s) may be positioned anywhere on the case body, and that
the protective elements may have any shape, size and/or
configuration, as desired.
[0037] FIGS. 4-6, when taken together, show another exemplary
embodiment of a flexible, protective case 300 according to the
present disclosure. Case 300 comprises the same features described
above with respect to case 100. In the present embodiment, in
addition to the features described above, the protective element 30
has a larger area, and is spaced apart from the edges of the case
body 12 by a spacer region 40. The spacer region 40 has a width
"W.sub.1" that can range in width as desired, provided there is
sufficient space to accommodate the zipper closure, or alternative
closures.
[0038] In the present embodiment, the larger area of the protective
element 30 may be desirable for devices that require larger
protective areas, while the presence of the spacer region maintains
flexibility in the edge regions of the case.
[0039] The case body 100 and optional liner can comprise a variety
of materials with different aesthetic and functional
characteristics, and which can be varied as needed or desired for a
particular application or design. Suitable materials for the case
body and optional liner include, but are 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 can
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 can be laminated and/or can comprise
a coating on one or both surfaces, to impart desirable functional
or aesthetic characteristics, such as water repellency, and the
like.
[0040] Examples of suitable non-extensible or low stretch materials
from which the case body and optional liner may be made include,
but are not limited to, nonwoven materials, including nonwoven
fabrics, leather, woven materials, such as ballistic fabrics, and
the like. Examples of ballistic 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, which has a weight of approximately 12
ounces per square yard (oz/sq yd), a polyurethane coating of
approximately 1-1.25 oz/sq yds on 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 DWR.
[0041] Examples of suitable extensible materials from which the
case body and liner may be made include, but are not limited to
elastane, and the like.
[0042] Construction of the foregoing cases 100, 200 comprises
selecting a suitable material for the case body, selecting suitable
dimensions for the case body, and forming or attaching the closure.
The sheet of case body material can comprise dimensions larger than
the item to be protected, in order to accommodate a seam allowance.
In the foregoing embodiments, the material for the case body is
folded to form edge 16, but those of ordinary skill in the art will
recognize that separate sheets of case body material can be
attached to form edge 16. Those of ordinary skill in the art will
recognize that a variety of attachment methods may be used to form
the edge 16 and/or case body including, but not limited to,
stitching, gluing, welding of any kind, or a combination of the
foregoing. In instances in which water resistance is desired, it
may be more desirable to heat seal, glue and/or welding the seams
and/or zipper together.
[0043] In the foregoing embodiments, which both include zipper
closures, the zipper is attached to the case body at the closure
end by stitching adjacent to the zipper teeth, along stitching line
"s".
[0044] In the embodiment depicted in case 100, the protective
element is attached to the case body by stitching through the case
body and the flange along stitching line "S," whereas in the
embodiment depicted in case 200, the protective element(s) 30 are
attached to the case body by welding. The protective elements 30
may be attached to the case body material prior to or after
constructing the case and/or exposed through a corresponding
opening in the case body.
[0045] As shown above, in both of the foregoing embodiments, the
protective elements 20, 30 are attached to exterior of the case
body, as shown above. However, if desired, the protective elements
20, 30 can be attached to the interior of the case body. In
addition, protective elements can be attached to both the interior
and the exterior surfaces of the case body and/or to the optional
liner and/or to the optional insert.
[0046] Those of ordinary skill in the art will recognize that a
combination of the foregoing materials and techniques can be used
to make flexible protective cases for a variety of devices that
need to be protected. 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 techniques can be modified and/or
combined with other features to be used for protection of other
items.
[0047] The foregoing flexible cases fit snugly, but stretch and
conform to the device, resulting in an integrated protection system
that protects the device from impact better than other products,
because the pad is in constant and direct contact with the device.
Cases incorporating the protective elements provide improved
protection from impact, because the base of the protective element,
or the material to which the base of the protective element is
attached, can be maintained in direct contact with the device
during use. That is, without the degree of flexibility of the
present cases, they would not be capable of conforming to the case.
For ease of discussion, the term "flexible," as used herein, means
the ability of the case to move by bending, twisting, flexing
and/or stretching, and the like.
[0048] Another aspect of the disclosure is a protective case with a
rigid housing and configurable protective inserts. The present case
is advantageous because it is capable of accommodating a range of
device shapes and sizes, by varying the size, shape and
configuration of the inserts, which are replaceable.
[0049] FIGS. 7-13, when taken together, show one embodiment of an
exemplary protective case 300 according to the present disclosure.
As shown, case 100 comprises a rigid, rectangular case body 12 with
a case body base 14 and a cover 16. Those of ordinary skill in the
art will recognize that it is not necessary for the case to have
rectangular shape, and that the case may have any shape and/or
configuration.
[0050] Case body 12 can comprise a variety of materials, as
described above, and additionally may comprise a light-weight,
rigid, impact-resistant material. One suitable material is
polycarbonate. Those of ordinary skill in the art will recognize
that any light-weight, rigid, impact-resistant material may be
used.
[0051] Case 300 comprises various protective elements disposed in
the interior of the case, having different shapes. Those of
ordinary skill in the art will recognize that case 300 can comprise
any number of protective elements, and that the protective elements
may have any quantity, shape, location and/or configuration.
[0052] Disposed on the inner surface of the base 14 is a protective
element 60, which is similar in construction to protective elements
20,30, as described above. However, sidewall and corner protective
elements 40,50 comprise more complex molded shapes than protective
elements 20,30, and are designed to receive the sidewall of, for
example, a laptop computer.
[0053] Disposed against the sidewall of base 14 are four (4)
sidewall protective elements 40. Each sidewall protective element
comprising a sidewall 42 and upper and lower retaining arms 44,48
extending outwardly from the sidewall to define a recess 48 for
receiving the edge of a rectangular item, such as a laptop
computer.
[0054] Disposed in each corner of base 14, against the sidewall of
base 14, are four (4) corner protective elements 50. Each corner
protective element 50 comprises a left side "L" and a right side
"R", with a plurality of flexible flanges 50, disposed an
accordion-style, between the left and right sides L and R, which
allows the element to be folded for insertion into the corners of
the base 14. Each of the left and right sides L and R comprise a
sidewall 52, and upper and lower retaining arms 54,58 extending
outwardly from the sidewall 52 to define a recess 58 for receiving
the edge of a rectangular item, such as a laptop computer.
[0055] As shown above, the protective elements 40, 50 are disposed
in the interior of the case, in the base. However, if desired, the
protective elements 40, 50 can be disposed against the sidewalls
and corners of the interior of the cover 14. Similarly, additional
protective elements 60 can be attached to one or both of the
interior and the exterior surfaces of the case body and/or to the
optional liner and/or to the optional insert.
[0056] Optionally, any of the cases 100, 200, 300 disclosed above
can comprise a plurality of access ports to provide access to
various functional keys on the device and/or to external devices,
such as battery chargers, and the like. Those of ordinary skill in
the art will recognize that that any number of access ports may be
included, that the access port(s) may be positioned anywhere on the
case body, and that the access ports may have any shape, size
and/or configuration, as desired, and can be disposed in any
location, as desired, to correspond with the location of such
features as found on commercial electronic devices, or any device
to be protected.
[0057] Optionally, any of the cases 100, 200, 300 disclosed above
can comprise a liner (not illustrated) attached to the interior of
one or both of the front and back sides of the case.
[0058] Optionally, any of the cases 100, 200, 300 disclosed above
can comprise a variety of accessories (not illustrated), such as
pockets for paper and/or writing instruments, handles, straps,
zippers, straps or other devices, including devices that allow the
case to be attached to other items, such as backpacks, luggage,
clothing, jackets, and the like, or integrated into the foregoing
items as a pocket or sleeve, and the like. Those of ordinary skill
in the art will recognize that that any number of accessories may
be included, that the accessories may be positioned anywhere in or
on the case body, and that the accessories may have any shape, size
and/or configuration, as desired.
[0059] Optionally, any of the cases 100, 200, 300 disclosed above
can comprise a structural insert (not illustrated) disposed in the
case body, or when a liner is included, disposed between the liner
and the case body. Alternatively, the insert can comprise the same
material as used for the protective elements, or can comprise the
rigid material as described above for case 300. 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 additional edge impact protection for the edges of the
device.
[0060] FIG. 14 shows a partial cross-section of protective element
30, disposed adjacent to the case body 12. As shown, protective
element 30 comprises an upper surface 70, a back surface 72, a
perimeter P, and an intermediate layer 80 disposed between optional
surface and base layers 82,84. In addition, an additional layer or
layers of materials can be disposed adjacent to, including bonded
to, the surface layer for extreme durability and/or aesthetics.
[0061] Optionally, the upper surface 70 of the protective element
may be contoured using a variety of geometries, including planar
surfaces, curved surfaces, and combinations of planar and curved
surfaces.
[0062] Optionally, one or more hinges 95 and/or grooves 97 may be
formed in the upper surface 80 of the protective elements, to
define cushioning regions 99. The hinges 95 and the grooves 97
increase the flexibility of the protective element, and as the
thickness of the cushioning layer 80 in the grooves 97 is
decreased, the flexibility of the grooves 97, and protective
element 30, increases. The width, depth, orientation and position
of the grooves 97 may be varied, depending on a number of factors
including, but not limited to, the desired direction and amount of
flexibility, and the like.
[0063] In the present embodiment, protective element 30 comprises
an optional perimeter flange 90, which has a width "W.sub.2"
defined by the spacing "S.sub.2" between the perimeter of the
outermost cushioning region 99 and the perimeter P of the
protective element. The width W.sub.2 of the perimeter flange 90
and the spacing "S.sub.2" may vary, as desired. As will be
described in greater detail below, the perimeter flange 90 is
thinner than the cushioning regions, allowing the protective
element to be attached to items such as clothing along the flange
area using a variety of techniques, such as by sewing, gluing,
bonding, and the like.
[0064] The size, shape, thickness and material composition of the
protective elements may be varied, depending on a number of factors
including, but not limited to, desired amount of flexibility for
the protective element. In addition, the configuration of the
protective elements may be varied, and more than one type of
medallion shape may be used in the protective elements.
[0065] Suitable materials and methods of making the protective
elements 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 any of the
foregoing protective elements.
[0066] The molds for the protective elements 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. As a result, the intermediate layer can be encapsulated,
which improves performance of the protective elements in high
humidity and under harsh conditions, such as encountered in
commercial laundering, cleaning procedures in medical environments,
and the like. Further improvements in performance are found when
the protective elements comprise the foregoing outer flange. It is
thought that the further improvements are the result of the
continuous bonding of the inner and outer layers to the
intermediate layer, but also because after molding, very little or
none of the material used in the intermediate layer remains, so the
inner and outer layers are bonded to one another in the channel
adjacent to the flange, essentially locking out fluids from
entering the perimeter of the protective element. In addition, the
channels with little or no foam can be designed to achieve areas of
flexibility, such as around corners, stress points and/or complex
shapes and, to improve washability and durability. The construction
of the protective elements is also advantageous because the
intermediate material is locked in place, so that it is not
possible for the material to shift, or for gaps to open up in the
material. In other words, the protective elements provide
lightweight flexibility, without shifting areas of protection.
[0067] In many embodiments, the protective elements may comprise
cushioning regions, hinges and channels, as described in the
applications mentioned above, but none of the foregoing is
necessary.
[0068] The protective elements can 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 material can comprise a dilatant or shear
thickening material, such as rate dependent materials. In one
exemplary embodiment, the material can comprise d3O. In one
exemplary embodiment, the material can comprise a material such as
polyborosiloxane. In another exemplary embodiment, the material can
comprise rate dependent foam. For such applications, it can be
desirable for such foams to have a density ranging from about 5 to
about 35 pounds per cubic foot (pcf), more particularly from about
10 to about 30 pcf, and more particularly still from about 15 to
about 25 pcf. Suitable rate dependent foams are available from
Rogers Corporation under the brand names PORON.RTM. and PORON
XRD.RTM., both of which are open cell, microcellular polyurethane
foams.
[0069] The optional outer layer is described in detail in the
referenced publications. Suitable outer layers can comprise any
material capable of providing sufficient elasticity to prevent
tearing and/or stretching when a force is applied thereto;
sufficient structural integrity to be formed into predetermined
shapes; and that is capable of withstanding the environment in
which it is intended to be used (e.g., repetitive deformations such
as twisting, bending, flexing, stretching, and the like), without
substantial degradation. Examples of suitable extensible materials
include, but are not limited to, thermoplastic elastomer ("TPE")
film. Thermoplastic polyurethanes ("TPU"), both polyester and
polyether, whether aromatic or aliphatic, have been found suitable.
Suitable film thicknesses can ranges 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, 10-60 mils, or more,
limited only by the characteristics and performance of the film
after molding.
[0070] One exemplary material is a polyester thermoplastic
polyurethane ("TPU") made by Bayer and sold under the name PS5400.
As noted above, polyester polyurethanes have been found to perform
unexpectedly well during repeated commercial laundering, and it is
thought that the unexpected performance is due to the bonding of
the materials, particularly at the perimeter of the protective
elements, and to the encapsulation of the intermediate layer.
[0071] Optionally, any of the foregoing cases 100, 200, 300
disclosed above can comprise a protective binding and/or gusset
(not illustrated) attached to or forming part of the outer edge,
including on the closure. The binding can comprise the same
material as used for the protective elements, particularly with
ballistic fabric, which provides a rugged edge. The binding can be
disposed such that the ballistic material is inverted, so
protective element is internal on the edge, and vice versa.
[0072] Those of ordinary skill in the art will recognize that a
combination of the foregoing materials and techniques can be used
to make semi-rigid or rigid protective cases for a variety of
devices that need to be protected, while providing the capability
to modify the interior of the case by replacing the protective
elements with those having a different size, shape and
configuration, to adapt to different devices. The case and
protective elements also can 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.
[0073] The cases disclosed herein can comprise one or more of the
following advantages: 1) the provide lightweight impact resistance;
2) certain of the case described above 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; and 3) improved economics as a result of the methods of
making the panels and retaining devices; and 4) the encapsulated
protective elements provide items that are rugged, durable, and
able to withstand the temperatures, detergents and mechanical
action used in industrial and/or commercial laundering, unlike
other cases, which cannot be washed, or tend to degrade under such
harsh conditions.
[0074] 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).
[0075] 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.
[0076] 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.
[0077] 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.
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