U.S. patent application number 13/595609 was filed with the patent office on 2012-12-20 for two-piece protective carrying case.
This patent application is currently assigned to Uncommon LLC. Invention is credited to Dustin Brown, Jon Godston, Scott Wilson.
Application Number | 20120317784 13/595609 |
Document ID | / |
Family ID | 43586840 |
Filed Date | 2012-12-20 |
United States Patent
Application |
20120317784 |
Kind Code |
A1 |
Wilson; Scott ; et
al. |
December 20, 2012 |
Two-Piece Protective Carrying Case
Abstract
A carrying case for a portable device is disclosed. Generally
speaking, the protective case for a portable device comprises a
first body section and a second body section, each having a back
surface and upturned sides, and a rim affixed to an edge of the
upturned sides of the body sections, the rim defining an open area.
Preferably, the first and second body sections are of contrasting
colors and connect to one another to form a cavity defined by the
respective back surfaces and upturned sides. Further, the first and
second body sections and the first and second rim are preferably
all formed of the same material.
Inventors: |
Wilson; Scott; (Chicago,
IL) ; Brown; Dustin; (Chicago, IL) ; Godston;
Jon; (Chicago, IL) |
Assignee: |
Uncommon LLC
Chicago
IL
|
Family ID: |
43586840 |
Appl. No.: |
13/595609 |
Filed: |
August 27, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12855311 |
Aug 12, 2010 |
8286789 |
|
|
13595609 |
|
|
|
|
61233146 |
Aug 12, 2009 |
|
|
|
Current U.S.
Class: |
29/464 |
Current CPC
Class: |
B44C 1/1712 20130101;
A45C 2011/002 20130101; A45C 13/08 20130101; B41M 5/382 20130101;
B44C 1/16 20130101; H04B 1/3888 20130101; B41M 5/41 20130101; B65D
81/02 20130101; B28B 11/001 20130101; A45C 11/00 20130101; Y10T
29/49895 20150115; B44C 1/165 20130101; B41M 5/52 20130101; B41M
5/035 20130101 |
Class at
Publication: |
29/464 |
International
Class: |
B23P 11/00 20060101
B23P011/00 |
Claims
1. A method for manufacturing a protective case for an electronic
device, the method comprising the steps of: forming a first body
section having a back surface and upturned sides; forming a second
body section having a back surface and upturned sides, wherein one
of either the first body section or second body section includes a
passage having an opening on each of the back surface and an inner
surface; forming first and second rims to be affixed to an edge of
the upturned sides of the first and second body sections,
respectively, wherein at least one of the rims includes at least
one integral toggle button area; transferring an image to the back
surfaces and upturned sides of the first and second body sections;
attaching at least one stop for frictionally engaging another
surface to the inner surface of the first body section and second
body section; and tightly bonding the first and second rims to the
upturned sides of the first and second body sections,
respectively.
2. The method of claim 1, wherein the step of transferring an image
comprises the step using heat to sublimate an image onto the back
surfaces and upturned sides.
3. The method of claim 1, wherein the first and second body
sections are formed of a material different than that of the
material for forming the first and second rims.
4. The method of claim 1, wherein the image has a pattern and the
pattern aligns when the first and second body sections are
connected together.
5. The method of claim 1, further comprising the step of
transferring an image to the first and second rims.
6. The method of claim 5, wherein the image transferred to the
first and second body sections is identical to the image
transferred to the first and second rims.
7. The method of claim 1, further comprising the step of concealing
imperfections resulting from the step of transferring an image.
8. The method of claim 7, wherein the step of concealing
imperfections comprises the step of affixing the first and second
rim to the upturned edges after the step of transferring the image.
Description
RELATED APPLICATIONS
[0001] The present application is a divisional of, claims priority
to, and incorporates herein by reference, U.S. patent application
Ser. No. 12/855,311 filed on Aug. 12, 2010, which claims the filing
priority of, and incorporates by reference, Provisional Application
No. 61/233,146, filed on Aug. 12, 2009.
TECHNICAL FIELD
[0002] The present invention relates to electronic device cases,
and more specifically to thermoformed protective cases formed with
two-piece resins to ensure high quality registration of features on
one or both sides of the item.
BACKGROUND OF THE INVENTION
[0003] Previously, to produce thermoformed items having details
disposed on one or both sides of the item, using a plastic or other
suitable material, required the use of different and multiple
molding processes. For example, a sheet of material or fluid
material from which an item was to be formed might be initially
positioned within or directed into an injection or compression
molding device in order to create detail or features required on at
least one side of the item. Subsequently, the material sheet would
then be positioned or run through a suitable second thermoforming
device to complete the formation of the item from the material. The
resulting thermoformed item might then be heat treated under vacuum
conditions with a dye printing sheet to print a pre-drawn design
onto a surface of the item.
[0004] However, these multi-step processes have a number of
significant drawbacks. First, the added steps typically slow
production time and increase production cost. Second, subjecting
the item to repeated high-temperature steps can have a detrimental
effect on the item.
[0005] As to the first point, to initially print the detailed
design on the thermoformed item, the process may require both a
detail molding device and step, which can be either an injection
molding step or a compression molding step, as well as a final
thermoforming step (e.g., melting or sublimation techniques) used
to create the final form for the item. Finally, the pre-drawn
design needs to be imprinted to the item. The multiple steps and
molding devices required for each step significantly increases the
complexity of the process and the costs for producing the final
item with an image or design printed thereon.
[0006] Of no less importance is the integrity of the final item.
That is, when a sheet of material is positioned within the heat
treatment device to finalize the transfer of the dye printing onto
the item, often times the process results in a partial or complete
deformation or destruction of the original detail from the initial
thermoforming steps. That is, due to the repeated use of
high-temperatures necessary to initiate transfer of the dye from a
pre-printed film to one or both sides of the thermoformed item, the
edges around the item may be unable to withstand such heat for the
required duration of the transfer process. However, shortened heat
transfer times would fail to ensure consistent transfer of the dye
on the entire surface of the item. Thus, the resulting item may
often be undesirable or unusable for its intended purpose due to
the damage done to the thermoform details on the item.
[0007] Therefore, it is desirable to develop a device and method
for thermoforming an item which is capable of effectively
transferring the image from the printing sheet to a surface of the
item in a single step utilizing only the thermoforming device
SUMMARY OF THE INVENTION
[0008] There is disclosed herein an improved protective carry case
for a device, such as a portable electronic device (e.g., a phone,
camera, PDA, etc.) which avoids the disadvantages of prior devices
while affording additional structural and operating advantages.
[0009] Generally speaking, the protective case for a portable
device comprises a first body section and a second body section,
each having a back surface and upturned sides, and rim affixed to
an edge of the upturned sides of the body sections, the rim
defining an open area. Preferably, the first and second body
sections are of contrasting colors and connect to one another to
form a cavity defined by the respective back surfaces and upturned
sides. Further, the first and second body sections and the first
and second rim are preferably all formed of the same material.
[0010] It is a further aspect of an embodiment of the invention to
provide at least one integral toggle button cover positioned on an
upturned side of one of either the first body section or the second
body section.
[0011] It is another aspect of an embodiment of the invention to
provide at least one stop on the inner surface of the case for
frictionally engaging another surface, such as that of the portable
device to be encased. In the event a camera or other sound or image
recording device is provided by the portable device, it is an
aspect of an embodiment of the invention to provide a passage
having an opening on each of the back surface and the inner surface
of one of either the first body section or the second body section,
the openings being connected by a sidewall. The sidewall is
preferably slanted outward to lessen possible interference with the
image and/or sound recording function.
[0012] These and other aspects of the invention can be more readily
understood from a reading of the following detailed description
accompanied by the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be better understood with reference to the
following drawings. The components in the drawings are not
necessarily to scale, emphasis instead being placed upon
illustrating the principles of the invention. In the drawings, like
reference numbers designate corresponding parts throughout.
[0014] FIG. 1 is a perspective front view of an embodiment of a
portable carrying case device in accordance with the present
invention;
[0015] FIG. 2 is a front view of the portable carrying case device
shown in the drawing of FIG. 1 and made in accordance with the
present invention;
[0016] FIG. 3 is a back view of the portable carrying case device
shown in the drawing of FIG. 1;
[0017] FIG. 4 is an enlarged side view of the portable carrying
case device shown in the drawing of FIG. 1;
[0018] FIG. 5 is an enlarged top view of the portable carrying case
device shown in the drawing of FIG. 1;
[0019] FIG. 6 is an enlarged bottom view of the portable carrying
case device of FIG. 1;
[0020] FIG. 7 is a partial cross-section of an embodiment of the
passage provided to align with a camera feature (e.g., lens) on an
electronic device;
[0021] FIG. 8 is an enlarged front exploded view of the portable
carrying case device of FIG. 1; and
[0022] FIG. 9 is an enlarged side exploded view of the portable
carrying case device of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
[0023] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawings and will herein be
described in detail a preferred embodiment of the invention with
the understanding that the present disclosure is to be considered
as an exemplification of the principles of the invention and is not
intended to limit the broad aspect of the invention to embodiments
illustrated.
[0024] Referring to FIGS. 1-9, there is illustrated an embodiment
of a protective carrying case, generally designated by the number
10, for a portable electronic device. The particular illustrated
embodiment is representative of a carrying case designed for an
iPhone, manufactured by Apple, Inc. However, a carrying case 10
made in accordance with the present invention may be configured to
fit any number of portable electronic devices, including other
smart phones, PDA devices, calculators, cameras, global positioning
system (GPS) devices, and the like. Those skilled in the relevant
art will be able to understand and provide the required design
changes to accommodate such alternate devices after a reading of
the present detailed disclosure, including the appended drawing
figures, without need for undue experimentation.
[0025] Reference numbers used within FIGS. 1-9 and in the detailed
description to follow, correspond as shown to the following
elements:
TABLE-US-00001 Reference Number Element 10 protective carrying
case; 12 first body section; 14 second body section; 16 rim; 17
open area; 18 back surface; 20 bottom opening; 22 cavity; 24 inner
surface; 25 edge; 26 upturned side; 28a/28b toggle button cover; 30
friction stop; 32 conical passage; 34 passage sidewall; 36 opening,
inner surface 38 opening, back surface 42 extended flange; and 44
receptacle.
[0026] With reference to the illustrated embodiment, a protective
carrying case 10 includes a first body section 12 and a second body
section 14. The first body section 12 and the second body section
14 are preferably formed of high-strength thermoplastic polymers
such as ABS and polycarbonate materials known in the art. Each of
the first and second body sections, 12 and 14, has a back surface
18 which transforms along an edge 25 into upturned sides 26. The
edge 25 is preferably radiused to provide a smooth transition from
back surface 18 to sides 26. However, the edge 25 may be in the
form of a traditional 45 degree corner, or some variation, as well.
When the two sections 12, 14 are connected together, a cavity 22 is
formed as defined by an inner surface 24 of the body sections, 12,
14, and the upturned sides 26.
[0027] The first body section 12 also includes at least one
integral toggle button cover 28 for aligning with control switches
on the encased electronic device (not shown), such as for volume
and on/off buttons. Toggle button covers 28 are preferably
positioned within the upturned side 26 of either the first body
section 12, the second body section 14, or both. In the illustrated
embodiment, a volume toggle button cover 28a is positioned on a
left or right side of the first body section 12 and an on/off
toggle button cover 28b is positioned on a topside of the first
body section 12. Additional toggle button covers may be used to
suit the various configurations of other electronic devices.
[0028] As shown best in FIGS. 2 and 8, a rim 16 is affixed to an
edge of the upturned side 26 of both the first body section 12 and
the second body section 14. The rim 16 provides a slight overhang
to the cavity 22 to facilitate securing an electronic device within
the carrying case. The rim 16 frames an open area 17 where
typically display and/or keyboard functions are located.
[0029] The inner surface 24 of the case 10 may include a plurality
of stops 30 for frictionally engaging an outer surface of an
electronic device. The stops 30 are preferably comprised of a
high-friction material, such as a rubber or other suitable polymer.
In the preferred embodiment, for ease of placement, the stops 30
are substantially clear, dome-shaped decals which adhere to the
inner surface 24 by any suitable adhesive. As shown, the stops 30,
of which there are three, are horizontally located in an aligned
arrangement on the inner surface 24 of the two-piece body sections
12, 14 to provide an overall, balanced engagement of the device.
That is, the number and positioning of the stops 30 allows a
portable electronic device (not shown) to be held securely after
being slidably pushed into the case 10.
[0030] Another contemplated use for the inner surface 24 of the
first body section 12 or the second body section 14 is as
advertising space. For example, corporate logos, brand names and
the like may be incorporated into the mold tooling.
[0031] With reference to FIGS. 8 and 9, the connection between the
first body section 12 and the second body section 14 can be more
readily understood. The second body section 14 includes an extended
flange 42, while the first body section 12 includes a corresponding
receptacle 44. After an electronic device is placed into the first
body section 12, the flange 42 of the second body section 14
inserts into the receptacle 44 of the first body section 12 as the
second body section is slid onto the device. The flange 42 and
receptacle 44, which may be switched on the two bodies, mate
frictionally to hold the first and second body sections, 12 and 14
about the device in a protective manner. Using similar
polycarbonate material for the first body section 12 and the second
body section 14 enables an exceptionally strong frictional
engagement between the two bodies.
[0032] Further, it is also contemplated that the first body section
12 and the second body section 14, may be provided with contrasting
colors to mask overprinting. Preferably, the first body section 12
is provided in black and the second body section 14 is provided in
white. If ink is printed, for example, over the white section and
overprints to the black section, the ink will not show on the
black. The effect will be a clean line at the junction of the two
colors. It will be understood that any contrasting color can be
applied to the first body section 12 and the second body section 14
to accomplish the intended goal of the present invention.
[0033] As mentioned above, it has been determined that many
materials, particularly plastics, are unable to withstand repeated
high temperatures (e.g., 160 .degree. C. and up) for the required
duration of the transfer process. For example, during a thermo
transfer process wherein the dye from the pre-printed film is
introduced to the second body section 14, the dye may not be
consistently transferred onto the entire second body section 14. In
fact, it is not uncommon for the edge 25 of the second body section
14 which corresponds and aligns with the edge 25 of the first body
section 12, to be susceptible to deformation at high temperatures.
As a result, the quality of the transferred dye on the first body
section 12 or the second body section 14 of the carrying case 10
may be functionally or aesthetically undesirable and even come
off.
[0034] However, the rim 16 is tightly bonded to both body sections,
12 and 14, which accomplishes at least a few goals of embodiments
of the present invention. First, the rim 16 creates a perfect line
about the open area 17 much like the contrasting colors of the two
sections, as described above. Second, the rim 16 is also able to
mask many physical imperfections in the edge 25 as a result of the
ink heat transfer (e.g., sublimation process). The rim 16 may also
provide structural support to the case in many instances.
[0035] Therefore, it is preferably contemplated that the rim 16
affixed to both the first body section 12 and the second body
section 14 is integrally bonded in either an injection molding or
compression molding process. This subsequent bonding of the rim
along an edge 25 of the upturned sides 26 of the first and second
body sections, 12 and 14, ensures that any loosely transferred dye
along this area of the first and second body sections 12, 14 is
masked by the rim 16.
[0036] The use of visually contrasting colors or shades between the
first body section 12 and the second body section 14 may have other
additional benefits. For example, the contrasting color of the
first body section 12 and the second body section 14, coupled with
side toggle button cover 28 and a bottom opening 20 to accommodate
a charging plug adapter, provides a user with a visual indication
to confirm proper orientation of the housing. Further, the
contrasting body sections can be used to indicate proper holding
orientation of the device and to enhance visibility of the device.
Alternatively or additionally, indicia may be printed on the back
surface 18 of the case 10 or on the inner surface 24 of either body
section 12, 14 to indicate proper orientation. Finally, the use of
contrasting shades or colors between the two body sections 12, 14
provides the visual impression that the housing is thinner than
other similar cases in the market used to protect a portable
electronic device.
[0037] Referring to FIG. 7, another optional feature of the present
case 10, conical passage 32, can be seen. The conical passage 32 is
used to align with the electronic device's camera lens feature. As
such, the conical passage 32 is preferably positioned on the back
surface 18 of the case 10 in either the first body section 12 or
the second body section 14. The passage 32 has an opening at each
of the back surface 18 and the inner surface 24 of the case. A
slanted sidewall 34 connects the two openings. Preferably, the
inner surface opening 36 has a diameter less than the back surface
opening 38. This configuration provides that a greater amount of
light will be able to enter the camera aperture for better quality
pictures. The conical sidewall 32 also prevents a photo "flash"
effect prevalent in devices using tubular passages where indirect
light reflects from the sidewall to "wash-out" a portion of the
photo.
[0038] It should be emphasized that the above-described embodiments
of the present invention, particularly, any "preferred"
embodiments, are possible examples of implementations merely set
forth for a clear understanding of the principles for the
invention. Many variations and modifications may be made to the
above-described embodiment(s) of the invention without
substantially departing from the spirit and principles of the
invention. All such modifications are intended to be included
herein within the scope of this disclosure and the present
invention, and protected by the following claims.
[0039] The matter set forth in the foregoing description and
accompanying drawings is offered by way of illustration only and
not as a limitation. While particular embodiments have been shown
and described, it will be apparent to those skilled in the art that
changes and modifications may be made without departing from the
broader aspects of applicants' contribution. The actual scope of
the protection sought is intended to be defined in the following
claims when viewed in their proper perspective based on the prior
art.
* * * * *