U.S. patent application number 13/620491 was filed with the patent office on 2013-03-21 for case for a portable electronic device with over-molded thermo-formed film.
This patent application is currently assigned to Speculative Product Design, LLC. The applicant listed for this patent is Bryan Lee Hynecek. Invention is credited to Bryan Lee Hynecek.
Application Number | 20130068634 13/620491 |
Document ID | / |
Family ID | 47721159 |
Filed Date | 2013-03-21 |
United States Patent
Application |
20130068634 |
Kind Code |
A1 |
Hynecek; Bryan Lee |
March 21, 2013 |
CASE FOR A PORTABLE ELECTRONIC DEVICE WITH OVER-MOLDED
THERMO-FORMED FILM
Abstract
The present disclosure relates to a case for a personal
electronic device comprising one or more layers formed from a
thin-film thermo-formed material and methods to manufacture the
same. In a disclosed embodiment, the case for the personal
electronic device comprises a flexible inner layer and a thin-film
thermo-formed outer-layer.
Inventors: |
Hynecek; Bryan Lee; (Redwood
City, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hynecek; Bryan Lee |
Redwood City |
CA |
US |
|
|
Assignee: |
Speculative Product Design,
LLC
Mountain View
CA
|
Family ID: |
47721159 |
Appl. No.: |
13/620491 |
Filed: |
September 14, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61536437 |
Sep 19, 2011 |
|
|
|
Current U.S.
Class: |
206/37 ;
156/73.6; 29/428 |
Current CPC
Class: |
B32B 3/02 20130101; B32B
27/32 20130101; B29C 66/71 20130101; B32B 2250/24 20130101; B32B
2571/00 20130101; B32B 27/08 20130101; B32B 2274/00 20130101; Y10T
29/49826 20150115; Y10T 428/1334 20150115; B29C 65/48 20130101;
B29C 65/02 20130101; Y10T 428/1352 20150115; Y10T 428/1386
20150115; B29C 65/06 20130101; B29D 22/003 20130101; B32B 2307/518
20130101; B32B 25/20 20130101; Y10T 156/108 20150115; B29C 65/562
20130101; B29L 2031/3481 20130101; B29K 2021/00 20130101; B32B
27/302 20130101; B29C 66/71 20130101; B32B 1/00 20130101; B32B
27/36 20130101; B29C 65/56 20130101; B32B 27/40 20130101; B32B
25/14 20130101; Y10T 428/31855 20150401; B32B 27/365 20130101 |
Class at
Publication: |
206/37 ; 29/428;
156/73.6 |
International
Class: |
A45C 11/00 20060101
A45C011/00; B32B 37/00 20060101 B32B037/00; B29C 69/00 20060101
B29C069/00 |
Claims
1. A case for a portable electronic device comprising: a flexible
elastomeric inner layer having an inner portion and an outer
portion, wherein the inner portion has a back portion and a side
portion forming an enclosure for the portable electronic device
and; wherein the flexible elastomeric inner layer has an attachment
for retaining the portable electronic device within the enclosure;
and a thermo-formed thin film outer-layer sized and shaped to cover
the outer portion of the flexible elastomeric inner layer.
2. The case of claim 1 wherein the thermo-formed thin film outer
layer is attached to the flexible elastomeric inner layer.
3. The case of claim 1 wherein the thermo-formed thin film outer
layer is permanently attached to the flexible elastomeric inner
layer by at least one of the following: chemical bonding, thermal
bonding, co-molding and mechanical attachments.
4. The case of claim 2 wherein the thermo-formed thin film outer
layer substantially covers the outer portion of the flexible
elastomeric inner layer.
5. The case of claim 1 wherein the thermo-formed thin film
outer-layer is sufficiently deformable to allow for insertion of
the personal electronic device into the enclosure, and wherein the
thermo-formed thin film outer-layer returns to its original shape
after insertion of the personal electronic device into the
enclosure.
6. The case of claim 1 wherein the thermo-formed thin film
outer-layer is formed from at least one of the following: plastic,
polyethylene terephthalate, polycarbonate, polypropylen, biaxially
oriented polypropylene, oriented polypropylene, styrene, amorphous
polyester terephthalate, and biaxially oriented polyethylene
terephthalate.
7. The case of claim 1 wherein the flexible elastomeric inner layer
is formed from at least one of the following: silicone, rubber,
neoprene, thermoplastic polyurethane and thermoplastic
elastomer.
8. The case of claim 1 wherein the thermo-formed thin film
outer-layer has a thermo-formed thin film outer-layer inner surface
and a thermo-formed thin film outer-layer outer surface, wherein
the thermo-formed thin film outer-layer inner surface contacts the
outer surface of the flexible elastomeric inner layer, and wherein
the thermo-formed thin film outer-layer outer surface contains a
graphic.
9. The case of claim 8 wherein the thermo-formed thin film
outer-layer outer surface is smooth.
10. A method for forming a case for a personal electronic device
with a thermo-formed thin film outer-layer and a flexible
elastomeric inner layer comprising the steps of: applying a sheet
of thermo-formed film to a form; forming a thin film outer-layer
from the thermo-formed film; trimming the formed thin film
outer-layer to its final configuration; attaching the trimmed thin
film outer-layer to a flexible elastomeric inner layer.
11. The method of claim 10 wherein the attaching is performed by at
least one of the following: co-molding, chemical bonding, vibration
welding, thermal bonding, and mechanical bonding.
Description
CROSS-REFERENCE
[0001] The present application claims the benefit of U.S.
Provisional Application No. 61/536,437 filed Sep. 19, 2011, which
is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field Of Invention
[0003] The present disclosure relates generally to protective cases
for an electronic device and specifically to cases that include at
least a flexible inner layer and a thermo-formed outer layer.
[0004] 2. Description Of The Background
[0005] Mobile phones, smart phones, tablet computers, personal
readers, personal electronic assistants, MP3 players as well as
other portable electronic devices are widely used and have become a
ubiquitous part of every day life. Such devices, although designed
to be used in real world environments, often contain sensitive
electronics and are subject to damage if dropped from a normal
operating position. Despite attempts to design these complicated
electronic devices for real world application, it is often
necessary to utilize some form of protective case to shield and
protect the electronic devices from damage due to drops or falls.
Many different types and designs of cases exist and provide a wide
range of protection. Cases may range from purely decorative to
utilitarian, from soft pliable cases, to co-molded soft and hard
cases to rigid cases. Soft case tend to provide less protection
then rigid cases but are easy to use and easy to install on an
electronic device. Rigid cases provide maximum protection, but due
to the nature of the rigid materials it is often hard or not
possible to insert the electronic device into a case molded from a
single piece. Accordingly, most rigid cases often composed of
multiple parts such as a front and back or top and bottom which may
increase their size and the thickness of the materials used and the
overall bulk of the device. They often need to be snapped together
and assembled around the device to form a rigid shell for the
device. Traditional co-molded cases, having soft and hard layers
provide the optimum balance of flexibility and protection, but due
to traditional manufacturing techniques, often result in cases with
thicker then necessary outer case resulting in cases that add
significant bulk to the device. It is therefore desirable to have a
multilayer case that provides protection and flexibility while
reducing the thickness and weight of the outer case. An embodiment
of the present application discloses such a device.
[0006] The present disclosure provides for a case that protects an
enclosed personal electronic device and is manufactured using
techniques that enable a thin film thermo-formed outer layer.
SUMMARY
[0007] Embodiments of the disclosed case may include at least two
layers; a flexible inner layer and a thermo-formed thin film outer
layer.
[0008] In some embodiments, the thermo-formed thin film outer layer
may enable the flexible inner layer to be manufactured from a
softer, more flexible material than would otherwise be preferred
because, for example, the thermo-formed thin film outer layer
contributes to the overall rigidity of the case without adding
significant bulk. In an embodiment, the thin-film outer layer is
between 0.178 mm to 0.5 mm and more preferably in the 0.188 mm or
0.25 mm range. The thinner a film, the much finer detailed designs
are possible. These thin films allow for deep draw conditions, but
are easier to deform and break. Thicker films do not produce as
intricate detail designs, are harder to form in deep draw
conditions, but offer more rigidity and protection to the case as a
whole.
[0009] In some embodiments, the case may be flexible enough so that
it deforms to accommodate the insertion of a portable electronic
device and, following insertion, return to its original shape.
[0010] In an embodiment, the thermo-formed thin film outer layer
may be manufactured from a hard plastic so that it contributes to
the overall rigidity of the case and protection of the enclosed
personal electronic device.
[0011] In other embodiments, a pattern or graphic may be printed
upon the thermo-formed thin film outer layer either prior to or
following the thermo-forming process. Also, the thermo-formed thin
film outer layer may provide a smooth, no-stick exterior to the
case and thereby allow for easy removal of the case from a user's
pocket and/or for manufactured finishes that can't be achieved with
other non-smooth substances like rubber or silicon.
[0012] In many embodiments, the thermo-formed thin film outer layer
may cover the entire back surface and a substantial portion of the
side surfaces of the flexible elastomeric inner layer.
[0013] In an embodiment, a case for a portable electronic device
comprising: a flexible elastomeric inner layer having an inner
portion and an outer portion. The inner portion has a back portion
and a side portion forming an enclosure for the portable electronic
device and the flexible elastomeric inner layer has an attachment
for retaining the portable electronic device within the enclosure,
and the case further comprises a thermo-formed thin film
outer-layer sized and shaped to cover the outer portion of the
flexible elastomeric inner layer.
[0014] In still another embodiment, the thermo-formed thin film
outer layer is attached to the flexible elastomeric inner layer. In
still another embodiment, the the thermo-formed thin film outer
layer is permanently attached to the flexible elastomeric inner
layer by chemical bonding, thermal bonding, co-molding or
mechanical attachments.
[0015] In still another embodiment, the thermo-formed thin film
outer layer substantially covers the outer portion of the flexible
elastomeric inner layer. In still another embodiment, the
thermo-formed thin film outer-layer is sufficiently deformable to
allow for insertion of the personal electronic device into the
enclosure, and the thermo-formed thin film outer-layer returns to
its original shape after insertion of the personal electronic
device into the enclosure.
[0016] In still another embodiment, the thermo-formed thin film
outer-layer is formed from at least plastic, polyethylene
terephthalate, polycarbonate, polypropylen, biaxially oriented
polypropylene, oriented polypropylene, styrene, amorphous polyester
terephthalate, or biaxially oriented polyethylene terephthalate. In
still another embodiment, the flexible elastomeric inner layer is
formed from at least silicone, rubber, neoprene, thermoplastic
polyurethane or thermoplastic elastomer.
[0017] In still another embodiment, the thermo-formed thin film
outer-layer has a thermo-formed thin film outer-layer inner surface
and a thermo-formed thin film outer-layer outer surface, and the
thermo-formed thin film outer-layer inner surface contacts the
outer surface of the flexible elastomeric inner layer, and the
thermo-formed thin film outer-layer outer surface contains a
graphic.
[0018] In still another embodiment, the thermo-formed thin film
outer-layer outer surface is smooth.
[0019] A method for forming a case for a personal electronic device
with a thermo-formed thin film outer-layer and a flexible
elastomeric inner layer is disclosed. The method comprises the
steps of applying a sheet of thermo-formed film to a form, forming
a thin film outer-layer from the thermo-formed film, trimming the
formed thin film outer-layer to its final configuration, and
attaching the trimmed thin film outer-layer to a flexible
elastomeric inner layer. In another embodiment, the attaching is
performed by co-molding, chemical bonding,
vibration welding, thermal bonding, or mechanical bonding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The methods, and devices described herein are further
described in terms of particular embodiments. These embodiments are
described in detail with reference to the drawings. These
embodiments are non-limiting embodiments, in which like reference
numerals represent similar structures throughout the several views
of the drawings, and wherein:
[0021] FIG. 1 depicts a cross-sectional view of a case in
accordance with an embodiment of the present disclosure;
[0022] FIGS. 2A-2C illustrate the steps of a method of forming a
case in accordance with an embodiment of the present
disclosure;
[0023] FIG. 3 is a flow diagram of the steps of a method of forming
a case in accordance with an embodiment of the present disclosure;
and
[0024] FIG. 4 is a perspective view of a case made in accordance
with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0025] In the following detailed description, numerous specific
details are set forth by way of examples in order to provide a
thorough understanding of the relevant teachings. However, it
should be apparent to those skilled in the art that the present
teachings may be practiced without such details. In other
instances, well known methods, procedures, and/or components, have
been described at a relatively high-level, without detail, in order
to avoid unnecessarily obscuring aspects of the present
teachings.
[0026] In general, the flexible inner layer, comprising an
elastomeric material such as TPU or TPE, and/or thermo-formed thin
film outer-layer may act to protect an enclosed personal electronic
device from damage due to, for example, exposure to dirt or
contaminants, impact, or shock.
[0027] Thermo-forming the outer layer allows the material
comprising the outer layer to be thinner than if manufactured using
a traditional injection-molding process. The flexible inner layer
may be shaped to enclose a portable electronic device, such as a
mobile phone, laptop computer, or tablet computer. The flexible
inner layer may have a back surface and one or more side surfaces
shaped to cover the back and one or more of the side surfaces of
the personal electronic device, respectively.
[0028] The flexible inner layer may be made from any appropriately
flexible elastomeric material, such as rubber, silicon, neoprene,
plastic, thermoplastic polyurethane (TPU) or thermoplastic
elastomer (TPE) and may include a mechanism for maintaining the
attachment between the case and the portable electronic device.
Some attachment mechanisms include clips, extensions, adhesive
materials, overhangs, bezels, detents, tabs, friction, or a
magnetic material. The flexible inner layer may be any color or
pattern of colors. The surface of the flexible inner layer that
contacts the portable electronic device may be smooth or contoured
and may contain dimples, cutouts, texturing, relief grooves, or any
other patterning. The internal texturing may be decorative and/or
may contribute to the function or protection of the device and may
enhance adhesion of the flexible inner layer to the portable
electronic device.
[0029] The thermo-formed thin film outer-layer may be manufactured
from any appropriate thin film material such as plastic or
polyethylene terephthalate (PET), polycarbonate (PC), polypropylene
(PP), biaxially oriented polypropylene (BOPP), oriented
polypropylene (OPP), styrene, amorphous polyester terephthalate
(APET), or biaxially oriented polyethylene terephthalate (BoPET)
and may be sized and shaped to snugly fit over and cover an outer
portion of the flexible inner layer via any thermo-forming process,
such as vacuum forming, chemical forming, thermal forming, pressure
forming, high pressure forming or compression forming. In an
embodiment, the thin-film outer layer is between 0.178 mm to 0.5 mm
and more preferably in the 0.188 mm or 0.25 mm range. In another
embodiments, the thermo-formed thin film outer-layer covers all or
substantially all of the flexible inner layer.
[0030] The thermo-formed thin film outer-layer may be affixed to
the flexible elastomeric inner layer by any method including, but
not limited to clips, adhesives, interlocking parts, epoxy,
co-molding, chemical bonding, vibration welding, thermal bonding,
mechanical bonding, heat bonding, molding, or vibration
welding.
[0031] FIG. 1 depicts a cross section of a multilayer cases in
accordance with an embodiment of the present disclosure.
Thermo-formed thin film outer-layer 105 is depicted in contact with
flexible inner layer 115. Flexible inner layer 115 forms an
enclosure 20 into which a portable electronic device may be
inserted. In this embodiment, attachment 10 used to retain the
portable electronic device within enclosure 20 is incorporated into
flexible inner layer 115. It is understood, that attachment 10 may
be integrated into or separate from flexible inner layer 115. As
will be understood by one skilled in the art, the present
disclosure is not limited to only two layers, but may employ
multiple thermo-formed thin film and flexible layers to form a
multiple layer case. For example, and not limitation, a case of the
present disclosure could combine a first thermo-formed thin film
layer with a flexible layer and a second thermo-formed thin film
layer to form a case of the present disclosure.
[0032] FIG. 2A-2C depict an embodiment of a process for
manufacturing a case in accordance with the present disclosure.
First, a sheet 200 of material to be thermo-formed is thermo-formed
over a predetermined form 210 as shown in FIGS. 2A and 2B. The
thermo-formed sheet 215 may be trimmed to specifications specific
to, for example, a particular case and/or personal electronic
device design as shown in FIG. 2C. The resulting trimmed
thermo-formed thin film outer-layer case 220 may then be inserted
into a mold and over-molded with a flexible material comprising
flexible inner layer 115 as shown in FIG. 1. Additionally and/or
alternatively, thermo-formed thin film outer-layer case 220 may be
attached via any attachment method such as mechanical, chemical,
adhesive, or welding to a pre-formed flexible inner layer 115 to
form a multilayer case.
[0033] The trimmed off remainder 225 of thermo-formed sheet 215 may
be recycled or discarded. Additionally and/or alternatively sheet
200 may be large enough to be used to thermo-form multiple cases at
a single time, and form 210 may embody multiple device forms
thereby resulting in multiple thermo-formed thin film outer-layer
cases 220 being formed simultaneously.
[0034] Sheet 200 may have a pattern or design imprinted onto it by
any printing method, such as screening, or stenciling, or may have
a design or pattern integrally formed with the sheet 200 before or
after thermo-formed thin film outer-layer case 220 is formed.
[0035] FIG. 3 depicts the steps of the method depicted in FIGS.
2A-2C. At step 300, sheet 200 is placed on predetermined form 210.
At step 310 the forming process is executed resulting in a formed
sheet 215. For purposes of clarity, thermo-forming is referenced
throughout the present disclosure, but it would be understood by
one skilled in the art, that the thin-film forming process may be
carried out by other processes such as vacuum forming, chemical
forming, thermal forming, pressure forming, high pressure forming
or compression forming or any combination thereof. At step 320, the
formed sheet 215 is trimmed resulting in thermo-formed thin film
outer-layer case 220. Thermo-formed thin film outer-layer case 220
may be further finished at step 330 where openings may be added to
thermo-formed thin film outer-layer case 220 to accommodate
accessories and/or openings required for the finished case. At step
340, thermo-formed thin film outer-layer case 220 may be molded
with a flexible inner layer 115 by any known means previously
disclosed.
[0036] FIG. 4 depicts case 400 formed by an embodiment of the
present disclosure. Case 400 comprises flexible inner layer 115,
thermo-formed thin film outer-layer case 220, accessory openings
410 and accessory covers or buttons 420. As disclosed with respect
to FIG. 3, accessory openings 410 and covers or buttons 420 may be
formed during the trimming process.
[0037] Those skilled in the art will recognize that the present
teachings are amenable to a variety of modifications and/or
enhancements. While the foregoing has described what are considered
to be the best mode and/or other examples, it is understood that
various modifications may be made therein and that the subject
matter disclosed herein may be implemented in various forms and
examples, and that the teachings may be applied in numerous
applications, only some of which have been described herein. It is
intended by the following claims to claim any and all applications,
modifications and variations that fall within the true scope of the
present teachings.
* * * * *