U.S. patent application number 14/964535 was filed with the patent office on 2016-07-14 for protective edge inserts, cases including such inserts and methods of making and using.
The applicant listed for this patent is G-Form, LLC. Invention is credited to Thomas CAFARO, Maria E. MACRINA, Daniel M. WYNER.
Application Number | 20160200498 14/964535 |
Document ID | / |
Family ID | 48141459 |
Filed Date | 2016-07-14 |
United States Patent
Application |
20160200498 |
Kind Code |
A1 |
WYNER; Daniel M. ; et
al. |
July 14, 2016 |
PROTECTIVE EDGE INSERTS, CASES INCLUDING SUCH INSERTS AND METHODS
OF MAKING AND USING
Abstract
Disclosed herein are protective inserts 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) ; CAFARO; Thomas; (Foster, RI) ;
MACRINA; Maria E.; (Providence, RI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
G-Form, LLC |
Providence |
RI |
US |
|
|
Family ID: |
48141459 |
Appl. No.: |
14/964535 |
Filed: |
December 9, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13657057 |
Oct 22, 2012 |
9238540 |
|
|
14964535 |
|
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|
61549715 |
Oct 20, 2011 |
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Current U.S.
Class: |
206/521 |
Current CPC
Class: |
A45C 13/36 20130101;
B65D 81/1275 20130101; A45C 13/02 20130101; A45C 2011/003 20130101;
B65D 81/053 20130101; A45C 2013/025 20130101; A45C 11/00
20130101 |
International
Class: |
B65D 81/05 20060101
B65D081/05; A45C 11/00 20060101 A45C011/00 |
Claims
1. A protective case, comprising: a first structural wall and a
second structural wall opposite the first structural wall; a gusset
comprising a longitudinal axis, disposed between the first and
second structural walls; a compartment defined by the gusset and
the first and second structural walls, for receiving an item
therein; wherein the gusset is defined by an externally facing
protective element comprising a plurality of channels.
2. A protective case, comprising: a first structural wall and a
second structural wall opposite the first structural wall; a gusset
comprising a longitudinal axis, disposed between the first and
second structural walls; a compartment defined by the gusset and
the first and second structural walls, for receiving an item
therein; wherein the gusset is defined by an internally facing
protective element comprising a plurality of channels.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation under 35 U.S.C.
.sctn.120 of commonly owned and co-pending U.S. application Ser.
No. 13/657,057, filed on Oct. 22, 2012, which claims the benefit
under 35 U.S.C. .sctn.119(e) of U.S. Provisional Application No.
61/549,715, filed on Oct. 20, 2011. Each of the foregoing
applications are incorporated herein by reference in their
entirety.
TECHNICAL FIELD
[0002] The disclosure relates to flexible impact protective inserts
for cases, and to case containing such inserts.
BACKGROUND
[0003] "Laptop" and "notebook" portable electronic devices have a
small form factor and reduced weight for convenience when
traveling. Manufacturers of such devices strive to provide the
smallest, lightest devices possible. Unfortunately, it is difficult
to manufacture a small, lightweight, portable computer that is
rugged enough to withstand being dropped or otherwise subjected to
shock loading. The small size of today's portable computers leaves
little or no internal room for shock absorbing materials to protect
the vulnerable operating parts of the computer such as the LCD
screen, the hard drive, the various electrical connectors or the
outer case.
[0004] Each computer manufacturer's design is different, and so
there is no universally safe level of shock for portable computers.
Manufacturers of LCD screens typically do not guarantee their
screens to withstand shocks that arise from a drop of more than a
few inches. Because carrying cases for portable computers are
usually hand held or hung from shoulder straps more than six inches
from the ground, it is important that the cases provide adequate
protection from the falls and bumps typically encountered in every
day travel and use.
[0005] Many manufacturers of carrying cases for portable computers
incorporate foam padding into their cases. Foam padding will
protect a computer, unless the padding is compressed completely
(i.e., compressed to half the thickness of the foam pad). In order
to provide a sufficient level of protection, the foam thickness is
in many instances as much as three (3) inches in thickness.
[0006] Other manufacturers attempt to provide protection by using
hard shell cases, which can be made thinner, but still may require
foam padding inside to provide sufficient protection. Overall, such
cases are less economical than those that rely solely on foam
reinforcement.
[0007] Still other manufacturers have attempted to create
suspension systems for the computers within cases, which add bulk,
complexity and cost to the manufacture of the case.
[0008] It is desired to produce a computer carrying case that
provide a high level of protection from impacts, that is
streamlined, and economical to manufacture.
SUMMARY
[0009] The present disclosure is directed, in one embodiment, to a
protective insert for a protective case. The protective insert
comprises a longitudinal body comprising opposing front and back
surfaces and at least one longitudinal protective element disposed
at the front surface. The protective element can include an upper
surface and a sidewall extending downwardly from the upper surface.
A plurality of channels can be defined in the at least one
protective element, and each of the channels can include a sidewall
extending downwardly from the upper surface. A plurality of
cushioning regions can be defined by the plurality of perpendicular
channels, disposed in the at least one protective element.
[0010] The present disclosure is directed, in another embodiment,
to a protective insert that includes a longitudinal body with
opposing front and back surfaces. The body can comprise a base
layer, an intermediate layer of a rate dependent material, and a
surface layer. The body can comprise at least one longitudinal
protective element, and the protective element can comprise a
plurality of spaced apart channels. The spaced apart channels can
be disposed about perpendicular to the protective element. The rate
dependent material can be encapsulated by the base layer and the
surface layer.
[0011] In certain embodiments, the protective insert can comprise
at least two spaced apart longitudinal protective elements.
[0012] In certain embodiments, the insert can comprise a flange,
and the rate dependent material in the flange can also be
encapsulated by the base layer and the outer layer.
[0013] In certain embodiments, the protective insert can be
disposed in a case. The case can comprise opposing walls and a
sidewall disposed between the opposing walls. The insert can be
disposed in the case adjacent to the base, permanently or
releasably and temporarily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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.
[0015] FIG. 1 is a front perspective view of one exemplary
protective insert for according to the present disclosure;
[0016] FIG. 2 is a side view of the protective insert shown in FIG.
1, through line 2-2;
[0017] FIG. 3 is an end view of the protective insert shown in FIG.
1, through line 3-3;
[0018] FIG. 4 is a top view of the protective insert shown in FIG.
1;
[0019] FIG. 5 is a front perspective view of the insert shown in
FIG. 1, folded along the longitudinal axis, with the back surface
folded inwardly;
[0020] FIGS. 6 and 7 are perspective views of the protective insert
shown in FIG. 5, further folded perpendicularly to the longitudinal
axis;
[0021] FIG. 8 is a front perspective view of another exemplary
protective insert for according to the present disclosure;
[0022] FIG. 9 is a side view of the protective insert shown in FIG.
8, through line 9-9;
[0023] FIG. 10 is a top view of the protective insert shown in FIG.
8;
[0024] FIG. 11 is an end view of the protective insert shown in
FIG. 8, through line 11-11;
[0025] FIG. 12 is an end view of an alternative embodiment of the
protective insert shown in FIG. 8, through line 12-12;
[0026] FIG. 13 is a perspective view of the insert shown in FIG. 8,
folded along the longitudinal axis A;
[0027] FIG. 14 is a perspective view of the folder protective
insert shown in FIG. 13, folded perpendicularly to the longitudinal
axis;
[0028] FIG. 15 is a perspective view of a section of the insert
shown in FIG. 13, showing the relative positions of the cushioning
regions when the insert is in a folded configuration;
[0029] FIG. 16 is a perspective view of one exemplary embodiment of
an envelope-style protective case that includes protective
sidewalls and a gusset formed by the protective insert shown in
FIGS. 1-7;
[0030] FIG. 17 is a perspective view of another exemplary
embodiment of an envelope-style case that includes protective
sidewalls and a gusset formed by the protective insert shown in
FIGS. 8-15;
[0031] FIG. 18 is a perspective view of another exemplary
embodiment of an enclosed carrying case with handles, that includes
a gusset formed by the protective insert shown in FIGS. 1-7;
and
[0032] FIG. 19 is a side view of the principal compartment of the
carrying case shown in FIG. 18.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0033] The present disclosure is directed to a protective insert
that can be inserted into a variety of items, such as computer
carrying cases, to provide improved impact protection for a variety
of items carried therein, particularly for the edges of items. The
protective inserts also can be integrated into the cases.
[0034] One aspect of the disclosure is a flexible protective
insert, which can be disposed in and/or attached to the interior
and/or exterior of existing cases, and is capable of accommodating
a range of case shapes and sizes, depending on its construction.
The protective inserts can be designed and used for any type of
case for an item that may need protection, such as electronic
devices, musical instruments, wine and liquor bottles, crystal, and
the like.
[0035] Some embodiments of the protective inserts 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
inserts, 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.
[0036] The protective inserts also can be used to make protective
cases that provide improved impact protection, lighter weight,
reduced bulk, improved aesthetics, reduced manufacturing costs,
improved fit, and less abrasion to the contained article.
[0037] Protective inserts according to the present disclosure can
comprise at least one protective element 20. FIGS. 1-7, when taken
together, show one exemplary protective insert 100, comprising a
protective element 20 and a flange 30 extending outwardly from the
protective element 20 to define an outer edge 12. In the present
embodiment, the protective element 20 comprises two longitudinal
sub-elements 22, but it should be understood that the protective
element may comprise multiple sub-elements, as needed or
desired.
[0038] The protective insert 100 comprises a contoured upper
surface 14 and a back surface 16, which are common to both the
protective element 20 and the flange 30, and a thickness T.sub.1.
One suitable thickness range T.sub.1 for a protective insert that
can be used for a carrying case for electronic devices ranges from
about 1/16 to about 1/2 inch, more particularly about 1/8 to about
3/8 inch. It should be understood that the thickness T.sub.1 may be
increased or decreased from the foregoing range, as needed or
desired for the intended application.
[0039] The upper surface 14 of protective element 20 may be
contoured using a variety of geometries, including planar surfaces,
curved surfaces, and combinations of planar and curved surfaces.
Similarly, the back surface is illustrated as planar, but it should
be understood that it also may be contoured, as needed or desired,
and that both the upper and lower surfaces may contoured, as needed
or desired.
[0040] The protective insert 100 comprises a width "W.sub.1" that
may vary as needed or desired, and a longitudinal axis "A," both of
which are common to the protective element 20. Similarly, the
protective element 20 comprises a width "W.sub.2" and flange 30
comprises a width "W.sub.3," both of which are narrower than width
W.sub.1, and both of which may vary, as needed or desired,
individually or in combination. A suitable width W.sub.1 for
carrying case for electronic devices ranges from 1/4 inch to abut 3
inches, more particularly about 1/2 inch to about 2 inches, more
particularly still about 3/4 inch to about 1 inch.
[0041] In the present embodiment, the two longitudinal sub-elements
22 are disposed parallel to axis A. Sub-elements 22 are identical
in the present embodiment, and are spaced apart from each other by
a spacer region 24, which has a spacing width "S.sub.1" that can
vary as needed or desired. A spacer region width S.sub.1 for
carrying cases for electronic devices ranges from about 1/32 inch
to about 1/2 inch.
[0042] In the present embodiment, the sub-elements 22 comprise an
upper surface 14 and sidewalls 23, 25 that extend downwardly from
the upper surface 14. In the present embodiment, the sidewalls
23,25 are about perpendicular to the back surface 16. The spacer
region 24 allows the insert 200 to be folded longitudinally along
axis A.
[0043] A plurality of channels 40 may be defined in the protective
element or sub-elements 22, to define a plurality of cushioning
regions 50. Channels 40 comprise a spacing width "S.sub.2" that can
vary as needed or desired. In the present embodiment, the channels
40 are disposed about perpendicularly to axis A, but it should be
understood that the channels 40 may be disposed in other
orientations or configurations. The width, depth, orientation and
position of the channels 24, 40 may be varied, depending on a
number of factors including, but not limited to, the desired length
of the cushioning regions 50, the desired amount of flexibility for
the insert, and the like. The channels 40 allow the insert 200 to
be folded perpendicularly to axis A. Cushioning regions 50 comprise
interior sidewalls 51, 52 that may be perpendicular to the base, or
disposed at an angle .beta., which may be varied as needed or
desired, and increasing angle .beta. increases the amount of
flexibility of the insert along channels 24.
[0044] In the present embodiment, the cushioning regions 50 vary in
length from L.sub.1-L.sub.5, such that the narrowest cushioning
region 50n is disposed at the center of the sub-elements 22 with a
length L.sub.5, and the widest cushioning regions 50w are disposed
at opposite ends of sub-elements 22 with a length L.sub.5. The
thickness and length of the cushioning regions 50 may be varied,
depending on a number of factors including, but not limited to, the
desired amount of flexibility for the insert, and the like. In the
present embodiment, the length of the cushioning regions 50 varies
according to a selected ratio of 1:1.4, but those of ordinary skill
in the art will recognize that any ratio may be selected, as
desired, and that it is not necessary for the length to vary.
[0045] Flange 30 comprises a thickness T.sub.2, which is less than
the thickness T.sub.1 of insert 100, and which is sufficient to
allow the insert 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.
[0046] Flange 30 also may comprise an optional perimeter channel 60
spaced apart from the outer edge 12. Perimeter channel 60 can
comprise a width "W.sub.4" which may vary, as desired. Perimeter
channel 60 comprises a thickness T.sub.3 which is less than the
thickness T.sub.2 of flange 30, which may be useful when attaching
the insert to items such as clothing along the perimeter channel 60
area using a variety of techniques, such as by sewing, gluing,
bonding, and the like.
[0047] FIGS. 8-15, when taken together, show another exemplary
embodiment of a flexible, protective insert 200 according to the
present disclosure, which comprises common features with respect to
insert 100. In the present embodiment, the outer sidewalls 25 are
about perpendicular to the back surface 16, and inner sidewalls 23
slope downwardly toward axis A, to define an angle .theta. with
respect to a axis "B" that is perpendicular to axis A. The angled
sidewalls 23, together with the flexible channel 24, allow the
insert 200 to be folded longitudinally along axis A, to bring the
sidewalls 23 adjacent to each other. Angle .theta. may be varied as
needed or desired, and increasing angle .theta. increases the
amount of flexibility of the insert along axis A.
[0048] All of the features disclosed above in either of the
foregoing embodiments are combinable and modifiable, as needed or
desired. For example, the total thickness of the protective
inserts, the thickness of the protective elements, the spacing
between the protective elements, the width of the channel
separating the sub-elements, the width of the flange, the width of
the perimeter flange, and the like, all can be varied individually
or in combination to achieve a variety of different functional
characteristics.
[0049] Another aspect of the present disclosure involves protective
cases with gussets formed using the foregoing protective inserts.
FIGS. 8 and 18 show two different embodiments of exemplary
protective cases 300, 400 according to the present disclosure, each
of which includes a pair of opposed structural walls 310, 410,
which are mirror images thereof, and a gusset disposed between the
opposed walls to define a principal compartment (not illustrated)
for receiving the item to be protected.
[0050] The gusset of case 300 is formed from protective insert 100,
described above. In the present embodiment, protective insert 100
is disposed such that the protective element 20 faces outwardly,
and the base 16 forms a surface of the principal compartment, but
it should be understood that the orientation may be reversed.
Channel 24 allows the gusset to open outwardly along axis A, and
channels 40 allow the protective insert 100 to ease and open around
the corners of the case 300. The protective elements 50 are
disposed externally, and provide improved edge protection from
impact, which is typically where the greatest forces are reached
during impacts.
[0051] The gusset of case 400 is formed from protective insert 200,
as described above. In the present embodiment, protective insert
200 is disposed such that the base 16 faces outwardly, and the
protective element 20 forms a surface of the principal compartment,
but it should be understood that the orientation may be reversed.
Channel 24 allows the protective insert 100 to fold inwardly along
axis A, and channels 40 provide each for the protective insert 100
to squeeze together in the corners of the case 400, without adding
bulk. The folding of the protective elements along axis A and
channels 40 provides an internal receiving channel (not
illustrated) or suspension system for an item disposed in the
principal compartment, providing improved edge protection from
impact.
[0052] In both of the foregoing cases 300,400, the protective
inserts 100,200 are connected to the sidewalls by stitching (not
illustrated) through flange 30, in the flange spacer region 60, but
it should be understood that a variety of connection techniques may
be used, such as gluing, welding, heat sealing, and the like.
[0053] In both of the foregoing cases 300,400, the opposed
structural walls 310, 410 may be reversed.
[0054] Those of ordinary skill in the art will recognize that it is
not necessary for the cases to have rectangular shape, and that
they may have any shape and/or configuration. Those of ordinary
skill in the art will recognize that the case may comprise a
closure, and that a variety of closures may be used including, but
not limited to, zippers, including waterproof, air resistant and
plastic zippers (e.g., Ziploc-style zippers); pillow flap type
enclosures; envelope-style enclosures; hook and eye tape; magnets;
clips; and the like. Those of ordinary skill in the art will
recognize that any number of protective inserts may be used to form
the gusset, and that the protective inserts may have any shape,
size and/or configuration, as desired.
[0055] In another aspect of the present disclosure, the protective
inserts according to the present disclosure can be used to retrofit
cases that have little or no protection. FIGS. 18 and 19 show an
exemplary embodiment of a retrofitted protective case 500 according
to the present disclosure, which includes a flexible, rectangular
case body defined by a pair of opposed front and back walls 510,
which are mirror images thereof, and a sidewall 520 disposed
between the opposed walls 510 to define a principal compartment 530
for receiving an item to be protected, with a zipper closure 520
extending partially around the case body. A protective insert 100
is disposed in the principal compartment 520 such that the
protective elements 50 are disposed internally. Channels 40 allow
the insert 100 to fold into the corners, without adding bulk to the
interior of the case. The protective insert can also be releasably
disposed in the principal compartment 500 between the opposed walls
to define a shock absorbing cradle which can be removed so that the
carrying case can be used for other purposes. If desired, the
protective insert also may be releasably attached to the sidewall
520 in the principal compartment using a variety of attachment
devices and/or techniques such as a pressure sensitive adhesive,
Velcro, snaps, rivets, and the like. Similarly, the protective
insert also may be permanently affixed to the sidewall 520 in the
principal compartment using a variety of techniques such as a
stitching, gluing, welding, and the like.
[0056] Optionally, the opposed front and back walls 510 also may be
retrofitted with a protective insert 600, as shown in FIG. 19.
Protective insert 600 is an example of a protective insert
comprising multiple rows comprising a plurality of circular
cushioning members 650. The protective insert 600 is disposed on
the back wall of the principal compartment, attached permanently or
temporarily using similar techniques as described above.
[0057] Those of ordinary skill in the art will recognize that it is
not necessary for the cases to have rectangular shape, and that
they may have any shape and/or configuration. Those of ordinary
skill in the art will recognize that a variety of closures maybe
used in the cases including, but not limited to, zippers, including
waterproof, air resistant and plastic zippers; pillow flap type
enclosures; envelope-style enclosures; hook and eye tape; magnets;
clips; and the like. Those of ordinary skill in the art will
recognize that any number of protective inserts may be used to form
the gusset, and that the protective inserts may have any shape,
size and/or configuration, as desired.
[0058] Optionally, any of the cases disclosed above can comprise a
protective binding (not illustrated) attached to the outer edge at
the closure. The binding can comprise the same material as used for
the protective inserts, particularly with ballistic fabric, which
provides a rugged edge. The binding can be disposed such that the
ballistic material is inverted, so protective insert is internal on
the edge, and vice versa.
[0059] Optionally, any of the cases 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.
[0060] Optionally, any of the cases 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.
[0061] Optionally, any of the cases 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.
[0062] Optionally, any of the cases disclosed above can comprise a
structural insert (not illustrated) disposed in the case body to
provide some rigidity to the side panels. The structural insert can
comprise the same material as used for the protective inserts, or
can comprise a rigid material. When the cases comprise a liner, a
structural insert can be disposed between the liner and the case
body. 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.
[0063] The protective inserts can comprise an optional base layer,
and optional outer layer, or optionally both base and outer layers.
In addition, an additional layer or layers of materials can be
disposed adjacent to, including bonded to, the surface layer for
further improvements in durability and/or aesthetics.
[0064] When the optional inner and outer layers are used, the
material described above becomes an intermediate layer disposed
between the inner and outer layers, such that the intermediate
layer may be encapsulated, and optionally bonded to the base and/or
outer layers, which improves performance of the protective inserts
in high humidity and under harsh conditions, such as encountered in
commercial laundering, cleaning procedures in medical environments,
and the like.
[0065] The protective inserts, or intermediate layer of the
protective insert, can comprise a variety of materials such as, but
not limited to, polymeric materials, including foamed polymeric
materials, composite materials, and the like.
[0066] The polymer material can comprise any polymeric material
comprising 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, without substantial
degradation. Examples of suitable polymeric materials include, but
are not limited to, thermosetting polymeric materials, elastomeric
polymeric materials, thermoplastic materials, including
thermoplastic elastomeric materials, composites thereof, foams
thereof, and combinations comprising at least one of the foregoing.
Some possible polymeric materials include, but are not limited to,
polyurethane, silicone, and/or the like, and combinations
comprising at least one of the foregoing materials.
[0067] 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 a rate dependent foam. For such
applications, it can be desirable for the rate dependent foam 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.
[0068] 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.
[0069] 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
inserts, and to the encapsulation of the intermediate layer.
[0070] Those of ordinary skill in the art will recognize that a
combination of the foregoing materials and techniques can be used
to make protective cases for a variety of devices that need to be
protected, while providing the capability to modify the width of
the case by varying the width of the protective inserts and/or
protective elements, to adapt to cases of varying sizes. The case
and protective inserts 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.
[0071] Construction of the foregoing cases comprises selecting a
suitable material for the case body, selecting suitable dimensions
for the case body, attaching one or more protective inserts to the
case body to form the gusset, 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.
Those of ordinary skill in the art will recognize that a variety of
attachment methods may be used to attach the protective inserts to
the case body to form the gusset 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. In the foregoing embodiments, the
protective inserts were attached to the case body by stitching
through the case body and the perimeter channel 60, adjacent to the
protective elements 50.
[0072] The size, shape, configuration, thickness and material
composition of any of the protective inserts disclosed herein may
be varied, depending on a number of factors including, but not
limited to, desired amount of flexibility, the degree of bend
required to wrap around corner or shaped device elements, the
amount of impact protection desired, and the like. In addition,
size, shape, configuration, thickness and material composition of
the protective inserts may be varied, and more than one type of
shape may be used in the protective inserts.
[0073] The case body 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.
[0074] 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.
[0075] 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.
[0076] 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 inserts for a variety of devices that
need to be protected. Cases incorporating the protective inserts
provide improved protection from impact on the outer edges of a
device. 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.
[0077] Suitable materials and methods of making certain of the
multilayer protective inserts and case bodies are disclosed in U.S.
Publication Nos. 2007/0261274, 2012/00084896 and 2012/0261289, the
subject matter of which is incorporated herein by reference in its
entirety.
[0078] 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; 3) improved economics as a result of the methods of making
the panels and retaining devices; and 4) the encapsulated
protective inserts 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.
[0079] 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).
[0080] 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.
[0081] 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.
[0082] 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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