Abstract:
A protective case for a mobile device having a multi-layered construction is disclosed. The multi-layered construction includes three layers that are co-molded to one another and is capable of being lightweight and low-profile, yet provide a high level of impact protection. The first layer generally forms the external back face surface of the case, the third layer generally forms the perimeter bumper of the case and the second layer forms the internal liner of the case and includes an elevated pattern of walls upon which the back face of the mobile device rest upon. The first layer is comprised of material that has a hardness greater than the other two layers. The third layer is comprised of a material that has a hardness that is greater than the second layer. The layers are configured to interact with one another so that they are capable of distributing and absorbing impact forces to mitigate damage to the mobile device.

Description:
INCORPORATION BY REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 14/585,148, filed Dec. 29, 2014, which claims benefit under 35 U.S.C. §119(e) from U.S. Provisional Application No. 61/923,631, filed on Jan. 3, 2014. The above applications are hereby incorporated herein by reference in their entirety and are to be considered as a part of this specification. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This patent document relates to user removable protective enclosures or cases for mobile devices and more particularly to such cases that have a unique integrated multi-layered construction. 
     Description of the Related Art 
     Mobile devices, such as smart phones, tablets, laptops and the like are known to sustain damage from impact and from contamination as a result of ingress of water or other fluid. The damage, for example, may result in a cracked screen, scratches on a finished surface, lost or damaged buttons or controls, cracked or bent external body components, and/or failed or malfunctioning electrical components. Protective cases have thus been provided to protect mobile devices from such and variant types of damage. 
     The bulkiness and weight of the protective case can be an issue for consumers. Thick and heavy cases, while capable of providing improved protection, are contrary to the very utilitarian qualities of mobility (lightweight and small size) that makes such mobile devices so attractive to consumers. Indeed many users carry their devices in their front or back pant pockets. Even a relatively modest increase in bulk or weight can, therefore, be more noticeable, uncomfortable, and less desirable. 
     Accordingly, it is here recognized that there is a continuing and an ever increasing desire to minimize the bulkiness and weight of protective cases for mobile devices yet maintain a high level of protection. 
     SUMMARY OF THE INVENTION 
     There exists a continuing need for new and improved designs for protective cases for mobile devices that provide high level of protection, yet are low profile. 
     Disclosed are numerous aspects of a unique and inventive protective case configured to receive, retain and protect a mobile device that includes a front face and a back face that define the height of the mobile device, a perimeter defined by top-end, bottom-end, right, and left sides residing between the front and back faces, and corners defined at the intersecting regions of the sides. The case may be for a mobile device that is in the form of a tablet, a mobile phone, an MP3 audio player, a gaming device, or other portable handheld electronic device and may have one or more touchscreens, including on its front face and/or back face. 
     The case may be formed of multilayered construction that includes three layers, various aspects of which are described. The first layer is defined by inner and outer surfaces and dimensioned to cover a portion of the back face of the mobile device and/or extend around a portion of the perimeter of the mobile device at the back face boundary. The inner surface of the first layer includes a plurality of protrusions that extend in a direction generally away from the outer surface. 
     The second layer is defined by inner and outer surfaces and also dimensioned to cover a portion of the back face of the mobile device and extend around a portion of the perimeter of the mobile device at the back face boundary. The second layer may further include a plurality of corner protrusions positioned along the perimeter region of the second layer to correspond in location with the corners of the mobile device. The second layer may further include an elevated pattern of interconnected walls extending from its inner surface a height above and in a direction away or opposite from the second layer&#39;s outer surface. The second layer further includes a plurality of apertures extending into its outer surface that surround (e.g., in close and firm proximity or contact with) one or more of the protrusions of first group of protrusions of the first layer. The second and/or first layers may each be configured to cover the entire, a majority, half or less than half of the back face of the mobile device and may be configured to extend around the entire, a majority, half or less than half of the perimeter of the mobile device at the back face boundary. 
     The third layer is similarly defined by third inner and outer surfaces and dimensioned to cover a portion of the top-end, bottom-end, right and/or left sides of the mobile device. The third layer may include one or more indentations in its inner surface at the corners. The indentations may be in the reverse image of, or otherwise dimensioned to receive, one or more of the corner protrusions of the second layer. The third layer may also include control apertures that are dimensioned and positioned to allow access to control buttons or ports on the mobile device. 
     The first, second, and third layers may be co-molded to form an integrated construction. The first layer may be made of a first material that has a first hardness, the second layer may be made of a second material that has a second hardness, and the third layer may be made of a third material that has a third hardness. The first hardness is greater than the third hardness, which in turn is greater than the second hardness. 
     For example, the first layer may have a Shore A durometer hardness that is 40% or more greater than the third layer, 30% or more greater than the third layer, 20% or more greater than the third layer, or 10% or more greater than the third layer all +/−5% as measured using the American Society for Testing and Materials (ASTM) standard D2240. The second layer may have a Shore A durometer hardness of 45+/−10, 45+/−5, or 45 as measured using the American Society for Testing and Materials (ASTM) standard D2240. The third layer may have a Shore A durometer hardness of 65+/−10, 65+/−5, or 65 as measured using the American Society for Testing and Materials (ASTM) standard D2240. The third layer may also, for example, have a Shore A durometer hardness that is 40% or more greater than the second layer, 30% or more greater than the second layer, 20% or more greater than the second layer, or 10% or more greater than the second layer all +/−5% as measured using the American Society for Testing and Materials (ASTM) standard D2240. 
     The first, second and third layers may be formed of a composition comprised of one or more materials including but not limited to polycarbonate (PC); thermoplastic urethane (TPU), thermoplastic elastomer (TPE), acrylonitrile butadiene styrene (ABS), nylon, metal, silicone rubber, or any combination thereof. For example, the first layer, which is the hardest of the three layers, may be formed of a composition comprised of polycarbonate, a combination of polycarbonate and ABS, nylon, fiber reinforced plastic, and/or metal. The second layer, which is the softest of the three layers, may be formed for example of a composition comprised of TPE, silicone rubber, or combination thereof or other suitable materials. The third layer, which has a hardness between the other two layers, may be formed for example of a composition that has a relatively high resistance to scratching such as a composition comprised of TPU and/or TPE or combination thereof or other suitable material. 
     Thus it is contemplated that in operation, when there is an impact at the corners, the third layer, which has a high resistance to scratching and a higher hardness than the second layer, distributes the force and to the extent the energy of the force is transferred to the second layer, the second layer can dampen the shock, especially at the impact prone corners, to thereby mitigate the transfer of the impact energy to the device. 
     One or more of the plurality of protrusions of the first layer may have a first external shape selected from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon, and heptagon. Also one or more of the plurality of protrusions may include an aperture residing within the protrusion that defines a first shape selected from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon, and heptagon. Also, the plurality of protrusions in the first layer may be dimensioned to be below, above, or flush with the height of the walls of the second layer that surround the protrusions. Thus, some of the plurality of protrusions in the first layer may be dimensioned to be flush with the height of the interconnected walls in the second layer adjacent thereto, some of the plurality of protrusions may be dimensioned to be below the height of the interconnected walls adjacent thereto, and some of the plurality of protrusions may be dimensioned to be above the height of the interconnected walls adjacent thereto. The plurality of protrusions may be comprised of multiple groups of protrusions with each protrusion in each group being equally or unequally spaced from one another or spaced in a defined pattern. The plurality of protrusions may be comprised of a first group configured to reside nearer the top end or side than the bottom end or side, a second group may be configured to reside nearer the bottom end or side than the top end or side, and a third group may be configured to reside an equal distance from the right and left sides. 
     The number of corner protrusions in the second layer may be two, three, four or more (depending on the number of corners on the mobile device), each of which is configured to reside at one, some or all of the corners of the mobile device or any combination of corners thereof. For example, one corner protrusion may be configured to reside at a corner defined in part by the top side of the mobile device and another corner protrusion may be configured to reside at a corner defined in part by the bottom side. By way of another example, one corner protrusion may be configured to reside at a corner defined in part by the right side of the mobile device and another corner protrusion may be configured to reside at a corner defined in part by the left side of the mobile device. By way of yet another example, a first corner protrusion may be configured to reside at a corner defined in part by the top side of the mobile device (e.g., the intersection between the top side and the right or left side), a second corner protrusion may be configured to reside at a corner defined in part by the bottom side (e.g., the intersection between the bottom side and the right or left side), a third corner protrusion may be configured to reside at a corner defined in part by the right side (e.g., the intersection between the right side and the top or bottom side), and a fourth corner protrusion may be configured to reside at a corner defined in part by the left side (e.g., the intersection between the left side and the top or bottom side). Correspondingly dimensioned corner indentations in the inner surface of the third layer may be provided to engagingly surround or receive one, some or all of the corner protrusions. Thus, some or all of the surfaces that define the indentions on the third layer may be in contact with a corresponding corner protrusion on the second layer. 
     The corner protrusions may be configured or dimensioned to reside above, below or flush with the height of the mobile device in any combination. For example, one of the corner protrusions may be configured to extend above the height of the mobile device and another of the corner protrusions may be configured to be flush with the height of the mobile device. Alternatively, all of the corner protrusions may be configured to be flush with the height of the mobile device or may be configured to reside below the height of the mobile device. One or all of the corner protrusions may also have uniform or varying dimensions in width and thickness between the base and the apex of the protrusion. For example, the corner protrusions may include a thickness defined between the inner and outer surfaces that varies with the height of the protrusion, such as being thicker (or thinner) at the base of the corner protrusion as compared to the thickness nearer the apex of the corner protrusion. By way of another example, the width generally perpendicular to the thickness may be wider (or narrower) at the base of the corner protrusion as compared to width near the apex of the corner protrusion. 
     The pattern of elevated interconnected walls of the second layer may be comprised of any arrangement of shapes selected for example from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon and heptagon or combination thereof. By way of example, the interconnected walls may be comprised of walls that form hexagons or portions thereof, which together create a honeycomb wall pattern. The apertures in the second layer and the plurality of protrusions of the first layer may also be hexagonal in shape and dimensioned to closely or snugly fit or mate together, so that one, some or all six of the walls that form the mating hexagons are in contact with one another. The pattern of elevated interconnected walls may be contiguous or dis-contiguous, may or may not extend to the perimeter regions of the second layer, may be positioned in discrete regions, or may be spaced apart from one another. Various patterns comprising one or more shapes may be employed alone or in combination with other patterns, such that one region of the inner surface of the second layer may have one pattern and another region of the inner surface of the second layer may have another pattern. The elevated pattern of interconnected walls may be configured in height and construction so as to suspend the back face of the mobile device above the apertures defined by the interconnected walls so that the back face of the mobile device does not bottom-out on (or become in contact with) the recessed inner surface of the second layer. Although not depicted, a pattern of interconnected walls may also be employed on the inner surface of the third layer to create an air-suspension frame around the mobile device at the perimeter and front face regions of the mobile device as well as the one created by the second layer vis-à-vis the back face region. 
     The second layer may further comprise one or more button protrusions that are dimensioned and configured to extend within one or more of the control apertures of the third layer. Each button protrusion may or may not be co-molded to the perimeter of the control aperture to form an integrated region therewith and may be configured to reside above or over a user control button on the mobile device such as a volume, power, mute, or other user button. 
     The third layer may also include one or more stability tabs configured to extend underneath the back face of the mobile device. The inner surface of the tab may be in contact with the outer surface of the second layer, while the outer surface of the tab may be exposed externally. The tab may be received within an aperture on the first layer that opens to the perimeter. The aperture may be configured to reside nearer one end of the mobile device than the other and may be configured to reside nearer to one side of the mobile device than the other. Alternatively the aperture and tab may be configured to be centrally positioned relative to one or more sides of the mobile device. 
     The third layer may also be configured to include a retention rim positioned to reside over the perimeter region of the front face of the mobile device to retain the mobile device within the case. The retention rim may encircle a portion or the entire front face. For example the retention rim may be configured to extend along the top, bottom, left, or right sides of the mobile device or any combination thereof. It is contemplated for example that the rim extend only in the corner regions or regions other than in the corners, or combination of corner and non-corner regions, which may facilitate insertion and removal of the mobile device from the phone. In this respect, the case is configured and constructed with sufficient flexibility to allow the user to install and remove the mobile device within the case without damaging the case or the mobile device. 
     The second layer may include one or more apertures to allow for functionality and so as to facilitate the intended use of the mobile device. For example, the second layer may include a camera lens aperture that extends there through and is configured to reside around the outside of a camera lens window on the back face of the mobile device. The walls that define the apertures may extend through the first layer and may overlap the outer surface of the third layer. To the extent there is a touchscreen on the back face or other surface region of the mobile device, second and first layer may have an aperture to allow user interaction with that touchscreen. 
     Methods of manufacturing a protective case that includes one or more of the various foregoing aspects are also disclosed. Manufacturing steps may, for example, include: 
     (1) co-molding three distinct layers within a mold to form an integrated protective case construct. 
     (2) molding the first layer defined by first inner and outer surfaces and dimensioned to cover at least a portion of the back face of the mobile device and extend around at least a portion of the perimeter of the mobile device at the back face boundary. The first layer may be molded to include a first plurality of protrusions extending from its inner surface in a direction away from its outer surface and being molded of a material that is harder than each of the second and third layers. 
     (3) co-molding, around the perimeter regions of the first layer, the third layer defined by third inner and outer surfaces and dimensioned to cover one or more regions of the top, bottom, right and left sides of the mobile device. The third layer may be further molded to include one or more control apertures dimensioned and positioned to allow access to control buttons or ports on the mobile device. The third layer may be further molded to include indentations in its inner surface at regions configured to reside at the corners of the mobile device, the indentations being dimensioned to surround corner protrusions of the second the layer. The third layer may be molded of material that is harder than the second layer. 
     (4) co-molding, onto the inner surface of both the first and third layers, the second layer defined by second inner and outer surfaces and dimensioned to cover at least a portion of the back face of the mobile device and extend around at least a portion of the perimeter of the mobile device at the back face boundary. The second layer being molded to include a plurality of corner protrusions positioned along the perimeter region of the second layer to correspond in location with corners of the mobile device and dimensioned to extend at, below, or above the height of the mobile device (as measured thereat between the front and back faces). The second layer may be further molded to include a pattern of walls extending from its inner surface a height above and in a direction away from its outer surface. The pattern of walls may form any arrangement of shapes selected for example from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon and heptagon or combination thereof. The second layer may further include a plurality of apertures that surround and are in contact with one or more of the protrusions in the first layer. 
     The various configuration and construction aspects of the three component layers described above or otherwise herein (including as illustrated in the drawings) may be included in the molding process of the layer with any of the foregoing steps, or portions of any of the foregoing steps, in any combination without limitation. 
     Each of the foregoing and various aspects, together with those set forth in the claims and summarized above or otherwise disclosed herein, including the drawings, may be combined to form claims for a device, apparatus, system, method of manufacture, and/or use without limitation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects and advantages are described below with reference to the drawings, which are intended to illustrate but not to limit the invention. In the drawings, like reference characters denote corresponding features consistently throughout similar embodiments. 
         FIGS. 1A-1F  are front face, back face, left side, right side, top side and bottom side views of a protective case for a mobile device with the mobile device received within the case. The mobile device depicted in the illustration is a depiction of an Apple iPhone 5s® mobile phone. 
         FIG. 2A  is a front face view of the protective case illustrated in  FIGS. 1A-1F  without the mobile device therein. 
         FIG. 2B  is a bottom side view of the protective case illustrated in  FIG. 2A . 
         FIGS. 2C-2D  are front and back face perspective views, respectively, of the disassembled protective case illustrated in  FIG. 2A  showing the three component layers of the case. The perspective views are both taken from the left side. 
         FIG. 3  is a more detailed partial cross-sectional front face view taken along plane A-A of  FIG. 2B  showing in greater detail the construction of the case at the bottom end region including the corners and sides thereof and the relationship and configuration of the three integrated component layers. 
         FIG. 4  is a more detailed partial cross-sectional view of the protective case illustrated in  FIG. 2A  taken along cross-section line B-B showing in greater detail the construction of the case and the relationship and configuration of the three integrated component layers. 
         FIG. 5  is a more detailed cross-sectional view of the protective case illustrated in  FIG. 2A  taken along cross-section line C-C showing in greater detail the construction of the case and the relationship and configuration of the three integrated component layers. 
         FIG. 6  is a more detailed cross-sectional view of the protective case illustrated in  FIG. 2A  taken along cross-section line D-D showing in greater detail the construction of the case and the relationship and configuration of the three integrated component layers. 
     
    
    
     Each drawing is generally to scale and hence relative dimensions of the various layers can be determined from the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As summarized above and illustrated in the drawings, disclosed herein are various aspects of a protective case for a mobile device capable of minimizing bulkiness and weight, yet maintain a high level of protection. Many of those aspects are summarized above and illustrated in the drawings. 
     Commonly disclosed in  FIGS. 1-6  is a protective enclosure or case  200  for a mobile device  100  that illustrate, by way of example, various configuration and construction aspects of the case. In this particular implementation, the case is configured for an Apple iPhone 5s mobile or smart phone device. It should be understood, however, that the case may be configured for any mobile device or electronic device, including but not limited to portable or cellular phones, PDAs, gaming devices, laptop computers or tablet devices. 
     As best depicted in  FIGS. 1A-1F , the mobile device  100  includes front and back faces  110  and  120 , and a left side  130 , a right side  140  (hidden from view), a top side  150 , and a bottom side  160  that together define the perimeter  170  of the mobile device  100 . The front and back faces are flat and the sides have flat surfaces that extend between the front and back faces  110 ,  120  and the distance between the front and back faces  110 ,  120  define the height of the device  100 . Corner regions  180  are defined at the curved regions where the sides intersect with one another. The front face  110  includes a touchscreen  112  user interface, a home button  114  with biometric sensor (surround the home button), speakers, a front facing camera, and proximity sensors  116 ,  117 , and  118  (located at the top end region on the front face of the phone) that are not shown in the illustrations, but well known to one of ordinary skill in the art. The back face  120  includes a camera lens window  122 , a flash  124 , and a microphone  125  that are grouped together in the upper corner on the right side of the phone  100 . The left side  130  includes volume control buttons  132  (hidden below the corresponding case + and − buttons) and ringer silent switch  134  that controls whether or not the phone is on silent mode. The top side  150  includes a depressible power button  152  (also hidden behind the corresponding power button  254  on the case). The bottom side  160  includes a headphone jack  162 , microphone grill  164 , and a data and charging port  166 . 
     Generally, the protective case  200  includes front and back face walls  210  and  220  and left side and right side walls  230  and  240  and top side and bottom side walls  250  and  260 . The side walls,  230 ,  240 ,  250 , and  260  reside between the front and back faces. Each of the walls  210 ,  220 ,  230 ,  240 ,  250 , and  260  are dimensioned to correspond in dimension to the front and back faces, and left, right, top and bottom sides  110 ,  120 ,  130 ,  140 ,  150 , and  160  of the mobile device  100 , respectively. 
     More specifically, the front face wall  210  is defined by inner and outer surfaces  211  and  212  and includes an inwardly projecting rim  214  (best illustrated in the cross-sectional views of  FIGS. 5 and 6 ). The back face wall  220  is also defined by inner and outer surfaces  221  and  222  and includes a camera lens and flash opening or aperture  224  extending there-through. 
     The left side and right side walls  230  and  240  are also each defined by inner and outer surfaces  231 ,  232  and  241 ,  242 , respectively. The left side wall  230  further includes volume control buttons  234  that are positioned, dimensioned, configured and adapted to interface and actuate the volume control buttons  132  on the mobile device  100 . Also included in the left side wall  230  is an opening or aperture  236  that is positioned and dimensioned to correspond with the ringer silent switch  134  of the mobile device  100  to provide functional user access to the switch  134 . The right side wall  240  does not include any apertures or control buttons as none are provided on the Apple iPhone 5s mobile device for which the case is configured to protect. However, it is contemplated that it may include either apertures and/or buttons to provide access or control over corresponding ports or buttons on the mobile device should the device have controls or ports on that side. It should be understood however, that the number of apertures can vary (increase or decrease) and their placement vary to correspond with controls on the mobile device. 
     The top side and bottom side walls  250  and  260  are also each defined by inner and outer surfaces  251 ,  252  and  261 ,  262  respectively. The top side wall  250  includes a mobile device power button  254  positioned, dimensioned, configured, and adapted to interface with the power button  152  on the mobile device  100 . In the implementation illustrated the button  254  resides within an aperture  255  and is connected thereto. For example, the button  254  may be connected in a levered manner  256  to top side wall  250  at one end or at a mid-section of the aperture  255 , such that when pressed, the button  254  hinges around the lever connection. The bottom side wall  260  includes perforated regions  264  positioned and dimensioned to correspond with the microphone grill  164  regions on the mobile device  100 . The bottom side wall  260  further includes a headphone jack and data/charging port apertures  266  and  267  that are positioned and dimensioned to correspond with the headphone jack port  162  and the data and charging port  166 , respectively. Collectively the side walls  230 ,  240 ,  250  and  260  define a perimeter  270  between the front and back faces  210  and  220  of the protective case  200 . 
     The case  200  is formed of a multilayered construction that includes three layers  300 ,  400  and  500  that are co-molded together to form a unitary integral construct. Various aspects of these layers and their inter-relationship, construction and manufacture are described in more detail. 
     As best illustrated in  FIGS. 2C-2D , the first layer  300  is defined by first inner and outer surfaces  310 ,  311 , respectively, and dimensioned to cover the back face  120  of the mobile device  100 . The first layer  300  is configured to extend to the perimeter  170  of the mobile device  100  at the back face  120  boundary, which is the perimeter defined by the intersection of the side walls (e.g.,  130 ,  140 ,  150  and  160 ) and the back face  120  of the mobile device  100 . The first inner surface  310  includes a first plurality of protrusions  320  (best illustrated in  FIGS. 2A and 2C ) extending generally in a direction away from the outer surface  311  of the first layer  300 . 
     The second layer  400  is defined by second inner and outer surfaces  410 ,  411  respectively, and is also dimensioned to cover the back face  120  of the mobile device and extend around the perimeter  170  of the mobile device  100  at the back face  120  boundary. The second layer  400  further includes a plurality of corner protrusions  420  positioned along the perimeter region of the second layer  400  to correspond in location with the corners  180  of the mobile device  100 . The corner protrusions  420  are dimensioned to reside at a height that is slightly below the height of the mobile device  100  at the corners  180 . However, it is contemplated, that one, some or all of the corner protrusions  420  may extend at, below, or above the height of the mobile device  100  in any combination. The second layer  400  may further include an elevated pattern of interconnected walls  430  extending from the second inner surface  410  a height above and in a direction away from the second outer surface  411 . Also included in the second layer  400  is a plurality of apertures  440  extending into the second outer surface  411 , such that one or more of the apertures  440  are dimensioned and positioned to surround (e.g., in close proximity and firm contact) one or more of the protrusions  320  of the first layer  300 . 
     The first and second layers  300 ,  400  may be configured to cover the entire, a majority, half or less than half of the back face  120  of the mobile device  100  and may be configured to extend to or around the entire, a majority, half or less than half of the perimeter  170  of the mobile device  100  at the back face  120  boundary. 
     In the illustrated implementation, the first layer  300  is configured to cover nearly the entire back face  120  of the mobile device  100 , with the exception of the flash and camera lens window aperture  224  and nearly the entire perimeter  170  of the back face  120  with the exception of the tab aperture  350 , described in more detail below. It should be understood however, that alternative configurations may be employed. For example, interposed or intervening regions, such as those between the protrusions  320  and/or apertures  440 , may be removed from the first and/or second layers  300 ,  400  while perimeter regions of the first and/or second layers  300 ,  400  may be maintained. Perimeter regions in the first and/or second layers  300 ,  400  that reside between one or more of the corners may be removed. Mid-section regions of the layers  300  and  400  may be removed to allow for access to, or user utilization of, user controls, additional touchscreen interface, and/or other device features (e.g., speakers, cameras, lights, microphone, etc.) that are located on the sides walls  130 ,  140 ,  150 ,  160  and/or back face  120  of the mobile device  100 . 
     Additionally, while the pattern of walls  430  in the second layer  400  is illustrated as being interconnected and elevated, it should be understood that the walls may be disconnected at one or more locations or in discrete regions. Also, while the pattern of walls  430  are illustrated as having a generally uniform height or elevation, it should be understood that the walls  430  may have differing heights at discrete regions within the pattern or within or at specific walls or wall segments within the pattern of walls  430 . 
     The third layer  500  is also defined by third inner and outer surfaces  510 ,  511 , respectively. The third layer  500  is generally dimensioned to cover the top, bottom, right and/or left sides  130 ,  140 ,  150 ,  160  of the mobile device  100  and forms the inwardly projecting rim  214  of the front face wall  210 . While in the illustrated embodiment, the third layer  500  extends around the entire perimeter of the mobile device  100 , it may be configured elsewise. Thus it is contemplated that the third layer  500  may cover the entire, a majority, half or less than half of the top, bottom, right and/or left sides of the mobile device  100  and/or may be configured to extend around less than the entire, a majority, half or less than half of the perimeter  170  of the mobile device  100  in any combination. Thus, for example the third layer may cover the corners of the mobile device alone or may cover the corners of the mobile device with and only a portion of one or more of the sides extending there-between. The third layer  500  includes one or more mobile device  100  control apertures  530  that extend through the layer that are dimensioned and positioned to allow access (or flow through with respect to speakers and the like) to control buttons or ports (e.g., power button  152 , volume button  132 , ringer silent switch  134 , headphone jack  162 , microphone grill  164 , and data/charging port  166 ) on the mobile device  100 . The third layer also further includes one or more indentations  540  in the third inner surface  510  at regions configured to reside at the corners  180  of the mobile device  100 . The indentations  540  are configured to be in the negative image of the corner protrusions or otherwise dimensioned to receive one or more of the plurality of corner protrusions  420  of the second layer  400 . 
     While, the first, second, and third layers  300 ,  400 ,  500  may be co-molded to form an integrated construction, it should be understood that it is contemplated that only portions of one or more of the layers may be co-molded, or each of the layers may be separately formed and mechanically attached to one another by clips, snaps or latches between each of the components or between for example the third layer and the first layer. A combination of co-molding and mechanical attachment of the layers or portions thereof may also be employed. In a fully integrated or co-molded construction the case  200  would be properly dimensioned and have sufficient flexibility to allow the user to insert and remove the mobile device  100  without damage to the case  200 . When the components are modular or separable from one another, the user may wrap the second layer around the mobile device  100  and then clip the first and third layers in position around the device  100 . The clips, snaps or hooks or other mechanical attachments be formed or molded into: (a) two or more of the layers at their perimeter regions, (b) the protrusions  320  and apertures  440  of first and second layers  300 , and  400 , (c) one or more of the corner protrusions  420  and indentions  540  in the second and third layers  400 ,  500 , (d) the control buttons  234  and corresponding apertures  530  on the second and third layers  400 ,  500  and/or (e) at any region where two or more layers are in contact or proximity to one another. Thus, a combination of co-molding and/or mechanical attachment of the layers may be employed. One or more of the layers may be adhesively attached or otherwise bonded to one another. 
     The materials that form the layers may be selected based on their hardness. For example, the first layer  300  may be made of a first material that has a first hardness, the second layer  400  may be made of a second material that has a second hardness that is different from the first layer, and the third layer  500  may be made of a third material that has a third hardness that is different from the first or second hardness. In a preferred implementation, the first hardness is greater than the third hardness and the third hardness is greater than the second hardness. 
     The first, second and third layers  300 ,  400 ,  500  may be formed of a composition comprised of one or more materials including but not limited to polycarbonate; thermoplastic urethane (TPU), thermoplastic elastomer (TPE), acrylonitrile butadiene styrene (ABS), nylon, metal, silicone rubber, or any combination thereof. For example, the first layer  300 , which is the hardest of the three layers, may be formed of a composition comprised of polycarbonate, a combination of polycarbonate and ABS, nylon, fiber reinforced plastic, and/or metal. The second layer  400 , which is the softest or least hard of the three layers, may be formed for example of a composition comprised of TPE, silicone rubber, or combination thereof or other suitable materials. The third layer  500 , which has a hardness between the other two layers, may be formed, for example, of a composition comprised of TPU and/or TPE or combination thereof or other suitable material. The second layer may be an elastic material. 
     The first layer  300  may have a Shore A durometer hardness that is 50% or more greater than the third layer  500 , 40% or more greater than the third layer  500 , 30% or more greater than the third layer, 20% or more greater than the third layer, or 10% or more greater than the third layer all +/−5% as measured using the American Society for Testing and Materials (ASTM) standard D2240. The first layer may have a Shore A durometer hardness of 100+/−15, 100+/−10, or 100+/−5, or 100 as measured using the American Society for Testing and Materials (ASTM) standard D2240. The second layer  400  may have a Shore A durometer hardness of 45+/−15, 45+/−10, 45+/−5, or 45 as measured using the American Society for Testing and Materials (ASTM) standard D2240. The third layer may have a Shore A durometer hardness of 65+/−15, 65+/−10, 65+/−10, or 65 as measured using the American Society for Testing and Materials (ASTM) standard D2240. The third layer may also, for example, have a Shore A durometer hardness that is 40% or more greater than the second layer, 30% or more greater than the second layer, 20% or more greater than the second layer, or 10% or more greater than the second layer all +/−5% as measured using the American Society for Testing and Materials (ASTM) standard D2240. It should be understood that the three layers may have a Shore A hardness that is comprised of any combination of hardness described above consistent with the teachings herein. 
     In the illustrated embodiment the protrusions  320  have a hexagonal external and internal shape. However, it should be understood that other shapes may be employed. For example, one or more or all of the plurality of protrusions  320  of the first layer  300  may have a first external shape selected from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon, and heptagon. One or more or all of the plurality of protrusions  320  may each include an aperture  321  residing therein that defines an internal shape selected from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon, and heptagon. One or more or all of the plurality of protrusions  320  may be dimensioned so that the upper surface  322  to be below, above, or flush with the upper surface  422  height of the interconnected walls  430  of the second layer  400  surrounding the protrusions  320  of the first layer  300 . Thus, some or none of the plurality of protrusions  320  may be dimensioned to be flush with the height of the interconnected walls  430  adjacent thereto (as shown in the drawings), some or none of the plurality of protrusions  320  may be dimensioned to be below the height of the interconnected walls  430  adjacent thereto, and some or none of the plurality of protrusions  320  may be dimensioned to be above the height of the interconnected walls  430  adjacent thereto. The plurality of protrusions  320  may be comprised multiple groups of protrusions with each protrusion  320  in each group being equally spaced from one another. The plurality of protrusions may be comprised of a first group configured to reside nearer the top end side  250  than the bottom end side  260 , a second group may be configured to reside nearer the bottom end side  260  than the top-end side  250 , and a third group may be configured to reside an equal distance from the right and left sides  230  and  240 . One or more protrusions may be positioned in each corner region, the mid region and/or nearer the perimeter than the middle of the case. 
     The number of corner protrusions  420  in the second layer  400  may be selected from a group consisting of two, three, and four (or more if mobile device has more than four) configured to reside at one, some or all of the corners  180  of the mobile device  100  or any combination of corners thereof. For example, one corner protrusion  420  may be configured to reside at a corner  180  defined in part by the top side  150  of the mobile device  100  and another corner protrusion  420  may be configured to reside at a corner defined in part by the bottom side  160 . By way of another example, one corner protrusion  420  may be configured to reside at a corner  180  defined in part by the right side  140  of the mobile device  100  and another corner protrusion  420  may be configured to reside at a corner  180  defined in part by the left side  130  of the mobile device  100 . By way of yet another example, a first corner protrusion  420  may be configured to reside at a corner  180  defined in part by the top side  150  of the mobile device  100 , a second corner protrusion  420  may be configured to reside at a corner  180  defined in part by the bottom side  160 , a third corner protrusion  420  may be configured to reside at a corner  180  defined in part by the right side  140 , and a fourth corner protrusion  420  may be configured to reside at a corner  180  defined in part by the left side  130 . Corresponding dimensioned corner indentations  540  in the third layer  500  may be provided to engagingly receive one, some or all of the corner protrusions  420 . Thus, some or all of the surfaces that define the indentions on the third layer may be in contact with corresponding surfaces of the corner protrusions  420  on the second layer  400 . In this respect, the corner indentations  540  may be configured to have a reverse image of the desired shape of the corner protrusions  420 . 
     The corner protrusions  420  may be configured or otherwise dimensioned to reside above, below or flush with the height of the mobile device  100 , in any combination. For example, one of the corner protrusions  420  may be configured to extend above the height of the mobile device  100  and another of the corner protrusions  420  may be configured to be flush with the height of the mobile device  100 . Alternatively, all of the corner protrusions  420  may be configured to be flush with the height of the mobile device  100  or may be configured to reside below or above the height of the mobile device  100 . The corner protrusions  420  may also have uniform or varying dimensions in width (best illustrated in  FIG. 4 ) and thickness (best illustrated in  FIG. 3 ) between the base  421  and the apex  422  of the corner protrusion  420 . For example, the corner protrusions  420  may include a thickness defined between the inner and outer surfaces that varies with the height (as measured from the base  421  to the apex  422 ) of the protrusion  420 , such as being thicker (or thinner) at the base  421  of the corner protrusion  420  as compared to the thickness nearer the apex  422  of the corner protrusion  420 . By way of another example, the width, which is generally perpendicular to the thickness, may be wider (or narrower) at the base  421  of the corner protrusion  420  as compared to width near the apex  422  of the corner protrusion  420 . For example, in the illustrated embodiment the thickness of the corner protrusions at the apex is 1.09 millimeters and at the base is 1.14 millimeters. 
     In the illustrated embodiment the pattern of elevated interconnected walls  430  employ a repeating hexagonal external and internal shape. However, it should be understood that other shapes may be employed. For example, the pattern of elevated interconnected walls may be comprised of any pattern including any arrangement of shapes such as a square, octagon, pentagon, rectangle, triangle, circle, hexagon or heptagon or combination thereof. It is also contemplated that the walls may be arranged in a random pattern. It is also contemplated that the walls  430  may have a greater density in number or composition in one region versus another. For example an increased or decreased density (either in composition or in number of the walls) may be employed around or near apertures. 
     In the illustrated embodiment, the interconnected walls  430  are oriented into hexagonal formations (or portions of a hexagonal formation) that together create a honeycomb wall pattern. The honeycomb pattern may be uniform or non-uniform. The apertures  440  in the second layer  400  and the plurality of protrusions  320  of the first layer  300  have corresponding hexagonal shapes that are dimensioned to snugly mate together, so that one, some or all six of the hexagonal walls are in contact with one another. The pattern of elevated interconnected walls  430  may, as previously noted, be contiguous or dis-contiguous, and may or may not extend to the perimeter regions of the second layer  400 , may be positioned in discrete regions, or may be spaced apart from one another. Various patterns comprising one or more shapes may be employed alone or in combination with other patterns. The elevated pattern of interconnected walls  430  may be configured in height and construction so as to suspend the back face of the mobile device above the apertures  321  defined by one or more of the interconnected walls  430  so that the back face  120  of the mobile device  100  does not bottom-out on the recessed inner surface  410  of the second layer  400 . 
     The second layer  400  may further comprise one or more button protrusions  450  that are dimensioned and configured to extend within one or more of the control apertures  530  of in the third layer  500 . Each button protrusion  450  may or may not be co-molded to the corresponding control aperture  530  to form an integrated region therewith. The button protrusions are generally configured to reside above a user control button on the mobile device  100  such as a volume  132 , power  152 , mute, or other user buttons. 
     The third layer  500  may also further include one or more retention or stability tabs  550  configured to extend underneath the back face  120  of the mobile device  100 . The inner surface of the tab may be in contact with the outer surface of the second layer, while the outer surface of the tab may be exposed externally. The tab  550  may be received within an aperture  350  on the first layer  300  that opens to the perimeter. The tab and aperture  550  and  350  may be configured to reside nearer one end of the mobile device  100  than the other and may be configured to reside nearer to one side of the mobile device than the other. 
     The third layer  500  may also be configured to include retention rim  214  positioned to reside over the perimeter region  170  of the front face  110  of the mobile device  100  to assist in retaining the mobile device  100  within the case  200 . The retention rim  214  may encircle a portion or the entire front face  110 . For example the retention rim  214  may be configured to extend at the top, bottom, left and/or right sides (at the corners or along the sides thereof) of the mobile device in any combination thereof. 
     The case  200  is configured and constructed with sufficient flexibility to allow the user to install and remove the mobile device  100  within the case without damaging the case or the mobile device. The flexibility may be implemented via the construction materials employed and the configuration of the layers or components. 
     A method of manufacturing the protective case  200  for a mobile device is also disclosed. The manufacturing process may include the steps of: 
     (1) co-molding three layers to form an integrated protective case construct. 
     (2) molding the first layer defined by first inner and outer surfaces and dimensioned to cover at least a portion of the back face of the mobile device and extend around at least a portion of the perimeter of the mobile device at the back face boundary. The first layer is molded to include a first plurality of protrusions extending from the inner surface of the first layer in a direction away from its outer surface and being molded of a material that is harder than either the second or third layers. 
     (3) co-molding, around the perimeter regions of the first layer, the third layer defined by third inner and outer surfaces and dimensioned to cover one or more regions of the top-end, bottom-end, right and left sides of the mobile device. The third layer is molded to include one or more control apertures dimensioned and positioned to allow access to control buttons or ports on the mobile device. The third layer being further molded to include indentations in its inner surface at regions configured to reside at the corners of the mobile device, the indentations being dimensioned to receive corner protrusions molded into the second the layer. The third layer being molded of material that is harder than the second layer. 
     (4) co-molding, onto the inner surface of the first and third layers, the second layer defined by second inner and outer surfaces and dimensioned to cover at least a portion of the back face of the mobile device and extend around at least a portion of the perimeter of the mobile device at the back face boundary. The second layer is molded to include a second plurality of corner protrusions positioned along the perimeter region of the second layer to correspond in location with corners of the mobile device and dimensioned to extend at, below, or above the height of the mobile device. The second layer being further molded to include a pattern of walls extending from its inner surface a height above and in a direction away from its outer surface, and a plurality of apertures that surround and are in contact with one or more of the first group of protrusions in the first layer. The pattern of walls may form any arrangement of shapes selected for example from a group consisting of a square, octagon, pentagon, rectangle, triangle, circle, hexagon and heptagon or combination thereof. 
     The various aspects relating to configuration and construction of each of the three component layers described above or otherwise herein and/or illustrated in the drawings may be included in the molding process of the layer with any of the foregoing steps, or portions of any of the foregoing steps, in any combination without limitation. 
     Each of the foregoing and various aspects, together with those set forth in the claims and described in connection with the embodiments of the protective cases summarized above or otherwise disclosed herein including the drawings may be combined to form claims for a device, apparatus, system, method of manufacture, and/or use without limitation. 
     Although the various inventive aspects are herein disclosed in the context of certain preferred embodiments, implementations, and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the various aspects have been shown and described in detail, other modifications, which are within their scope will be readily apparent to those of skill in the art based upon this disclosure. It should be also understood that the scope this disclosure includes the various combinations or sub-combinations of the specific features and aspects of the embodiments disclosed herein, such that the various features, modes of implementation, and aspects of the disclosed subject matter may be combined with or substituted for one another. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments or implementations described above, but should be determined only by a fair reading of the claims. 
     Similarly, this method of disclosure, is not to be interpreted as reflecting an intention that any claim require more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment.