Patent Publication Number: US-2020288833-A1

Title: Mobile device cases and case systems with embedded sidewall shock absorber

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 15/208,574, filed on Jul. 12, 2016, which the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/192,030, filed on Jul. 13, 2015, the entireties of which are hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Field of the Invention 
     The present disclosure relates to protective cases for mobile devices. 
     Description of the Related Art 
     Mobile electronic devices, such as smartphones, tablets, laptops, and the like, are known to sustain damage from impact and from contamination as a result of the ingress of water or other fluids. Such damage may result, for example, 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 can protect mobile electronic devices from such damage and other types of damage. 
     There is a continuing need for protective cases and case systems for mobile devices that provide improved protection that can be readily perceived by a user and incorporated into case configurations or systems with varying levels of protection. 
     SUMMARY 
     Protective cases and case systems for a mobile device are disclosed herein. The cases include a multi component structure that defines a compartment that is dimensioned to receive a mobile device and includes one or more shock absorber elements embedded within its side walls. The multi-component construct may be configured as a standalone case or as a sleeve that reversibly fits within another external component or shell. The shock absorber element may be formed in multiple segments and may be formed of a softer material than adjacent regions of the case and co-molded into a channel in a supporting wall component that is formed of a more rigid material. The shock absorber component may have one or more channels formed in its outer surface and may extend internally into the device compartment to form relatively soft corner pads or cushions. When a shell is employed, additional level of protection to the mobile device may be provided. The shell may have transparent side walls that allow visibility to the shock absorber elements so that the user can perceive the protective construction of the case. A screen protector lid that retentively snaps into and out of the case or sleeve so as to provide additional protection to the mobile device is also disclosed herein. The shell may be used with or without the screen protector lid. 
     In some embodiments, the cases have one or more discrete shock absorber elements integrally molded and embedded into the external surface of a sidewall of another component that houses the mobile device and that may be made of a material that is harder than the material that forms the shock absorber. The shock absorber may include one or more channels that are formed on its outer surface. The channels provide space that allows the channel walls to flex with force and thereby facilitate absorption of the force. The construct may be in the form of a stand-alone case or a sleeve configured to be received within another component. 
     In some embodiments, the material that forms the shock absorber element also forms internal corner pads that are capable of providing additional cushion at the corners of the mobile device. 
     In some embodiments, the case or case system may include a separate shell component that is configured to reversibly receive a flexible sleeve, which is configured to house the mobile device and which includes a molded component that forms the shock absorber element. The shell component may be composed of transparent sidewalls that provide visibility to the shock absorber element and may be formed of a material that is more rigid than the materials that form the sleeve component. 
     In some embodiments, the case or case system may include a screen protector that reversibly snaps or clips into and out of the case or sleeve to cover the front face or screen of the mobile device. 
     Numerous configuration and construction aspects of the various components and their manufacture are also described herein. 
     Each of the foregoing and various aspects, together with those set forth in the claims and summarized above or otherwise disclosed herein, including the figures, may be combined without limitation to form claims for a device, apparatus, system, method of manufacture, and/or method of use. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The figures provided herewith are intended to illustrate but not to limit the invention. Like reference characters in the figures denote corresponding features consistently throughout similar embodiments. Each drawing is generally to scale and hence relative dimensions of the various layers and components can be determined from the drawings. 
         FIG. 1  illustrates a front face perspective view of a first embodiment of the disclosed protective case. The embodiment illustrated is particularly configured for an Apple® iPhone® 6 device. 
         FIG. 2  illustrates a front face view of the embodiment shown in  FIG. 1 . 
         FIG. 3  illustrates a back face view of the embodiment shown in  FIG. 1 . 
         FIG. 4  illustrates a left side view of the embodiment shown in  FIG. 1 . 
         FIG. 5  illustrates a right side view of the embodiment shown in  FIG. 1 . 
         FIG. 6  illustrates a top side view of the embodiment shown in  FIG. 1 . 
         FIG. 7  illustrates a bottom side view of the embodiment shown in  FIG. 1 . 
         FIG. 8  illustrates a cross-sectional perspective view taken along line A-A of the embodiment shown in  FIG. 1 . 
         FIG. 9  illustrates a cross-sectional perspective view taken along line B-B of the embodiment shown in  FIG. 1 . 
         FIG. 10  illustrates an exploded perspective view of the components of the embodiment shown in  FIG. 1 . 
         FIG. 11  illustrates an exploded right side view of the components of the embodiment shown in  FIG. 1 . 
         FIG. 12  illustrates a front face perspective view of a second embodiment of the disclosed protective case. The embodiment illustrated is particularly configured for an Apple® iPhone® 6 device. 
         FIG. 13  illustrates a front face view of the embodiment shown in  FIG. 12 . 
         FIG. 14  illustrates a back face view of the embodiment shown in  FIG. 12 . 
         FIG. 15  illustrates a left side view of the embodiment shown in  FIG. 12 . 
         FIG. 16  illustrates a right side view of the embodiment shown in  FIG. 12 . 
         FIG. 17  illustrates a top side view of the embodiment shown in  FIG. 12 . 
         FIG. 18  illustrates a bottom side view of the embodiment shown in  FIG. 12 . 
         FIG. 19  illustrates a cross-sectional perspective view taken along line A-A of the embodiment shown in  FIG. 12 . 
         FIG. 20  illustrates a cross-sectional perspective view taken along line B-B of the embodiment shown in  FIG. 12 . 
         FIG. 21  illustrates an exploded perspective view of the components of the embodiment shown in  FIG. 12 . 
         FIG. 22  illustrates an exploded right side view of the components of the embodiment shown in  FIG. 12 . 
         FIG. 23  illustrates a front face perspective view of a third embodiment of the disclosed protective case. The embodiment illustrated is particularly configured for an Apple® iPhone® 6 device. 
         FIG. 24  illustrates a front face view of the embodiment shown in  FIG. 23 . 
         FIG. 25  illustrates a back face view of the embodiment shown in  FIG. 23 . 
         FIG. 26  illustrates a left side view of the embodiment shown in  FIG. 23 . 
         FIG. 27  illustrates a right side view of the embodiment shown in  FIG. 23 . 
         FIG. 28  illustrates a top side view of the embodiment shown in  FIG. 23 . 
         FIG. 29  illustrates a bottom side view of the embodiment shown in  FIG. 23 . 
         FIG. 30  illustrates a cross-sectional perspective view taken along line A-A of the embodiment shown in  FIG. 23 . 
         FIG. 31  illustrates a cross-sectional perspective view taken along line B-B of the embodiment shown in  FIG. 23 . 
         FIG. 32  illustrates an exploded perspective view of the components of the embodiment shown in  FIG. 23 . 
         FIG. 33  illustrates an exploded right side view of the components of the embodiment shown in  FIG. 23 . 
         FIG. 34  illustrates an exploded perspective top face view of the embodiment shown in  FIG. 23  with an iPhone® 6 disposed below the lid component. 
         FIG. 35  illustrates an exploded perspective bottom face view of the embodiment shown in  FIG. 23  with an iPhone® 6 disposed below the lid component. 
         FIGS. 36A-36E  illustrate isometric cross-section views of various configurations of the shock absorber component. 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
     Protective cases and case systems for a mobile device are disclosed herein. The cases include a multi component structure that defines a compartment that is dimensioned to receive a mobile device and includes one or more shock absorber elements embedded within its side walls. The multi-component construct may be configured as a standalone case or as a sleeve that reversibly fits within another external component or shell. The shock absorber element may be formed in multiple segments and may be formed of a softer material than adjacent regions of the case and co-molded into a channel in a supporting wall component that is formed of a more rigid material. The shock absorber component may have one or more channels formed in its outer surface and may extend internally into the device compartment to form relatively soft corner pads or cushions. When a shell is employed, additional level of protection to the mobile device may be provided. The shell may have transparent side walls that allow visibility to the shock absorber elements so that the user can perceive the protective construction of the case. A screen protector lid that retentively snaps into and out of the case or sleeve so as to provide additional protection to the mobile device is also disclosed herein. The shell may be used with or without the screen protector lid. 
     In some embodiments, the cases have one or more discrete shock absorber elements integrally molded and embedded into the external surface of a sidewall of another component that houses the mobile device and that may be made of a material that is harder than the material that forms the shock absorber. The shock absorber may include one or more channels that are formed on its outer surface. The channels provide space that allows the channel walls to flex with force and thereby facilitate absorption of the force. The construct may be in the form of a stand-alone case or a sleeve configured to be received within another component. 
     In some embodiments, the material that forms the shock absorber element also forms internal corner pads that are capable of providing additional cushion at the corners of the mobile device. 
     In some embodiments, the case or case system may include a separate shell component that is configured to reversibly receive a flexible sleeve, which is configured to house the mobile device and which includes a molded component that forms the shock absorber element. The shell component may be composed of transparent sidewalls that provide visibility to the shock absorber element and may be formed of a material that is more rigid than the materials that form the sleeve component. 
     In some embodiments, the case or case system may include a screen protector that reversibly snaps or clips into and out of the case or sleeve to cover the front face or screen of the mobile device. 
     As illustrated in  FIGS. 34-35 , mobile devices  10  that may be reversibly secured by the disclosed protective cases and case systems typically include sides (left  11 , right  12 , top  13 , and bottom  14 ), a back face  15  and a front face  16 . The sides typically have one or more user interface ports and buttons (e.g., charging ports, power buttons, volume buttons, and microphone and speaker grills). The back face typically includes one or more camera and/or flash lens and sometimes also includes speakers or microphones and sometimes also includes touchscreen interfaces. The front face typically includes one or more touchscreens, optionally a home button, one or more microphones and/or speakers, a camera lens, and one or more proximity sensors. 
       FIGS. 1-11  illustrate a first embodiment of a protective case  100  that is generally comprised of a first molded component  110  that defines a compartment that is dimensioned to receive and protect the mobile device  10  (illustrated in  FIGS. 34-35 ) for which it is configured, a second molded component  130  in the form of a shock absorber co-molded within the side walls of the first molded component  110 , and a relatively rigid back face panel  150  that is co-molded to the bottom perimeter of the first molded component  110 . 
     The first molded component  110  is formed of a polymer that is relatively more rigid (or less flexible) than the material that forms the second molded component  130  but less rigid (or more flexible) than the material that forms the back face panel  150 . Hence the second molded component  130  is formed of a material that is the most flexible out of the three components. For example the first molded component  110  may be formed of thermoplastic polyurethane (TPU) having a Shore A hardness of 85, the second molded component  130  may for formed of a thermoplastic elastomer (TPE) having a Shore A hardness of 65, and the molded back face panel  150  may be formed of a polycarbonate material having a hardness that exceeds the other two materials (e.g., Rockwell hardness of M70). While specific construction materials have been identified herein, it should be understood that any suitable polymer, polyurethane, plastic, or thermoplastic elastomer having suitable properties to allow for the desired flexibility or elasticity, and preferably also having sufficient durability and resistance to oil, grease, and abrasion, may be employed. 
     As illustrated in  FIGS. 1-11 , the first molded component  110  is configured to extend around the perimeter of the mobile device  10  and includes inner and outer surfaces  111  and  112 , respectively, which define walls having upper and lower end regions  115  and  116  that are configured to extend from the front face  16  of the device  10  towards the back face  15  of the device  10  with the inner surfaces of the walls being dimensioned to reside adjacent and snugly against the sides of the mobile device  10 . The inner and outer surfaces of the first molded component  110  define side walls (left, right, top, and bottom sidewalls  123   a ,  123   b ,  123   c , and  123   d  of the case  100  that correspond with the left, right, top, and bottom sides  11 ,  12 ,  13 , and  14  respectively of the mobile device  10  and extend longitudinally from the corners  122   a ,  122   b ,  122   c , and  122   d  that are defined thereby. 
     One or more user interface apertures  117   a ,  117   b ,  117   c , and  117   d  are provided in the defining walls of the component  110  to correspond with various user interfaces including the silent switch  17   a , the headset jack  17   b , the charging/communication port  17   c , and speakers/microphone grill  17   d  of the device  10 . In addition multiple control buttons  118   a ,  118   b , and  118   c , which in the illustrated embodiment protrusions  119  are provided on the inner surface  111  and are configured to correspond with various control buttons on the device including, for example, the + and − volume control buttons  18   a  and  18   b  and the power button  18   c . The wall thickness between the outer and inner surfaces  112  and  111  may be thinner near the buttons as compared to adjacent or other regions to allow for additional flexibility by the user. 
     The first molded component further includes a projecting edge or lip  113  that is configured to extend from the upper end region  115  over the front face  16  of the mobile device  10  so as to define a major aperture  114  through which the front face  16  and the touchscreen of the mobile device  10  may be visible to the user when the device  10  is in the case  100 . The lip  113  is configured to retain the device  10  within the compartment defined by the first molded component  110 , yet also be flexible enough to allow for insertion and removal of the device  10  into the case  100  through the major aperture  114 . As depicted in the drawings, the lip  113  protrudes around the entire major aperture  114  a uniform distance as measured from the outer surface  112 . It should be understood, however, that the lip  113  may protrude different distances, less or more in one or more regions, and may not extend around the entire perimeter of the major aperture  114 , but only partially or in discrete regions (e.g., one, two, three, or all sides (or portions thereof) and/or one, two, three, or all four corners). 
     The first molded component  110  also includes one or more channels  120  disposed within its outer surface  112  between the upper and lower end regions  115  and  116  that extend longitudinally along one or more of the walls  123   a - 123   d . In the illustrated embodiments the channels  120  do not extend into the user interface aperture regions  117   a - 117   d  or the regions where the control buttons  118   a - 118   c  are provided. It is contemplated, however, that the channels may be configured to extend into one or more or all of those regions. 
     Retention apertures  121  (best seen in  FIGS. 10-11 ) extending from the outer surface  112  to the inner surface  111  may also be provided in the first molded component  110 . In the illustrated embodiment, the retention apertures  121  are positioned within the channels  120  at each of the four corners  123   a - 123   d . It should be understood, however, that the apertures  121  may be positioned elsewhere along the channel  120 , for example along one or more of the sides with or without the corner apertures. As will be described below, the retention apertures  121  may assist in securing and retaining the second molded component  130  to the first molded component  110  when they are co-molded to one another and thereby reduce the likelihood of the second molded component  130  peeling off the first molded component  110 . This also provides a mechanism by which force may be transferred from the mobile device housed within the case. 
     The second molded component  130  is co-molded into the channel  120  of the first molded component  110 . It has an inner, outer, and side surfaces  131 ,  132 , and  133  respectively. The inner and side surfaces  131  and  133  are in contact with the outer surfaces  112  of the channel  120  of the first molded component  110 . The outer surface  132  includes one or more channels  134  which overlie and run longitudinally in parallel with the channel  120  defined in the first molded component  110 . In the illustrated embodiments, the channel  134  is in the form of a “V” as generally depicted in  FIG. 36 a   . It should be understood that the channel  134 , or portions thereof, may have different cross-sectional configurations such as those depicted in  FIGS. 36 b -36 e   . Such configurations may include a semi-circle or semi-elliptical configuration such as that depicted in  FIG. 36 b   , may have multiple channels  134  that are the same or different in cross-section, that have the same or different depths, or that are immediately adjacent to one another or are spaced apart such as those depicted in  FIGS. 36 c   - 36   e.    
     The inner surface  131  of the second molded component  130  is configured to conform with the corresponding channel  120  configuration of the first molded component  110  and may, as illustrated, be slightly concave to conform with the outer surface  112  of the channel  120 , which in turn corresponds to the curvature of the sides of the iPhone® 6 smart phone which it is designed to house. It should be understood, however, that the outer surface  112  of the channel  120  may be flat or convex or a combination of different surfaces that may or may not correspond with the side walls of the mobile device that the case is configured to house. 
     When force is applied to the first molded component  110  (e.g., form impact of drop or the like), the force is transferred to the second molded component  130  which can absorb and dissipate the force through the inward and/or outward flexing of the walls that form channels  120  and  134 . Improved protection of the mobile device may thereby be achieved. The second molded component  130  thereby is capable of serving as a mechanical shock absorber that is embedded within the sidewalls of the first molded component  110 . 
     In order to provide improved co-molding adherence and protection, the second molded component  130  bleeds through the retention aperture  121  at the corners to form internal corner bumpers  135 . Hence, the second molded component  130  sandwiches the first molded component  110  at those discrete regions in the corner. Because the internal corner bumpers  135  are formed of the relatively softer material that forms the second molded component  130 , additional cushioning can be provided to the mobile device at the corners. This can be important inasmuch as the corners tend to be the regions that receive the greatest impact force when mobile devices are dropped or are subject to other impacts. 
     As depicted in the illustrated embodiments, the second molded component  130  corresponds in dimension with the channels  120  of the first molded component  110  and does not extend into the user interface aperture regions  117   a - 117   d  or the regions where the control buttons  118   a - 118   c  are provided. As previously noted, however, it is contemplated that the channels  120  may be configured to extend into one or more or all of those regions and hence it is contemplated that the second molded component  130  will in such embodiments also extend into those areas to correspond with the channel  120  regions of the first molded component  110 . Also, in the illustrated embodiments the second molded component  130  is generally flush or recessed at the channel  134  regions relative to the outer surface  112  of the first molded component  110 . 
     It should be understood, however, that the second molded component  130  may protrude outward in one or more regions beyond the plane of the outer surface  112  of the first molded component  110 . In some preferred embodiments, the second molded component may be formed of a differently colored material than the first molded component so that the user or consumer can readily appreciate and perceive the design features and construction of the protective cases disclosed herein. Thus, it is contemplated that the first molded component may be formed of a dark material and the second molded component may be formed of a lighter material or vice versa. It is also contemplated that the second molded component may be formed of strikingly bright, vivid, glowing, or even fluorescent material as compared to the material that forms the first molded component. 
     In the first embodiment illustrated in  FIGS. 1-11 , the back face panel  150  is co-molded to the lower end region  116  at the bottom perimeter of the first molded component  110 . It is formed of a more rigid polymer, such as polycarbonate. The back face panel  150  is configured to cover the back face  15  of the mobile device  10  and includes one or more additional apertures  151  that are configured to correspond with functional features of the mobile device such as the rear camera and flash that are commonly provided on the back faces of tablets, smart phones, and other mobile devices. It should be understood that additional apertures may also be included, such as for example apertures that correspond to other functional features such as microphones, speakers, and other touchscreen or interactive screens elements that are positioned on the back face  15  of the mobile device  10 . Thus, while the back face panel  150  in the illustrated embodiments is configured to cover nearly all of the back face  15  of the mobile device  10 , it should be understood that the back face panel  150  may only cover discrete or partial regions of the back face  15  of the mobile device  10 . Indeed, it should be understood that the back face panel  150  may only cover very small regions, such as perhaps only around the perimeter of the back face  15  similar in amount to the protruding edge that forms the lip  113  and thus would leave nearly all of the back face  15  of the device  10  exposed akin to a protective bumper. The perimeter regions of the back face panel  150  that mate with the first molded component  110  may include tabs  152  having reduced thickness that facilitate adhesion to the co-molded lower end regions  116  of the first molded component  110 . 
     The embodiment illustrated in  FIGS. 1-11  may be manufactured via a multi-step injection molding process that may include a double injection molding process. For example, a first steel mold is provided that has the shape of the back face panel  150 , and polycarbonate or another suitable material is injected into the mold and allowed to cool for a suitable period of time. The back face panel is removed and placed into another mold that is configured to form the first molded component. A first TPU is injected into a second mold to form the first molded component  110  co-molded over the tabs  152  of the back face panel  150 . The resulting construct (with or without the second mold) is inserted into another or third mold that is configured to form the second molded component  130  and a second TPU material (less rigid and more flexible than the first TPU material) is injected into the third mold to form the second molded component  130  that forms the embedded shock absorber. The first molded component  110  may be formed for example of a TPU having a Shore hardness of 85 and the second molded component  130  for example may be formed of a TPE having a Shore hardness of 65. The back face panel  150  may be formed, for example, of a PC that has a greater hardness than either the TPU or TPE material used to form the other components in the construct. The construct may be printed in one or more regions to finish the case. For example, pad or tampography printing may be used to include a black camera ring around the camera/flash aperture  151 . 
       FIGS. 12-22  illustrate a second embodiment of a protective case  200 . The second embodiment  200  generally includes the co-molded first and second molded components  210  and  230  as previously described in connection with the first and second molded components of the first embodiment. However, rather than including a relatively rigid back face panel  150  that is co-molded to the first molded component  110 , the first and second molded components  210  and  230  together form a relatively soft or flexible sleeve  240 . Rigidity in the case is provided by a separate housing or shell  250  that is dimensioned to reversibly receive the relatively soft sleeve component  240 . When the sleeve  240  is secured over the mobile device  10  and then inserted into the shell  250  it is configured to fit firmly and snugly within the shell  250  so as to be retained therein by the force of the shell walls against the sleeve and hence the against the mobile device  10 . The first and second molded components  210  and  230  have generally the same features as in the first protective case embodiment  100 . 
     Namely, the first molded component includes inner and outer surfaces  111  and  112  that define the left, right, top, and bottom side walls  123   a - 123   d  having upper and lower end regions  115  and  116 ; edge protrusion or lip  113  that extends inwardly from the upper end region  115  and defines a major aperture  114 ; user interface apertures  117  to facilitate interaction with the user interfaces (ports and switches and speakers) on the device  10 ; control buttons  118   a - 118   c  that correspond with the control buttons  18   a - 18   c  on the device  10  and corresponding protrusions  119  thereof; longitudinally extending channels  120  that extend along the sidewalls; corner retention apertures  121  that facilitate adhesion and provide additional cushioning at the corner  122   a - 122   d ; all as previously described, with two exceptions. 
     First the regions of the sidewalls  123   a - 123   d  residing below the upper end region  115  are configured to be recessed relative to the upper end region  115  (generally around outer surfaces  112  that contain the channeled areas  120 ) so that the upper end regions  115  form an external overhang or edge protrusion  124  that extends radially outwardly relative to the underlying side walls  123   a - 123   d . The edge protrusion  124  is dimensioned and configured to reside on top of the edges of the shell  250  when the sleeve  240  is inserted into the shell  250 . The sidewall regions that are not recessed (e.g., where the user interfaces  117  and control buttons  118  reside) are configured to snugly fit within corresponding pen-sided apertures  255  in the sidewalls of the shell  250  so as to further secure the sleeve  240  within the shell  250 . 
     Second, the lower end region  116  of the first molded component  210  is not co-molded to the back face panel as in the first embodiment. Rather, the lower end region  116  is configured to extend into and form a continuous flexible back face panel  160 , which includes a honeycomb pattern  161  on its inner surface  111  that is defined by relatively elevated honeycomb patterned walls  162  and recessed surfaces  163  residing within the honeycomb patterned walls  162 . Thus, the back face panel  160  in the second illustrated embodiment  200  is a unitary extension of the first molded component  210  thereof as opposed to the discrete component  150  in the first illustrated embodiment  100  that is co-molded to the first molded component  110  thereof. While the illustrated embodiments only disclose the honeycomb pattern walls on the inner surface of the flexible back face panel  160  of the sleeve  240 , it is contemplated that the honeycomb pattern may be formed on the back side or outer surface  112  of the back face panel  160  or may be formed on both the inner and outer surfaces  111  and  112  of the back face panel  160 . 
     In the illustrated embodiments, the back face panel  160  (like the back face panel  150 ) is configured to cover the back face  15  of the mobile device  10  and includes one or more additional apertures  164  that are configured to correspond to functional features of the mobile device such as the rear camera and flash that are commonly provided on the back faces of tablets, smart phones, and other mobile devices. It should be understood that additional apertures may also be included, such as for example apertures that correspond to other functional features such as microphones, speakers, and other touchscreen or interactive screen elements that are positioned on the back face  15  of the device  10 . Thus, while the flexible back face panel  160  in the illustrated embodiment is configured to cover nearly all of the back face  15  of the mobile device  10 , it should be understood that the flexible back face panel  160  may only cover discrete or partial regions of the back face  15  of the device  10 . Indeed, it should be understood that the flexible back face panel  160  may only cover very small regions, such as perhaps only around the perimeter of the back face  15  similar in amount to the protruding edge that forms the lip  113  and thus would leave nearly all of the back face  15  of the device  10  exposed akin to a protective bumper. Corresponding apertures in the flexible back face panel  160  may be formed in the shell  250  to allow user accessibility to the corresponding features of the device  10 . 
     Similarly, the second molded component  230  of the second embodiment of the protective case  200  includes the same features as the second molded component  130  of the first embodiment of the protective case  100 . Namely, the second molded component  230  includes the inner and side surfaces  131  and  133  that are in contact and co-molded to the walls of the channel  120  of the first molded component  210 ; an exterior or outer surface  133  that includes one or more channels  134  formed and extending therein; and corner bumpers  135  that extend into the mobile device compartment at the corners  122   a - 122   d  via apertures  121  in the first molded component to form relatively soft internal corner pads that can provide additional cushioning to the mobile device  10  as previously described. 
     The shell component  250  is configured to surround the sleeve  240  including under the flexible back face panel  160  and along the sidewalls  123   a - 123   d  as illustrated. The shell component  250  thereby is capable of providing additional rigidity to the assembled case and protection to the mobile device  10 . The shell component  250  is generally composed of a back face component  257  and left, right, top, and bottom sidewalls  258   a - 258   d  respectively. The back face component  257  includes one or more apertures  259  that generally correspond to the apertures  164  on the back face panel  160  of the first molded component  210  to allow user accessibility to the features on the back face  15  of the device  10 . In addition, the back face component  257  of the shell  240  includes a honeycomb pattern  261  on its inner surface  265  that corresponds in configuration to the honeycomb pattern  161  on the back face panel  160  of the first molded component  210  so that the walls  162  and recesses  163  overlie and track corresponding walls  262  and recesses  263  that form the honeycomb pattern  261  on the inner surface of the back face component  257  of the shell  250 . The sidewalls  258  include the open-sided apertures  255  that are configured to snugly receive the sidewall regions of the first molded component  210  that are not recessed (e.g., where the user interfaces  117  and control buttons  118  reside) so as to further secure the sleeve  240  within the shell  250 . Regions of the shell  250  underlying or adjacent to the apertures  250  may be strengthened by making those regions thicker or by incorporating support members across the apertures or underneath the apertures. 
     In the illustrated embodiments, the shell component  250  is generally formed of two co-molded components  270  and  280 . The first is a relatively rigid or hard panel component  270  formed of PC or the like that defines the internal side of the back face component  257  and the side walls  258   a - 258   d . The second is a relatively softer and less rigid cover panel  280  formed of TPU or the like that covers or caps the outer surface  271  of the panel component  270 . Interlocking honeycomb wall structures  282  extending from the inner surface  281  of the cover panel  280  extend through the corresponding recessed regions  263  adjacent walls  262  that form the honeycomb pattern  261  on the inner surface  265  of the shell  250 . The relatively softer pliable material that forms the cover panel may deaden impact while the more rigid perimeter panel component protects the core. 
     The embodiment illustrated in  FIGS. 12-22  may be manufactured via a multi-step injection molding process that may include multiple double injection molding processes. With respect to the construction of the sleeve  240 , for example, a first steel mold is provided that has the shape of the first molded component  210  including the back face panel  160 . TPU or another suitable material is injected into the mold and allowed to cool for a suitable period of time. The first molded component  210  is then placed into another mold or tool that is configured to facilitate co-molding the second molded component  230  into the channel  120  and through the apertures  121  of the first molded component  210 . A second TPU or a TPE material (less rigid and more flexible than the first TPU material) is injected into the second mold or tool to form the second molded component  230 , which includes the embedded shock absorber and corner cushions or bumpers  135  which together form the soft flexible sleeve component  240 . The resulting sleeve is removed for inspection and/or finishing. The TPU that forms the first molded component  210  may have a Shore hardness of 85 and the TPE that forms the second molded component may be relatively softer with a Shore hardness of 65. 
     With respect the manufacture of the more rigid shell, another steel mold is provided that is generally shaped like the rigid panel component  270  including apertures and honeycomb pattern. PC or the like is injected into the mold and allowed to cool for a suitable time to form the rigid panel component  270 . The resulting rigid panel component is inserted into another mold that is configured to co-mold the cover panel  280  over the outer surface of the rigid panel component  270 . A softer TPU or like material is then injected into the mold to form the cover panel  280  and allowed to cool for a suitable period. The resulting shell pre-form construct is removed for inspection and finishing. For example, pad or tampography printing may be used to include a black camera ring on the outer surface  266  around the camera/flash aperture  259 . The cover panel  280  may be formed using the same TPU (thus having the same mechanical properties, e.g., the same Shore hardness and having the same or a different color) as that used to form the first molded component  210 . It is contemplated, for example, that the TPU material is opaque and not transparent. The PC material that forms the relatively more rigid panel component  270  including the sidewalls  258   a - 258   d  of the shell  250  may be formed of a more transparent or clear material so that a user can see or better perceive the embedded bumper of the second molded component  230  when the sleeve  240  is inserted into the shell  250 . The relatively more rigid material surrounding the bumper component effectively acts as a brace such that when the bumper deforms under stress the bumper pushes on the surrounding more rigidly formed components. 
     In operation, a user inserts the mobile device  10  into the relatively soft and flexible sleeve  240  via the major aperture  114 . Once inserted, the sleeve  240  (with the mobile device contained therein) is inserted into the shell  250  so that the protruding side wall regions in the sleeve are fitted to corresponding open-end apertures in the shell  250 . 
       FIGS. 23-35  illustrate a third embodiment of a protective case  300 . The third embodiment  300  is identical to the second embodiment including the first and second molded components  210  and  230  that form the sleeve  240  and the shell component  250 , except it includes additional protection over the screen or front face of the device and at the ports. Specifically, the third embodiment includes a transparent lid or screen protector  390  having a perimeter profile  391  that clips or fits into a corresponding channel  392  that is provided on the outer surface of the edge protrusion or lip  113  of the first molded component  210 . Additionally, the sleeve  240  and in particular the first molded component  210  is fitted with molded flaps or doors  393  that are hinged to (or swing from) the upper end region  115  of the first molded component  210  over user interface apertures  117  such as the apertures that correspond to the charging/data port and headphone jack apertures at the bottom side  123   c  of the case  300 . Also, as illustrated, the sidewalls of the shell may include supporting tabs  394  that are dimensioned to fit between the flaps  393  to provide additional support and to further seal the device compartment from debris. 
     The lid panel or screen protector  390 , as best illustrated in  FIGS. 32-33 , is composed of a molded frame  395  that is adhered to a die cut transparent window  396 . The molded frame may, for example, be formed of PC injected into a mold that is configured to have the shape of the frame  395 . The PC material may be opaque (e.g., black or a color that matches the first molded component for example) and may include a recessed region on the inwardly facing side that is dimensioned to receive and mate with the transparent window  396 . The transparent window may be made of any suitable material including a glass, tempered glass, or any suitable polymer such as polyethylene terephthalate (“PET”). When made of a transparent polymer sheet, like PET, the window may be die cut to size and adhered via a double sided tape or adhesive to the inwardly facing recessed region on the frame  395 . A jig may be used to apply pressure between the frame  395  and the window  396  to assure sufficient adherence there-between. One or more apertures  397  may be formed in the screen protector  390  to facilitate user interactions with the mobile device such as the home button, proximity sensors, speakers, and front facing camera features. The screen protector  390  is configured to be readily attached and detached by the user. 
     In operation, like the second embodiment, the user inserts the mobile device  10  into the relatively soft and flexible sleeve  240  via the major aperture  114 . Once inserted, the sleeve  240  (with the mobile device contained therein) may be inserted into the shell  250  so that the protruding side wall regions in the sleeve are fitted to corresponding open-end apertures in the shell  250 . The lid or screen protector  390  may be clipped or snapped into the channel  392  that is formed in the first molded component  210 , either before or after the sleeve  240  is inserted into the shell  250 . 
     While the illustrated embodiment illustrates a configuration in which the perimeter profile  391  transparent lid or screen protector  390  clips or fits into a corresponding channel  392  that is provided on the outer surface of the edge protrusion or lip  113  of the first molded component  210 , it should be understood that the channel  392  be may be provided on the top edges of the wall of the shell  250  and the lid/screen protector  390  would then clip/snap or be otherwise be attached to the shell  250  as opposed to only the sleeve  240 . Similarly it should be understood that the lid/screen protector  390  may have multiple protrusions at its perimeters that allow for attachment to channels in both the shell  250  and the sleeve  240 . 
     The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention disclosed herein. Although the various inventive aspects are disclosed in the context of certain illustrated embodiments, implementations, and examples, it should be understood by those skilled in the art that the 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 various inventive aspects have been shown and described in detail, other modifications that are within their scope will be readily apparent to those skilled in the art based upon reviewing this disclosure. It should be also understood that the scope of 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. The generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. 
     Similarly, the disclosure is not to be interpreted as reflecting an intent that any claim set forth below requires more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects may reside in a combination of fewer than all features of any single foregoing disclosed embodiment. 
     Each of the foregoing and various aspects, together with those set forth in the claims and summarized above or otherwise disclosed herein, including the figures, may be combined without limitation to form claims for a device, apparatus, system, method of manufacture, and/or method of use. 
     All references cited herein are hereby expressly incorporated by reference.