Patent Publication Number: US-2015065209-A1

Title: Cover member and method for manufacturing the same

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit under 35 U.S.C. §119(a) of a Korean patent application filed on Sep. 2, 2013 in the Korean Intellectual Property Office and assigned Serial No. 10-2013-0104890, the entire disclosure of which is hereby incorporated by reference. 
     TECHNICAL FIELD 
     The present disclosure relates to a cover member such as an exterior case or a detachable exterior cover of an electronic device including a portable device, and a method for manufacturing the same. More particularly, the present disclosure relates to a method for manufacturing an exterior case of a portable device using an inexpensive material that provides a high quality look and protection of a genuine material. 
     BACKGROUND 
     Electronic devices including portable devices refer to devices that can be carried and that provide a variety of entertainment programs for users&#39; entertainment. Examples of portable devices include cellular phones, Motion Pictures Expert Group (MPEG-1 or MPEG-2) Audio Layer III (MP3) players, Portable Digital Assistants (PDAs), Portable Multimedia Players (PMPs), electronic books, and the like. 
     Assuming portable devices of the related art have only insignificant differences in price and functions, users generally prefer portable devices having better designs. In this regard, a design of the exterior, more specifically, an exterior case, of a portable device may be an important priority to users in selecting a portable device. 
     To refine the exterior case of a portable device, a metallic material, for example, a light-weight aluminum alloy, may be used. However, such a metallic material is difficult to process into a particular shape. For example, there are many difficulties in implementing the design of the exterior case of the portable device in a desired shape with the metallic material. 
     Moreover, when the exterior case of the portable device is formed of the metallic material, the portability of the device may be lowered due to the weight of the metallic material. Thus, synthetic resin is often used as a material for the exterior case of the portable device because it is easy to mold and process and it is also suitable for mass production. When the exterior case of the portable device is manufactured by injection using synthetic resin, an electrically non-conductive metallic material, such as tin, may be used to express metallic texture. 
     For sophistication of the exterior case of the portable device, a genuine material, such as leather, or a fake material having a texture similar to that of leather may be processed and may be attached to or may be integrated with an outer surface of the exterior case. 
     Also, to refine the exterior case of the portable device, a pattern may be processed on a mold and the mold may be coated using paint having a color and texture that are similar to those of a genuine material. 
     However, such a method for processing a genuine material or a fake material having genuine-like texture and attaching or integrating the processed material to the exterior case of the portable device has some limitations in ensuring the durability of the exterior case of the portable device. Moreover, such a method may increase the overall cost of the portable device due to the cost of the genuine material, lower product yield, and increased production time, thereby degrading product competitiveness. 
     Furthermore, the method for manufacturing the exterior case by pattern-processing a mold to refine the exterior case of the portable device has limitations in implementing the exterior having genuine-like texture. In addition, it may degrade a quality completion level of an exterior of the exterior case in comparison to when a genuine material is used. 
     Therefore, a need exists for an exterior case of a portable device using an inexpensive material that provides the quality look and protection of a genuine material, thereby guaranteeing the cost competitiveness of the exterior case, and a method for manufacturing the exterior case. 
     The above information is presented as background information only to assist with an understanding of the present disclosure. No determination has been made, and no assertion is made, as to whether any of the above might be applicable as prior art with regard to the present disclosure. 
     SUMMARY 
     Aspects of the present disclosure are to address at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present disclosure is to provide a cover member such as an exterior case of a portable device using an inexpensive material that provides the quality look and protection of a genuine material, and a method for manufacturing the cover member. 
     Another aspect of the present disclosure is to provide a cover member of a portable device that provides the quality look and protection of a genuine material, while having no restriction on its design, and a method for manufacturing the cover member. 
     Another aspect of the present disclosure is to provide a cover member of a portable device that provides the quality look and protection of a genuine material, while guaranteeing the durability of the exterior case, and a method for manufacturing the cover member. 
     Other aspects to be provided in the present disclosure may be understood by various embodiments described below. 
     In accordance with an aspect of the present disclosure, a cover member of an electronic device including a portable device is provided. The cover member includes a case on at least a portion of which a material pattern is formed, a color layer formed on the material pattern provided on the case and a Smooth Feel (SF) coating layer on the color layer, in which a portion of the color layer is at least partially marked different from the material pattern. 
     The marked portion may be formed by film-removing the portion of the color layer using a laser. 
     The exterior case may further include a primer layer between the color layer and the SF coating layer. 
     The primer layer may be formed on the marked portion. 
     The marked portion may be a color of the case through film-removal of the color layer. 
     The marked portion may be formed by property-changing the portion of the color layer by using a laser. 
     The marked portion may be in a color that is different from that of the color layer. 
     The exterior case may further include a primer layer between the color layer and the SF coating layer. 
     The marked portion may include a printing layer that is printed at least partially differently from the material pattern on the color layer by using a Direct Digital Printing (DDP) method. 
     The exterior case may further include a primer layer on the color layer and the printing layer. 
     The material pattern may provide a leather texture and the marked portion may provide a texture in a stitch form. 
     The case may be formed by injection molding using a mold in which the material pattern is processed. 
     In accordance with another aspect of the present disclosure, a method for manufacturing a cover member of an electronic device including a portable device is provided. The method includes manufacturing a case that includes at least one material pattern on at least a portion thereof, applying a color on the material pattern, marking an additional material pattern on a surface of the color-coated case, and applying an SF layer on the color-coated material pattern. 
     In accordance with another aspect of the present disclosure, a method for manufacturing a cover member of an electronic device including a portable device is provided. The method includes manufacturing a case that includes at least one material pattern on at least a portion thereof, applying a color on the material pattern, printing an additional material pattern on a surface of the color-applied case, and applying an SF layer on the color-applied material pattern. 
     In accordance with another aspect of the present disclosure, a detachable exterior case for an electronic device is provided. The detachable exterior case includes a case formed with a first material pattern on an outer surface, the first material pattern includes a random pattern and regular or irregular grooves or protrusions, a color layer on the material pattern, a second material pattern providing a texture in a stitch form, and a Smooth Feel (SF) coating layer on the color layer and the second material pattern. 
     In accordance with another aspect of the present disclosure, the detachable exterior case further includes a primer layer formed between the color layer and the SF coating layer, and between the second material pattern and the SF coating layer, respectively. The primer layer and the SF coating layer are made of a transparent material. 
     Other aspects, advantages, and salient features of the disclosure will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses various embodiments of the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects, features, and advantages of certain embodiments of the present disclosure will be more apparent from the following description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view illustrating an exterior of a portable device according to an embodiment of the present disclosure; 
         FIGS. 2A ,  2 B and  2 C are cross-sectional views sequentially illustrating a process of manufacturing an exterior case of a portable device according to an embodiment of the present disclosure; 
         FIG. 3  is a cross-sectional view illustrating a structure for manufacturing an exterior case of a portable device based on a change in property of a color layer of the exterior case according to an embodiment of the present disclosure; 
         FIG. 4  is a cross-sectional view illustrating a structure for manufacturing an exterior case of a portable device using a Direct Digital Printing (DDP) method according to an embodiment of the present disclosure; 
         FIG. 5  illustrates an outer surface of a case on which a leather-material pattern is formed according to an embodiment of the present disclosure; 
         FIG. 6  illustrates an outer surface of a case on which a leather-material pattern and a stitch pattern are formed according to an embodiment of the present disclosure; 
         FIG. 7  is a flowchart illustrating a method for manufacturing an exterior case of a portable device according to an embodiment of the present disclosure; and; 
         FIG. 8  is a flowchart illustrating a method for manufacturing an exterior case of a portable device according to an embodiment of the present disclosure. 
     
    
    
     Throughout the drawings, like reference numerals will be understood to refer to like parts, components, and structures. 
     DETAILED DESCRIPTION 
     The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness. 
     The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the present disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the present disclosure is provided for illustration purpose only and not for the purpose of limiting the present disclosure as defined by the appended claims and their equivalents. 
     It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces. 
     By the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide. 
     The present disclosure will be described as being applied to ‘portable devices’. However, the term ‘portable device’ is a general term and embodiments of the present disclosure may be equally applied to any one of a mobile phone, a palm-size Personal Computer (PC), a Personal Communication System (PCS), a Personal Digital Assistant (PDA), a Hand-Held PC (HPC), a smart phone, a Wireless Local Area Network (WLAN) terminal, a laptop computer, a netbook, a tablet PC, an electronic book, and the like. 
     Therefore, the use of the term ‘portable device’ should not be used to limit application of the embodiments of the present disclosure to a device of a particular type. 
     Moreover, various embodiments of the present disclosure are not necessarily limited to portable devices, and may be equally applied to any electronic device to which a case having an exterior is applied. 
     Embodiments of the present disclosure will be described using a ‘smart phone’. 
       FIG. 1  is a perspective view illustrating an exterior of a portable device according to an embodiment of the present disclosure. 
     Referring to  FIG. 1 , a portable device  10  may be a bar type, on a front surface of which a touch screen  100  is disposed and on a rear surface of which a battery cover, although not shown, is disposed. Although the touch screen  100  is disposed globally on the front surface of the portable device  10 , a camera lens  102  and a speaker  104  are disposed in an upper portion of the front surface and a home touch button  103  and a back touch button  105  are disposed in a lower portion of the front surface. An on/off key (not shown) is disposed on a lateral surface of the portable device  10 , a volume control key  106  is disposed on another lateral surface of the portable device  10 , and an earphone terminal or port  108  is disposed on further another lateral surface of the portable device  10 . 
     Since multiple lateral surfaces and a bottom surface of an exterior case  12  of the portable device  10  are exposed to the outside, various embodiments of the present disclosure are applied to all or only some outer surfaces of the exterior case  12 . 
     While various embodiments of the present disclosure will be described as being applied to the exterior case  12  of the portable device  10  because the exterior case  12  of the portable device  10  is shown to users and contacts the users, various embodiments of the present disclosure may also be applied to an exterior cover that protects the portable device  10  and is mounted on and removable from the portable device  10  as an accessory. The mentioned exterior cover refers to a cover which protects the portable device  10  from an external environment, for example, a shock, such as dropping, is provided as an accessory for expressing a user&#39;s individuality with its various shapes or colors, and protects a front surface (i.e., a touch screen portion). 
     Meanwhile, as described above, various embodiments of the present disclosure are not necessarily limited to portable devices, and may be equally applied to any electronic device to which a case having an exterior is applied. Also various embodiments of the present disclosure may be applied to a cover member which is detachable to the electronic device. 
     Referring to the accompanying figures, a description will now be made of a structure of a case applied to the exterior case  12  of the portable device  10  to implement (i.e., imitate) a leather material mainly used for sophistication among a number of materials, and a method for manufacturing the case. 
     In the following description, the term ‘leather material’ generally includes crocodile leather, cow leather, or leather of other animals. A leather material not only has high durability but also provides outward sophistication to a user, and a soft texture to a user&#39;s touch. The leather material may also have a substantially planar outer surface or a slightly uneven outer surface, that is, an outer surface having a random pattern and regular or irregular grooves or protrusions. 
     While it will be described that a leather-material texture is expressed on the exterior of the exterior case  12  in the current embodiment of the present disclosure, the current embodiment may also be equally applied to express patterns having characteristics of other materials, for example, a pattern like a tree&#39;s annual rings, or any type of material having various patterns, for example, a genuine texture of a natural or an artificial material, such as rubber. 
       FIGS. 2A ,  2 B and  2 C are cross-sectional views sequentially illustrating a process of manufacturing an exterior case of a portable device according to an embodiment of the present disclosure. 
     Referring to  FIGS. 2A ,  2 B and  2 C, a structure of the exterior case  12  applied to the portable device  10  according to one of various embodiments of the present disclosure will be described. The exterior case  12  shown in  FIGS. 2A to 2C  uses a pattern and a texture that are similar to those of leather. The current embodiment may be applied to the exterior case  12  of the portable device  10  and may also be applied to at least some exterior surfaces exposed when the exterior case  12  is mounted on the portable device  10 . 
     The exterior case  12  may include a case  120  including a material pattern, a color layer  122  coated on the case  120 , an additional material pattern provided in a marked portion, which is part of the color layer  122 , a primary layer  126 , and a Smooth Feel (SF) layer  128 . 
     The case  120  is mass-produced by a mold (not shown). However, the case  120  is not necessarily manufactured by a mold, and may be manufactured using a different process. For example, the case may be manufactured using post-processing, mechanical/metal processing, deposition, or a 3-Dimensional (3D) printer. In the following description, the case manufactured using a mold will be used as an example. A material pattern is processed on the mold, such that the material pattern is formed on an outer surface of the case  120  injection-molded by the mold. For example, on the outer surface of the injected case  120 , a material pattern, that is, a leather-material pattern, and a pattern for stitches may be formed. For the material pattern provided in the mold, the pattern shape is processed using a mechanical processing or a chemical etching. 
       FIG. 5  illustrates an outer surface of a case on which a leather-material pattern is formed according to an embodiment of the present disclosure. 
     Referring to  FIG. 5 , material patterns P 1  and P 2  are formed on the case. The material pattern P 1  is similar to a leather pattern. The material pattern P 1  is formed by the mold on a surface  120   a  of the case  120  of  FIG. 2A , and along a circumference of the surface  120   a . Also, the spaced and repeated material pattern P 2  for representing stitches is shown. As will be described below, a laser may be locally applied to a portion of the material pattern P 1  to form a material pattern having another color or may also be applied to the material pattern P 2  to form a material pattern having another color. In this case, the material pattern P 2  may be a draft for applying a laser. 
     The color layer  122  in  FIG. 2C  is provided on the surface  120   a  of the case  120  in a color that is the same as or similar to a genuine material to double the effect of the material pattern of the case  120 . The color layer  122  may be formed on the surface  120   a  using coating or deposition. The color layer  122  may also be coated or deposited in various colors depending on the material used to form the exterior case. The color layer  122  is formed to a thickness of substantially 3-4 μm on the material pattern of the case  120 . The term ‘substantially’ may mean that a cited feature, parameter or value does not need to be accurately achieved and it is achieved not to exclude effects to be provided by deviation, change, or characteristics including an allowable error, a measurement error, a measurement accuracy limitation, and other elements known to those of ordinary skill in the art. 
     A material pattern P 3  (hereinafter, a second material pattern) having a color that is different from that of the material pattern P 1  or P 2  (hereinafter, a first material pattern) may be configured in various ways in a marked portion ( 123  of  FIG. 2A ). A description will now be made of a structure of a material pattern with reference to the accompanying figures. 
     The marked portion  123  is a region in which the second material pattern is formed. The marked portion  123  may be a portion of the color layer  122  that is film-removed by applying heat (e.g., using a laser) applied to a portion of the color layer  122  where the first material pattern is formed. Once the laser is applied to the portion of the color layer  122  (the marked portion  123 ) where the first material pattern is formed, the heat-applied portion of the color layer  122  is film-removed. Thereafter, a primer layer  126  is formed on the color layer  122 , such that the primer layer  126  is formed on the film-removed portion of the color layer  122 . The SF layer  128  is provided on the primer layer  126 . The primer layer  126  or the SF layer  128  is formed using coating. Since the primer layer  126  and the SF layer  128  are made of a transparent material, the second material pattern is implemented and seen from the outside with the material pattern and color provided in the case  120 . The primer layer  126  is formed to a certain thickness to protect the first and second material patterns formed in the case  120  and provide abrasion resistance, and for ease in attachment. The primer layer  126  is formed to a thickness of substantially 3-4 μm. The SF layer  128  is a surface protection layer formed to provide gloss as well as a soft texture as that of genuine leather. The SF layer  128  is formed to a thickness of substantially 25-30 μm. The gloss may be adjusted depending on a change in the applied thickness. 
       FIG. 3  is a cross-sectional view illustrating a structure for manufacturing an exterior case of a portable device based on a change in property of a color layer of the exterior case according to an embodiment of the present disclosure. 
     Referring to  FIG. 3 , the exterior case  12  is manufactured based on the change in property of the color layer  122 . A pattern layer  125  is a portion that is discolored by applying heat (e.g., using a laser) to a portion of the color layer  122  formed on the first material pattern. Once the laser is applied to the portion of the color layer  122  (marked portion) where the first material pattern is formed, the color of the heat-applied portion of the color layer  122  becomes different from that of the color layer  122 . The primer layer  126  is provided on the color layer  122  and the SF layer  128  is provided on the primer layer  126 . The primer layer  126  or the SF layer  128  is formed using coating. Since the primer layer  126  and the SF layer  128  are made of a transparent material, the pattern layer  125  is implemented and seen from the outside in a color that is different from that of the case  120 . The primer layer  126  is formed to a sufficient thickness to protect the first and second material patterns formed on the case  120  and to provide abrasion resistance, and for ease in attachment. The primer layer  126  is formed to a thickness of substantially 3-4 μm. The SF layer  128  is a surface protection layer formed to provide gloss as well as a soft texture as that of genuine leather. The SF layer  128  is formed to a thickness of substantially 25-30 μm. The gloss may be adjusted depending on a change in the coated thickness. 
       FIG. 4  is a cross-sectional view illustrating a structure for manufacturing an exterior case of a portable device using a Direct Digital Printing (DDP) method according to an embodiment of the present disclosure. 
     Referring to  FIG. 4 , a second material pattern  127  may be formed on the color layer  122  using the DDP method, instead of using thermal processing, such as a laser. If the second material pattern  127  is formed on the color layer  122  using the DDP method, reference numeral  127  may indicate a printing layer. The printing layer  127  is visible from the outside through the primer layer  126  and the SF layer  128 . The primer layer  126  and the SF layer  128  are made of a transparent material, such that the second material pattern  127  is implemented in a color that is different from that of the material pattern provided in the case  120 . The primer layer  126  is formed to a sufficient thickness to protect the first and second material patterns formed in the case  120  and to provide abrasion resistance, and for ease in attachment. The primer layer  126  is formed to a thickness of substantially 3-4 μm. The SF layer  128  is a surface protection layer formed to provide gloss as well as a soft texture as that of genuine leather. The SF layer  128  is formed to a thickness of substantially 25-30 μm. The gloss may be adjusted depending on a change in the applied thickness. 
       FIG. 6  illustrates an outer surface of a case on which a leather-material pattern and a stitch pattern are formed according to an embodiment of the present disclosure. 
     Referring to  FIG. 6 , a portion of the exterior case  12  on which the second material pattern P 3  is formed is illustrated. Along a circumference of the case  120 , a spaced and repeated material pattern is formed, such that the second material pattern P 3  that is different from the first material pattern is formed using a laser or the DDP method. By applying a laser to a portion of the spaced and repeated first material pattern P 2 , the second material pattern P 3  for stitches is formed. With the first material pattern P 1  and the second material pattern P 3  shown to the outside, the exterior of the injected case  12  has a pattern that is very similar to leather. 
       FIGS. 7 and 8  are flowcharts illustrating methods for manufacturing an exterior case of a portable device according to embodiments of the present disclosure. 
     Referring to  FIG. 7 , at least one material pattern is provided on the surface of the case on which the at least one material pattern is formed at operation  701 . The method mass-produces the case using a mold (not shown), but the case is not necessarily manufactured using the mold and the case may also be manufactured using post-processing, mechanical/metal processing, deposition, or a 3D printer. 
     At operation  703 , a color that is the same as or similar to that of a material to be used is applied on the case on which the material pattern is formed. The color is applied to a thickness of substantially 3-4 μm. 
     At operation  705 , the color-applied case may be changed by applying heat (e.g., using a laser) to a portion of the color layer on which the material pattern is formed. Once the laser is applied to the portion of the color layer, the color of the laser-applied portion becomes different from that of the color layer due to film-removal or property-change. At operation  707 , the primer layer is formed on the case on which the material pattern is formed. The primer layer is formed to a thickness of substantially 3-4 μm. 
     At operation  709 , the SF layer is formed on the primer layer. The SF layer protects the outer surface and provides gloss and texture similar to that of a genuine material, for example, a genuine leather-like texture, such as faux leather. The SF layer is formed to a thickness of substantially 25-30 μm. Once the case is manufactured in this order, a material pattern that is similar to a genuine material is implemented on the case. 
     Referring to  FIG. 8 , the color layer is formed having a material that is the same as or similar with a material intended by the material pattern on the outer surface of the case on which the at least one material pattern is provided at operation  801 . The color layer may be formed to a thickness of substantially 3-4 μm. 
     At operation  803 , a color that is the same as or similar to that of a material to be used is applied on the case on which the material pattern is formed. In this case, an additional material-pattern color may be printed on the color layer on which the material pattern is formed, by using the DDP method at operation  805 . After this processing, the additional material pattern color is provided as the printing layer of a certain thickness. At operation  807 , the primer layer is formed on the case where the material pattern is formed. The primer layer is formed to a thickness of substantially 3-4 μm. The applied thickness of the primer layer may be adjusted. 
     At operation  809 , the SF layer is formed on the primer layer. The SF layer protects the outer surface and provides the quality look and texture of a genuine material, for example, leather. The SF layer is formed to a thickness of substantially 25-30 μm. The applied thickness of the SF layer may be adjusted and the degree of softness or gloss may be adjusted. 
     As is apparent from the foregoing description, the exterior case according to various embodiments of the present disclosure provides an exterior of a case having the quality look and texture of a genuine material and allows superior product durability and mass production at low cost, guaranteeing cost competitiveness. 
     More particularly, the exterior case according to various embodiments of the present disclosure provides an exterior having a stereoscopic texture as well as texture like that of a real material, improves a design value through free exterior designing, and is able to be mass produced using a mold. 
     Moreover, various embodiments of the present disclosure are suitable for an exterior case that provides a leather texture. 
     The other effects may be explicitly or implicitly disclosed in the description of the present disclosure. 
     While the present disclosure has been shown and described with reference to various embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims and their equivalents.