Patent Publication Number: US-2015060505-A1

Title: Case

Description:
RELATED APPLICATIONS 
     This patent claims priority to U.S. Provisional Patent Application Ser. No. 61/870,451, filed Sep. 17, 2013 for a “Case,” the entire contents of which are incorporated by this reference. 
    
    
     RELATED FIELDS 
     Cases for portable electronic devices and methods for making the same. 
     BACKGROUND 
     There are a wide variety of cases available for use in protecting one&#39;s portable electronic devices (e.g. smart-phones or tablet computers) from damage. This patent describes a variety of improved cases, improved case components, and improved manufacturing methods for cases. 
     SUMMARY 
     In one non-limiting example, the case may be a protective case for a portable electronic device, the protective case comprising: (a) a front, the front including a transparent screen protector; (b) a back; (c) a sidewall extending between the front and back, the front, back and sidewall defining an interior configured to receive the portable electronic device by sliding the portable electronic device between the front and the back; (d) a tailgate extending between the front and the back, the tailgate movable between open and closed orientations; and (e) a door extending between the front and the back, the door movable between open and closed orientations; (f) wherein opening the tailgate and the door creates an opening through the sidewall configured to receive the portable electronic device in a sliding fashion. 
     The protective case may include a door that comprises a first door and a second door, wherein the first door is located at a first corner of the protective case and wherein the second door is located at a second corner of the protective case, wherein the tailgate extends between the first door and the second door when the tailgate and the doors are in the closed orientations. 
     The protective case may include a tailgate wherein, when the tailgate is in the closed orientation, the tailgate impedes the doors from moving between the open and closed orientations. 
     The protective case may include first and second doors, wherein the first and second doors define first and second curved sidewall corners of the case. 
     The protective case may include a tailgate, wherein the tailgate is joined to one of the front or the back at a hinge aligned with an edge of the front or the back. 
     The protective case may include a tailgate, wherein the tailgate further comprises a latch extending over one of the front or the back when the tailgate is in the closed orientation. 
     The protective case may include a door, wherein the door is joined to a portion of the sidewall at a hinge aligned with an edge of the portion extending between the front and the back. 
     The protective case may include a tailgate, wherein the hinge of the tailgate and the hinge of the door are oriented substantially perpendicular to one another. 
     The protective case may include a transparent screen protector that extends across substantially the entire front of the case. 
     The protective case may include a transparent screen that further comprises openings extending through the transparent screen protector. 
     The protective case may include a front that further comprises an anti-slip ring extending about a periphery of the transparent screen protector. 
     The protective case may include a front that further comprises a stiffening element extending about the periphery of the transparent screen protector. 
     The protective case may include a front that is joined to the sidewall at a permanent bond. 
     The protective case may include a front that is joined to the sidewall at an ultrasonic weld. 
     The protective case may include a front that is substantially planar. 
     The protective case may include a slide, the slide mounted in an aperture of the sidewall in a sliding fashion such that the slide is configured to translate through a plane aligned with the sidewall, the slide configured to operate a switch of the portable electronic device. 
     In another non-limiting example, the case may be a protective case for a portable electronic device, the protective case comprising: (a) a front, the front including a transparent screen protector; (b) a back; (c) a sidewall extending between the front and back, the front, back and sidewall defining an interior configured to receive the portable electronic device by sliding the portable electronic device between the front and the back through an opening in the sidewall; and (d) a slide, the slide mounted in an aperture of the sidewall in a sliding fashion such that the slide is configured to translate through a plane aligned with the sidewall, the slide configured to operate a switch of the portable electronic device. 
     The protective case may include a slide that includes a protrusion extending beyond an interior surface of the sidewall into the interior of the protective case. 
     The protective case may include a protrusion that includes a channel configured to receive a switch of the portable electronic device in a sliding fashion as portable electronic device is slid into the protective case. 
     The protective case may include a channel that is open at least at an end of the protrusion facing towards the opening in the sidewall. 
     The protective case of claim may include a slide that is mounted to the sidewall in a sliding fashion by at least one of a pair of grooves and a pair of rails. 
     The protective case may include an aperture of the sidewall that includes the pair of rails and wherein the slide includes the pair of grooves. 
     In another non-limiting example, a method of manufacturing a protective case for a portable electronic device comprises: (a) positioning a first component of the protective case relative to a second component of the protective case, the first component comprising a back and a sidewall of the case, the second component comprising a front of the case including a transparent screen protector, the sidewall defining an opening sized to allow the portable electronic device to be inserted between the back and the front in a sliding fashion through the opening after manufacture; and (b) bonding the first component to the second component. 
     The method may include bonding the first component to the second component by ultrasonically welding the first component to the second component. 
     The method may include forming the first component by co-molding a first thermoplastic material and a second thermoplastic material, the first thermoplastic material being a different material from the second thermoplastic material. 
     The method may include forming the second component by bonding the transparent screen protector to at least one thermoplastic sub-component. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a front perspective view of one non-limiting example of a protective case. 
         FIG. 2  is a rear perspective view of the case of  FIG. 1 . 
         FIGS. 3-8  show various components and portions of the case of  FIG. 1 . 
         FIG. 9  is a front view of the case of  FIG. 1 . 
         FIG. 10  is a rear view of the case of  FIG. 1 . 
         FIG. 11  is a left side view of the case of  FIG. 1 . 
         FIG. 12  is a right side view of the case of  FIG. 1 . 
         FIGS. 13 and 14  are cross-sectional views of the case of  FIG. 1 . 
         FIG. 15  is a top view of the case of  FIG. 1 . 
         FIG. 16  is a bottom view of the case of  FIG. 1 . 
         FIGS. 17 and 18  are cross-sectional views of the case of  FIG. 1 . 
         FIGS. 19 and 20  are perspective views of a slide of the case of  FIG. 1 . 
         FIGS. 21 and 22  are perspective views of an aperture of a portion of the case of  FIG. 1 . 
         FIG. 23  is a perspective view of the case of  FIG. 1 , shown with a tailgate and doors of the case in one example of an open orientation. 
     
    
    
     DETAILED DESCRIPTION OF DRAWINGS 
       FIGS. 1 through 23  show one non-limiting example of a protective case  10  for a portable electronic device. As shown in  FIGS. 1 and 2 , the case  10  includes a front  12 , a back  14 , and a sidewall  16  extending around the perimeter of the case  10  between the front  12  and back  14 . The front  12 , back  14 , and sidewall  16  define an interior  18  (see, e.g.  FIG. 3 ) configured to receive the portable electronic device by sliding the portable electronic device through an opening between the front  12  and back  14 , as discussed in further detail below. The case  10  may be sized and otherwise configured for a particular make and model of portable electronic device, or may be sized and otherwise configured for a variety of makes and/or models of portable electronic devices. 
     As shown in  FIGS. 5 and 6 , the front  12  of the case  10  includes a transparent screen protector  20 . In this example, the transparent screen protector  20  is made out of PET film that is die cut to the specific shape of the case. The PET film may have a 2H hardness and an inner textured screen to prevent or reduce water marks. In other examples, the screen protector may be a clear polycarbonate, poly-urethane film, RPET film, glass, or armor glass. In the embodiment shown, the screen protector  20  includes openings  22  extending through the screen protector  20 , located over particular components of the portable electronic device, although in other embodiments the transparent screen protector  20  does not include such openings or includes an additional film or other material covering the openings. 
     The screen protector  20  extends across substantially the entire front  12  of the case  10 . For instance, the screen protector  20  extends at least partially over the sidewall  16  on left, right, upper, and lower sides of the case  10 . In other embodiments, the screen protector  20  may extend to, although not necessarily over, the sidewall  16 . In still other embodiments, the screen protector does not extend to the sidewall  16 . 
     As shown in  FIGS. 5 and 6 , the front  12  of the case  10  also includes a stiffening element  24  and an anti-slip ring  26  on top of the screen protector  20 . In this embodiment, the anti-slip ring  26  and the stiffening element  24  are opaque or semi-opaque.  FIGS. 5 and 6  also show a tailgate  36  that is part of the sidewall  16  of the case  10  and is discussed further below. 
     In the embodiment shown, the stiffening element  24  is polycarbonate and is configured to increase the stiffness of the front  12  of the case  10 . The stiffening element  24  includes two planar panels  28  on either side of one of the openings  22  and a ring  30  extending about the perimeter of the front  12 . In the embodiment shown, the ring  30  is less than 2.5 mm thick (and in other embodiments may be between 3 mm and 1 mm thick). As shown in  FIG. 6 , the stiffening element  24  includes a recess for receiving the screen protector  20 , and also includes protrusions  32  extending from a back side of the stiffening element  28 , the purpose of which will be described in further detail below. 
     In the embodiment shown, the anti-slip ring  26  is a thermoplastic elastomer (although in other embodiments it may be a silicone) and is configured to sit in a groove formed in a front side of the stiffening element  24  such that only a very thin portion of the anti-slip ring  26  extends above the top of the stiffening element  24  (e.g. 0.5 mm or less). In the embodiment shown, the combined stiffening element  24  and anti-slip ring  26  extend less than 3.2 mm above the front surface of the transparent screen protector. In the embodiment shown, the front  12  of the case  10  is substantially planar. 
     As shown in  FIGS. 13 ,  14 ,  17 , and  18 , a ramped surface  34  extends gradually upward from the exposed surface of the screen protector  20  (i.e. the portion of the screen protector  20  not covered by the stiffening element  24  and anti-slip ring  26 ). In the particular embodiment shown, the ramped surface  34  is slightly concave (although in other embodiments it may be straight) in cross-section and extends away from the screen protector  20  at an obtuse angle (e.g. in the range of 135 degrees to 170 degrees). In some non-limiting embodiments, the angle of the ramped surface  34  facilitates user interaction with the device&#39;s touchscreen. 
     In the embodiment shown in the figures, the back  14  of the case  10  includes multiple layers (see, e.g.,  FIGS. 7 and 8 ), including an inner liner  38 , a back planar member  40 , and a back plate  42 . In this example, the inner liner  38  is a silicone padding layer, the back planar member  40  is an opaque polycarbonate, and the back plate  42  is a decorative layer (e.g. a metal, wood, faux-wood, or other material with or without printed graphics or engraved designs) adhered or otherwise affixed to the back planar member  40 , or may be a thermoplastic material (e.g. a thermoplastic elastomer) co-molded with the back planar member. In other embodiments, the back  14  of the case  10  may be configured in other ways and have additional or less layers. 
     As shown in  FIGS. 7 and 8  the back planar member  40  and the back plate  42  are notched to provide clearance for the tailgate  36  discussed in greater detail below. As also shown in  FIGS. 7 and 8 , the planar surface of back planar member  40  includes a recess  44  for receiving a portion of the tailgate  36 , and includes connectors (in this instance, apertures  46 ) for securing portions of the tailgate  36 . The inner liner  38 , back planar member  40 , and back plate  42  also include apertures/notches to provide a camera opening for the electronic device. 
       FIGS. 7 and 8  also show the sidewall  16  of the case  10  (except for the tailgate  36 , which is formed in this example with the anti-slip ring  26 , as shown in  FIGS. 5 and 6 ). In this particular example, the sidewall  16  includes a thermoplastic elastomer portion  48  and a polycarbonate portion  50 , although other configurations are also possible. The sidewall  16  includes buttons  52  for actuating some of the controls of the electronic device and also includes a slide  54  for actuating other controls (in this example, specifically the switch for silencing the electronic device), which is discussed in further detail below. 
     The case  10  shown in the figures allows the portable electronic device to be inserted into its interior  18  through an opening in the sidewall  16  created by opening a tailgate  36  and doors  56  of the sidewall  16 .  FIG. 1  shows the tailgate  36  and doors  56  in a closed orientation.  FIG. 23  shows the tailgate  36  and the doors  56  in an open orientation. When the tailgate  36  and the doors  46  are in the open orientation of  FIG. 23 , the portable electronic device may be slid laterally into the interior  18  of the case  10 , and the tailgate  36  and doors  46  may be subsequently re-closed. In some embodiments, the portable electronic device slides along an axis that is parallel to the substantially planar front  12  and back  14  of the case. In some embodiments, the portable electronic device laterally slides into the interior of the case through an opening of the sidewall  16 . In the embodiment shown in the figures, the portable electronic device slides through an opening in the bottom of the case. In other embodiments, the portable electronic device slides through an opening the top, left, or right side of the case. 
     The tailgate  36  shown in the figures extends between the front  12  and back  14  of the case when it is in the closed configuration. The tailgate  36  is joined to the front  12  of the case  10  at a hinge  58 . In the particular embodiment shown, the hinge  58  is a living hinge (i.e. it is formed as an integral portion of the tailgate  36  and anti-slip ring  26  and is resilient such that the tailgate  36  can be rotated about the long axis of the hinge  58 ). In the embodiment shown, the rotational axis of the hinge  58  is aligned with (or coincides with) an edge of the front  12 . In the embodiment shown, the rotation axis of the hinge  58  is parallel with and slightly offset from the portion of the anti-slip ring  26  closest to the tailgate  36 . 
     The tailgate  36  also includes plugs  60  that may be rotated relative to other portions of the tailgate (for accessing a charging port and headphone jack of the electronic device). The tailgate  36  also includes speaker grills  66 . The tailgate  36  also includes a latch portion  62  that fits into the recess  44  of the back planar member  40  when the tailgate  36  is in the closed orientation. Connectors on the latch portion (in this instance, protrusions  64 , see  FIG. 23 ) fit into apertures  46  of the back planar member  44  to help retain the tailgate  36  in the closed orientation. In the particular example show, the protrusions  64  extend outwardly and parallel to the latch portion. In other embodiments, the protrusions may extend outwardly and perpendicular to the latch portion. In some embodiments, the protrusions may have a triangular or other cross sectional shape that increases in width as the protrusions extend away from the latch portion to provide a firm engagement with the apertures or other structure of the case to help retain the tailgate in a closed orientation. 
     The doors  56  shown in the figures extend between the front  12  and back  14  when the doors  56  are in closed orientations. The doors  56  in the example shown in the figures form two corners of the sidewall  16  of the case, on either side of the tailgate  36 . As shown in  FIGS. 1 and 23 , the doors  56  define curved portions of the sidewall  16 . As shown in  FIG. 3 , for example, each door  56  is associated with a hinge  68  (here, also a living hinge created by an area of reduced thickness of the thermoplastic elastomer portion of the sidewall  16 ). Hinges  68  are generally perpendicular to the front  12  and back  14  of the case  10 . Hinges  68  are aligned with edges of the sidewall  16  that join to the hinges  68 . 
     In the example shown in the figures, the axes of rotation of hinges  68  are substantially perpendicular to the hinge  58  of tailgate  36 . In the example shown in the figures, the doors  56  rotate outwardly from the sidewall  16  of the case  10  whereas the tailgate  36  rotates upwardly away from the back  14  and towards the front  12 . 
     When the tailgate  36  and doors  56  are in the closed orientations, the tailgate  36  inhibits or impedes the doors  56  from opening. As shown in  FIGS. 7 ,  8  and  23 , the doors  56  include vertically oriented lips  70  that are captured by the tailgate  36  when the tailgate  36  and doors  56  are in closed orientations, such that the doors  56  cannot be opened until the tailgate  36  is rotated to an open orientation, such as shown in  FIG. 23 . 
     As shown in  FIGS. 1 ,  11 , and  12 , the doors  56  define elongated gaps  72  between the doors  56  and back  14  of the case  10 , which, in the example shown, offset the door further away from the back  14  of the case  10  than the front  12  of the case  10 . In other words, in the example shown, the gaps  72  between the doors  56  and the back  14  of the case are wider than gaps (to the extent there is one) between the doors  56  and the front  12  of the case. Although not shown in the figures, in some embodiments, the doors  56  may include small support members extending through the gaps  72  to the back  14  to further strengthen the case  10  against certain loads or forces. As shown in, for example,  FIG. 23 , the doors  56  may also include protrusions  74  on upper surfaces of the doors  56  for engaging recesses in an underside surface of the front  12  of the case to facilitate retaining doors  56  in the closed orientation. In still other examples, gaps are not necessary or are minimal in size, and supports/protrusions on the doors are not necessary or are smaller in size. In still other examples, the doors are not necessarily uniform in size. In other words, one door may be larger than the other door. In some examples, one of the doors may take the place of the tailgate (e.g. the door extends all the way or almost all the way across the bottom of the case). 
       FIGS. 19 through 22  show the afore-mentioned slide  54  and portions of sidewall  16  that interact with the slide  54 . An outer surface of the slide  54  (shown in  FIG. 19 ) includes a protrusion  78  for helping a user actuate slide  54 . An inner surface of slide  54  (shown in  FIG. 20 ) includes structure for interacting with a switch (such as a toggle switch) of the portable electronic device. In the specific example shown, the structure for interacting with the switch includes two protrusions  80  extending from the back surface of slide  54  such that, when mounted in the sidewall  16 , the protrusions  80  extend beyond the sidewall  16  into the interior  18  of case  10  such that the protrusions  80  can contact the switch of the electronic device during use. Protrusions  80  define a channel between them for receiving the switch of the electronic device. Ramped surfaces  82  on the protrusions  80  (which may be straight or curved) are on the sides of the protrusions  80  facing towards the insertion opening of case  10 , such that the ramped surfaces  82  can interact with the switch of the electronic device as it is slid between the front  12  and back  14  of the case into its interior  18 , such that the slide  54  will align with the switch of the electronic device and not substantially impede insertion of the electronic device into the case  10 . As shown in  FIG. 22 , a channel  84  extends through a raised portion  86  of the interior of the sidewall  16  to provide clearance for the switch of the electronic device as it is slid into the case  10 . In the particular example shown, channel  84  also includes a ramped surface  88 , which will facilitate aligning the switch of the electronic device such that it does not significantly impede insertion into the case  10 . 
     Slide  54  mounts in an aperture  76  of the sidewall  16  in a sliding fashion such that the slide is configured to translate through a plane aligned with the sidewall. In the particular example shown, the slide  54 , when mounted in aperture  76 , can translate through a portion of the aperture  76 , but cannot rotate or pivot in or relative to the aperture  76 . In the particular example shown in the figures, the translational movement of the slide  54  in the aperture  76  is controlled by a pair of rails  90  and a pair of grooves  92 . In the particular example shown, the rails  90  extend into aperture  76 , and are aligned with an axis extending between the front  12  and back  14  of the case  10 . In the particular example shown the grooves  92  are formed by protrusions extending from the rear surface of slider  54 , such grooves also aligned with an axis extending between the front  12  and back  14  of the case  10  when the slider  54  is mounted in the aperture  76 . As shown in  FIG. 20 , the protrusions forming the grooves  92  are shorter than the protrusions  80  for interacting with the electronic device&#39;s switch. 
     While not shown in the figures, in some examples, the case may include an ejector mechanism to facilitate removal of the electronic device from the case. In one example, the case may include a pusher or slider that, when depressed or slid, moves the electronic device towards the opening in the case, to facilitate its removal. 
     The case  10  shown in the figures may be formed from a variety of materials. Some (or all) of the materials forming the case may be molded. Portions of the front  12 , back  14 , and sidewall  16  of the case may be formed by one or more co-molding, over-molding, or other molding processes. In the specific example shown in the figures, the front  12  of the case  10  is formed by co-molding or over molding a poly-carbonate thermo-plastic stiffening element  24  and a thermo-plastic elastomer anti-slip ring  26  (the tailgate  36  also being integrally formed with the thermo-plastic elastomer anti-slip ring  26 ). The transparent screen protector  20  may be joined to one or both of the other components shown in  FIGS. 5 and 6  by an adhesive, ultrasonic welding, or other methods. In other embodiments, the transparent screen protector  20  may be snap fit into the front of the case (and, in some instances, may be removable/replaceable). In the specific example shown in the figures, the back  14  and sidewall  16  of the case is formed by co-molding or over molding a poly-carbonate thermo-plastic portion (including a portion  50  of sidewall  16  and the back planar member  42 ) and a thermo-plastic elastomer portion  48  of the sidewall  16 . The inner liner  38  may be joined to the back planar member  42  by adhesive or other mechanisms. The back plate  42  may be jointed to the back planar member  42  by adhesive, ultra-sonic welding, co-molding or over-molding, or by other mechanisms. 
     In the particular embodiment shown, such as illustrated in  FIGS. 3 and 4 , once the front  12  construct and the back  14  and sidewall  16  construct are formed, those two constructs may be joined together to complete manufacture of the case  10 . In some instances, those two constructs may be joined permanently to one another, such as by ultrasonically welding the two constructs together. In the particular example shown in the figures, protrusions and recesses  94  on those constructs may facilitate alignment of the two constructs relative to one another during manufacture. 
     Those of ordinary skill in the art will recognize that additions, deletions, substitutions, and other changes or modifications may be made to the case  10  shown in the figures and described above without departing from the scope or spirit of the present inventions reflected by this patent, which are specified by the claims of this patent.