PATENT DOCUMENT

Publication Number: US-9760118-B2
Application Number: US-201414167600-A
Country: US
Kind Code: B2

Title: Foldable case for use with an electronic device

Abstract:
This is directed to a case for securing and protecting an electronic device. The case can include a cover connected to a pouch by a hinge such that the cover can be overlaid over a device interface (e.g., a device display). The case can be constructed by layering and combining several types of materials, including for example materials having resistant outer surfaces, materials limiting the deformation of the case, materials providing a soft surface to be placed in contact with the device, and rigid materials for defining a structure of the case. In some embodiments, the case can include a tab that allows a user to fold open the cover of the case to form a triangular prism. The prism can be placed on any of its surfaces such that the device can be oriented towards a user at particular angles (e.g., a typing-specific orientation and a media playback orientation).

Claims:
What is claimed is: 
     
       1. A protective case for a portable electronic device, the protective case comprising:
 a pouch portion configured to cover a surface of the portable electronic device and expose at least a portion of the portable electronic device, the pouch portion having a first edge and a second edge opposite the first edge, wherein the pouch portion includes an external layer comprising polyurethane, a polyester knit layer adjacent the external layer, and a rigid layer bonded to the polyester knit layer by an adhesive and comprising fiberglass or polycarbonate; and 
 a flexible flap coupled to the pouch portion and including a hinge portion pivotally coupled to a cover portion, wherein the hinge portion and the cover portion cooperate to present the portable electronic device in a closed configuration, a typing configuration, and a viewing configuration, wherein:
 when the flexible flap is in the closed configuration, the cover portion covers at least a portion of an opening of the pouch portion, 
 when the flexible flap is in the typing configuration, the hinge portion cooperates with the cover portion to support the portable electronic device at a typing angle with respect to a support surface, wherein the first edge of the pouch portion is closer to the support surface than the second edge of the pouch portion; and 
 when the flexible flap is in the viewing configuration, the hinge portion cooperates with the cover portion to support the portable electronic device at a viewing angle with respect to the support surface, wherein the second edge of the pouch portion is closer to the support surface than the first edge of the pouch portion. 
 
 
     
     
       2. The protective case as recited in  claim 1 , wherein the cover and hinge portions comprise hard elements. 
     
     
       3. The protective case as recited in  claim 1 , wherein the pouch portion fully covers at least the back side of the portable electronic device when the portable electronic device is secured within the protective case. 
     
     
       4. The protective case as recited in  claim 1 , wherein the cover portion contacts a back surface of the pouch portion when the flexible flap is in the typing configuration or the viewing configuration. 
     
     
       5. The protective case as recited in  claim 1 , wherein the flexible flap includes a microfiber material configured to contact the display of the portable electronic device. 
     
     
       6. The protective case as recited in  claim 1 , wherein the cover portion includes a fastening mechanism for retaining the cover portion over the pouch portion. 
     
     
       7. The protective case as recited in  claim 6 , wherein the fastening mechanism comprises a mechanical snap, a magnetic snap, or a hook and fastener material. 
     
     
       8. The protective case as recited in  claim 6 , wherein the fastening mechanism comprises a magnet. 
     
     
       9. A case for an electronic device, the case comprising:
 a pouch portion configured to cover a surface of the electronic device and expose at least a portion of the electronic device through an opening of the pouch portion, the pouch portion including a first edge and a second edge opposite the first edge, wherein the pouch portion includes an external layer comprising polyurethane, a polyester knit layer adjacent the external layer, and a rigid layer bonded to the polyester knit layer by an adhesive and comprising fiberglass or polycarbonate; and 
 a flap coupled to the pouch portion and having a hinge portion pivotally coupled to a cover portion, the flap operative to transition between a closed configuration and a presentation configuration, wherein the cover portion covers at least a portion of the opening of the pouch portion when the flap is in the closed configuration, and cover portion is coupled with a back surface of the pouch portion when the flap is in the presentation configuration, wherein the hinge portion cooperates with the cover portion to support the electronic device at a typing angle or a viewing angle when the flap is in the presentation configuration, wherein:
 when the case supports the electronic device at the typing angle, the first edge of the pouch portion is closer to a support surface than the second edge of the pouch portion, and 
 when the case supports the electronic device at the viewing angle, the second edge of the pouch portion is closer to the support surface than the first edge of the pouch portion. 
 
 
     
     
       10. The case as recited in  claim 9 , wherein the pouch portion includes at least one interface opening. 
     
     
       11. The case as recited in  claim 9 , wherein the pouch portion further includes a microfiber layer. 
     
     
       12. The case as recited in  claim 11 , wherein the microfiber layer corresponds to an internal layer of the pouch portion. 
     
     
       13. The case as recited in  claim 9 , wherein a length of the cover portion is greater than a length of the hinge portion. 
     
     
       14. The case as recited in  claim 9 , wherein the polyester knit layer and the external layer are adhesively bonded together. 
     
     
       15. The case as recited in  claim 9 , wherein a rigid element of the cover portion is separated from a rigid element of the hinge portion by a flexible portion. 
     
     
       16. A case for a portable electronic device, the case comprising:
 a pouch configured to surround a surface of the portable electronic device and expose at least a portion of the portable electronic device, the pouch including a first edge and opposing second edge wherein the pouch includes an external layer comprising polyurethane, a polyester knit layer adjacent the external layer, and a rigid layer bonded to the polyester knit layer by an adhesive and comprising fiberglass or polycarbonate; and
 a flap coupled to the pouch and having a hinge portion and a cover portion, wherein the flap is configured to transition among a closed configuration, a viewing configuration, and a typing configuration, wherein: when the flap is in the closed configuration, the cover portion covers at least a portion of an opening of the pouch, 
 when the flap is in the viewing configuration, the hinge portion cooperates with the cover portion to support the pouch at a viewing angle with respect to the hinge portion, and 
 when the flap is in the typing configuration, the hinge portion cooperates with the cover portion to support the pouch at a typing angle with respect to the cover portion. 
 
 
     
     
       17. The case as recited in  claim 16 , wherein a portion of the flap coupled to the pouch has a width shorter than a width of the portable electronic device. 
     
     
       18. The case as recited in  claim 16 , wherein the viewing angle is greater than the typing angle. 
     
     
       19. The case as recited in  claim 16 , wherein the cover portion includes a fastening mechanism for retaining the cover portion over the opening when the case is in the closed configuration. 
     
     
       20. The case as recited in  claim 19 , wherein the fastening mechanism comprises a magnet.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 12/683,328, filed Jan. 6, 2010, entitled “FOLDABLE CASE FOR USE WITH AN ELECTRONIC DEVICE” now U.S. Pat. No. 8,672,126, the disclosure of which is hereby incorporated by reference in its entirety for all purposes. 
    
    
     BACKGROUND OF THE INVENTION 
     This is directed to a case for protecting an electronic device. In particular, this is directed to a case having a foldable flap for selectively covering a display of the device, and for creating a stand supporting the device in a particular orientation. 
     A portable electronic device can include several interfaces through which a user can interact with the device. In particular, a device can include one or more displays and input interfaces via which the user can consume displayed content or control the manner in which content is displayed. The device can include an outer shell supporting the several interfaces and defining a volume into which electronic device components can be placed and supported. For example, the outer shell can be used to retain a power supply (e.g., a battery), processing circuitry, communications circuitry, positioning circuitry, storage and memory, and electrically conductive paths (e.g., a bus) connecting the device components. 
     The outer shell can be constructed from one or more distinct components. For example, the outer shell can include a housing having one or more components, a bezel placed around the periphery of the housing, and a display. The housing can include a back plate and sidewalls extending from the back plate that the bezel can engage. The bezel can include one or more features for engaging and retaining the window within the bezel periphery. 
     During use, the device outer shell can be exposed to impacts or to the environment around the device. Because impacts can damage the outer shell or damage components within the device, a user may wish to protect an electronic device by placing the device in a protective case. The protective case can be constructed from any suitable soft or hard material, and can protect some or all of the electronic device. For example, the case can cover the housing and bezel and only part of the display. As another example, the case can substantially the entirety of the electronic device such that the device can be removed from the case during use. As still another example, the case can selectively cover the display (e.g., with a cover). The cases, however, may have limited aesthetic appeal or may have limitations in the manner in which they protect the device. 
     SUMMARY OF THE INVENTION 
     This is directed to a case for use with a portable electronic device having a display. In particular, this is directed to a case having a pouch into which an electronic device can be placed, and a cover that can fold over the pouch to selectively protect the device display. 
     To protect an electronic device display, the case can include a pouch element coupled to a cover element by a hinge. The pouch element can provide a protective surface around at least some of the electronic device. For example, the pouch can protect one surface and the sidewalls of the device, leaving only the display window exposed. The hinge and cover can be sized such that the cover can be folded over the pouch to substantially entirely cover the exposed display window. 
     The case can be constructed from any suitable material. In some embodiments, the case can be constructed by combining several different materials having different properties. For example, several different materials can be layered to form the case. The materials can include, for example, polyester microfiber, polycarbonate fiber, polyurethane adhesive, polyester knit, and polyurethane sheets. The different materials can be layered in different orders, and can include only some of the materials based on the section of the case. For example, portions of the cover can include fiberglass plates, but portions of the pouch can include only softer layers (e.g., polyurethane and microfiber). 
     The case can include one or more tabs for holding the case at an angle relative to the ground. For example, a back surface of the case can include a tab into which the cover can be folded. As the cover is folded into the tab, the case can define a triangular shape that can be disposed on any of the three sides of the triangle. In some embodiments, the length of the sides of the triangle can be selected to provide different viewing angles for the device within the case (e.g., a typing angle and a media playback angle). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a schematic view of an illustrative electronic device in accordance with one embodiment of the invention; 
         FIGS. 2A-C  are a series of schematic views of an illustrative case in accordance with one embodiment of the invention; 
         FIGS. 3A-C  are a series of schematic views of an illustrative case in accordance with one embodiment of the invention; 
         FIG. 4  is a schematic view of an illustrative pouch used in a case for retaining an electronic device in accordance with one embodiment of the invention; 
         FIG. 5  is an end view of the pouch of  FIG. 4  taken from viewpoint  402  in accordance with one embodiment of the invention; 
         FIG. 6  is a schematic view of the pouch of  FIG. 4  in which the flap has been folded over a device in accordance with one embodiment of the invention; 
         FIG. 7  is an end view of the pouch of  FIG. 6  taken from viewpoint  402  in accordance with one embodiment of the invention; 
         FIG. 8  is a cross-sectional view of the flap of the pouch of  FIG. 4  along line  8 - 8  in accordance with one embodiment of the invention; 
         FIG. 9  is a cross-sectional view of periphery stack  420  taken along line  9 - 9  in accordance with one embodiment of the invention; 
         FIG. 10  is a cross-sectional view of the tab and periphery stack of the pouch of  FIG. 4  taken along line  10 - 10  in accordance with one embodiment of the invention; 
         FIG. 11  is a schematic view of a base stack in accordance with one embodiment of the invention; 
         FIG. 12  is a cross-sectional view of base layer stack  1110  taken along line  12 - 12  and connected to a peripheral layer stack in accordance with one embodiment of the invention; 
         FIGS. 13A and 13B  are end views of a folded over case defining a prism in accordance with one embodiment of the invention; 
         FIG. 14  is a cross-sectional view of tab  1150  taken along line  14 - 14  in accordance with one embodiment of the invention; and 
         FIG. 15  is a flowchart of an illustrative process for assembling a case for protecting an electronic device in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device can include an external shell in which different components can be secured to provide electronic device functionality. The external shell can include one or more interfaces for interacting with the device, including for example, one or more displays and input mechanisms. As another example, the external shell can include one or more ports or connectors, or openings for the ports or connectors (e.g., USB, power and audio connectors). As still another example, the external shell can include an opening for a speaker. To protect the external shell from impacts or other external forces applied to the device, the device can be placed within a case. 
     The case can have any suitable shape suitable for protecting at least a portion of the electronic device. In some embodiments, the case can include a primary pouch for receiving the electronic device. The pouch can include an opening through which one or more of a display and an input interface can be accessible. In some embodiments, the opening can include a transparent film or layer through which the interface can be accessed (e.g., an interface through which a touch interface can be operated). To protect the display and interface through the opening, the case can include a cover connected to the pouch by a hinge, such that the cover can be folded over the pouch opening. 
     The case can be constructed from any suitable material to provide a particular aesthetic finish or desired level of protection. For example, the case can be constructed from a hard material. As another example, the case can be constructed from a softer material, but include one or more hard elements to provide resistance to impacts. In one implementation, the case can be constructed by layering different types of material to form a stack. The material stack can include different types of materials, including materials selected based on different physical properties. For example, the material stack can include a soft material (e.g., to be placed in contact with the device, a hard material (e.g., fiberglass) to withstand impacts, and a stain-resistant or water-resistant material (e.g., polyurethane) to provide a pleasing outer surface for the case. 
     The case can include a tab embedded or attached to the back surface of the pouch such that the cover can be folded back along the hinge and secured with in the tab. This can define a triangular prism, where the cover, hinge and pouch of the case define the three rectangular sides of the prism. The tab can be positioned on the pouch such that the length of the hinge and the length of the cover provide two different angles at which the case can be positioned. For example, the angles can be selected to optimize a typing angle and a viewing angle for the device. 
     Any suitable electronic device can be placed within the case.  FIG. 1  is a schematic view of an electronic device in accordance with one embodiment of the invention. Electronic device  100  can include housing  110 , bezel  112 , and window  120 . Bezel  112  can be coupled to housing  110  in a manner to secure window  120  to the bezel. Housing  110  and bezel  112  can be constructed from any suitable material, including for example plastic, metal, or a composite material. In one implementation, housing  110  can be constructed from plastic or aluminum, and bezel  112  can be constructed from stainless steel. Window  120  can be constructed from any suitable transparent or translucent material, including for example glass or plastic. Different electronic device components can be retained within electronic device  100  to provide different functionality to the user. 
     To protect the electronic device from damage caused by impacts or to wear and tear caused by the environment, the electronic device can be placed in a case.  FIGS. 2A-C  and  FIGS. 3A-C  are a series of schematic views of an illustrative case in accordance with one embodiment of the invention. Cases  200  and  300  can be operative to receive an electronic device, for example within pouch elements  210  and  310 , respectively. The pouch elements can include an opening through which a display can be viewed (e.g., described in more detail below). To protect the display, cases  200  and  300  can include covers  220  and  320 , respectively, connected to the pouch elements via hinges  220  and  320 , respectively. The hinges can be constructed from a pliable material such that covers  220  and  320  can bend towards or away from the opening of pouches  210  and  310  (e.g., over the display to protect the device display when stored, or behind the pouch exposing the display when the device is in use. 
     Cases  200  and  300  can include flap  215  assembled into or coupled to an opening in pouches  210  and  310 , respectively into which the device can be inserted. Flaps  215  and  315  can extend away from the openings such that the flaps can be folded over the device and retain the device within the pouch. In some embodiments, flaps  215  and  315  can include one or more rigid elements for assisting a user in folding the flap over the device, or for maintaining the flap between the device and the pouch surface. 
     In some embodiments, a user may wish to fold covers  220  and  320  behind pouch elements  210  and  310 , respectively, so as to define other surfaces on which the case may rest. For example, a user can fold covers  220  and  320  into tabs  250  and  350 , respectively, such that covers  200  and  300  form prisms, where each of pouch elements  210  and  310 , hinges  220  and  320 , and covers  220  and  320  define side walls of the prism. The covers can be placed on any of the sidewalls of the prism (e.g., resting on the hinge or on the cover) such that the device display within the pouch is angled to the user at a particular angle. In some embodiments, the position of tabs  250  and  350 , and the length of hinges  220  and  320 , and covers  220  and  320  can be selected such that the device is displayed at a particular angle when cases  200  and  300  rest on hinges  220  and  320 , and covers  220  and  320 . 
     Cases  200  and  300  can be oriented in any suitable manner. In the examples of  FIGS. 2A-C  and  FIGS. 3A-C , cases  200  and  300  are oriented in landscape and portrait modes, respectively. For example, hinge  220  is along the long end of rectangular pouch element  210 , while hinge  320  is along the short end of rectangular pouch element  310 . It will be understood, however, that the pouch element can have any suitable shape, and that the hinge can be along one or more of any of the sides of the pouch element (e.g., a hinge along two non-adjacent or non-continuous edges of a multi-sided polygon. For the sake of simplicity, however, the following discussion will provide examples and details in the context of the landscape-oriented cases (e.g., case  200 ). 
       FIG. 4  is a schematic view of an illustrative pouch used in a case for retaining an electronic device in accordance with one embodiment of the invention. Pouch element  400  can include a back layer or primary stack  410  to which a periphery or secondary stack  420  can be coupled. Periphery stack  420  can be positioned around the periphery of back layer stack  410  such that when an electronic device is inserted within pouch  400 , the periphery of the device is constrained between stacks  410  and  420 . The width of periphery stack  420  can be selected based on any suitable criteria, including for example the size of the device to be placed within the pouch. In particular, periphery stack  420  can be sized such that an electronic device cannot pass through an opening of the periphery stack (e.g., opening  422 , described below) once it has been inserted in the pouch. Periphery stack  420  can include opening  422  through which the electronic device can be visible and manipulated. For example, opening  422  can be substantially sized to match the size of a display area or window of the device. As another example, opening  422  can be sized such that a display and an input interface (e.g., a keyboard) are visible and accessible through the opening. 
     An electronic device can be placed within pouch  400  (e.g., between stacks  410  and  420 ) using any suitable approach. In some embodiments, the pouch can include an opening through which the device can be slid into the pouch. This may be necessary if opening  422  is sized such that the device cannot pass through the opening (e.g., for insertion or removal).  FIG. 5  is an end view of the pouch of  FIG. 4  taken from viewpoint  402  in accordance with one embodiment of the invention. As shown in  FIG. 5 , pouch  400  can include opening  440  through which device  500  can be inserted. To secure the electronic device between stacks  410  and  420 , flap  430  can be coupled with or embedded within one of the stacks (e.g., stack  420 ). Flap  430  can extend out of periphery stack  420  and away from opening  422  such that flap  430  can be folded towards stack  410  and define a sidewall between stacks  410  and  420 .  FIG. 6  is a schematic view of the pouch of  FIG. 4  in which the flap has been folded over a device in accordance with one embodiment of the invention. As shown in  FIG. 6 , flap  430  has been folded within opening  440  and towards stack  410  of pouch  400 .  FIG. 7  is an end view of the pouch of  FIG. 6  taken from viewpoint  402  in accordance with one embodiment of the invention. As shown in  FIG. 7 , flap  450  can around device  500  such that the free end of flap  430  is between device  500  and stack  410 . This can allow flap  430  to form a sidewall for pouch  400 , and thus secure device  500  on all sides (flap  430  on one side, and the interface between stacks  410  and  420  on the other sides). 
     Returning to  FIG. 4 , flap  430  can have any suitable width  432  adequate for securing the electronic device once flap  430  has been folded beneath the device. In particular, width  432  can be selected such that width  432  is substantially larger than height  434  of device  500 . The length of width  432  less height  434  can be selected such that it provides sufficient resistance (e.g., from friction between flap  430  and stack  410  to prevent flap  430  from slipping out). To enhance a user&#39;s ease in inserting flap  430  around device  500 , flap  430  can include one or more rigid elements  436  and  438  separated by flexible portion  437 . In some embodiments, flexible portion  437  can be the same as the non-rigid portions of flap  430  (e.g., rigid elements  436  and  438  are created from the introduction of addition materials within flap  430 ). The width of rigid element  436 , as well as the position of rigid element  436  relative to the border of flap  430  and stack  420  can be selected such that a user can easily fold rigid element  436  over a device and into pouch  400 . In particular, the width of rigid element  436  can be no more than the distance  433  between rigid element  436  and stack  420  (e.g., the smallest distance between portions of rigid element  436  and stack  420 ). In other words, flexible portion  437  can extend to distance  433 . 
     Because the height of the device (e.g., height  434 ) is less than distance  433  between rigid element  438  and stack  420 , flap  430  can include an additional section that a user may wish to insert between device  500  and stack  410  to ensure that device  500  remains secured within pouch  400  (e.g., so that only an amount of flap  430  equal to height  434  is not between the device and the back layer stack). Rigid element  438  can substantially be placed within this portion to provide a hard component that a user can easily slide into pouch  400 . Rigid element  438  can have any suitable size, including for example a width of no more than the different between distance  433  and height  434  (e.g., the length of the amount of flap  430  remaining to slide within pouch  400 ). In some embodiments, rigid element  438  can be placed at the limit of height  434  to provide guidance as to how far flap  430  should be inserted. 
     Rigid elements  436  and  438  can be constructed from any suitable material. In some embodiments, rigid elements  436  and  438  can include polycarbonate layers providing a that are flexible for bending around an axis in the plane of the layers, but stiff and resisting bending around an axis that is not in the plane of the layers (e.g., perpendicular to the plane of the layers).  FIG. 8  is a cross-sectional view of the flap of the pouch of  FIG. 4  along line  8 - 8  in accordance with one embodiment of the invention. The cross-section  800  of flap  430  can include several materials. Layers  802  and  804  can form the outermost surfaces of flap  430 . Because at least one of layers  802  and  804  will be in contact with the electronic device when it is in the pouch (e.g., layer  804 ), the material selected for these layers can be soft so as not to scratch the device shell. In one implementation, layer  802  and  804  can be constructed from microfiber (e.g., polyester microfiber). Although the example of  FIG. 8  shows layers  802  and  804  being constructed from the same material, different materials can instead be used. In one implementation, at least one of layers  802  and  804  (e.g., layer  802 ) can be the extension of a layer of periphery stack  420  (e.g., a layer coming into contact with the electronic device in other portions of pouch  400 ), and therefore also a soft layer. 
     Layers  802  and  804  can be coupled to each other using any suitable approach, including for example using an adhesive. In the example of  FIG. 8 , flap  430  can include adhesive layer  810  extending between layers  802  and  804 . Any suitable adhesive can be used, including for example a polyurethane based pressure adhesive. Flap  430  can include rigid elements  836  and  838 , corresponding to rigid elements  436  and  438  ( FIG. 4 ). Rigid elements  836  and  838  can be constructed from any suitable material having sufficient stiffness or rigidity. In one implementation, rigid elements  836  and  838  can be constructed form a fiberglass component (e.g., a fiberglass board). To ensure that rigid elements  836  and  838  bond to layers  802  and  804 , flap  430  can include additional adhesive layers  812  and  814  applied to the surfaces of the rigid elements. 
     Returning to  FIG. 4 , pouch  400  defines an enclosure for the electronic device by binding base layer stack  410  to periphery stack  420 . Periphery stack  420  can define a surface having opening  422  through which a user can interact with device  500 . Opening  422  can be empty, or alternatively can be filled by a transparent or translucent component that retains the user&#39;s ability to interact with the device. Periphery portion  424  of periphery stack  424  can define a substantially continuous surface for retaining the edges (e.g., the periphery) of device  500 . Periphery portion  424  can have any suitable width (e.g., width  425 ) adequate for retaining device  500 . In particular, width  425  can be selected such that device  500  cannot be removed from pouch  400  through opening  422 , but not so large as to adversely affect a user&#39;s interaction with the device interface. Although width  425  is shown to be constant in pouch  400 , it will be understood that in some embodiments, width  425  can vary. 
     When device  500  is inserted into pouch  400 , the small width  425  of periphery stack  420  can cause the periphery portion to flare out, and adversely affect the cosmetic appeal and use of the case. To ensure that periphery stack  420  remains in contact with the device enclosure, periphery stack  420  can include rigid ring  426  within periphery portion  424  and defining a continuous or substantially continuous ring around opening  422 . Ring  426  can prevent periphery portion  424  from flaring out (e.g., stretching away from the device enclosure) and instead maintain the surface of the device having the display in contact with the pouch. 
     Rigid ring  426  can be embedded within periphery stack  420  using any suitable approach.  FIG. 9  is a cross-sectional view of periphery stack  420  taken along line  9 - 9  in accordance with one embodiment of the invention. Cross-section  900  of periphery stack  420  can include several layers having different physical properties combining to provide a particular cosmetic and physical effect. On its outermost surface, periphery stack  420  can include external layer  902 . Layer  902  can include any suitable property, including for example an aesthetically pleasing surface, a surface that is comfortable to the touch, resistant to stains, tears, or other damage, or has any other property. In one implementation, layer  902  can be constructed from polyurethane. Because polyurethane is stretchable, periphery stack  420  can include layer  904  for resisting the deformation by stretching of layer  902 . For example, layer  904  can include a polyester knit that resists to tension along the plane of the knit. Layer  904  can be bonded to layer  902  using any suitable approach, including for example using an adhesive layer (not shown), but pressure, or any other suitable approach. In some embodiments, an adhesive layer on the other side of layer  904  (e.g., adhesive layer  907 ) can traverse layer  804  (because it is knit) and ensure that layer  904  bonds to layer  902 . 
     To form the rigid ring around the periphery of periphery stack  420 , cross-section  900  can include rigid layer  910 . Rigid layer  910  can be constructed from any suitable material, including for example fiberglass (e.g., as described above in connection with ring  426 ,  FIG. 4 ). To ensure a proper bond between layer  910  and the remaining layers, adhesive layers  906 ,  907  and  908  can be applied around rigid layer  910  (e.g., adhesive layers  907  and  908  on the top and bottom surfaces of layer  910 , and layer  906  between layers  904  and  912  where there is no rigid layer  910 ). Layers  906 ,  907  and  908  can be formed using any suitable adhesive, including for example a pressure or heat adhesive (e.g., a polyurethane based adhesive). 
     The last layer of periphery stack  420  is placed in contact with electronic device enclosure. Accordingly, layer  912  can be constructed from a soft material that will not damage the enclosure. Such materials can include, for example, a microfiber (e.g., polyester microfiber). Stack  420  can be assembled in any suitable manner. In some embodiments, each layer can be individually added and adhered or integrated in the stack in sequence. Alternatively, some or all of the layers can be overlaid, and a pressure or heat-based process can be applied to assemble the stack. The individual layers can be pre-cut and assembled, or alternatively can be assembled and once the stack crated, cut to a particular shape (e.g., die cut). 
     In some embodiments, flap  430  can include at least one layer that is shared with periphery stack  420 .  FIG. 10  is a cross-sectional view of the tab and periphery stack of the pouch of  FIG. 4  taken along line  10 - 10  in accordance with one embodiment of the invention. Cross-section  1000  of periphery stack  420  and flap  430  can include the distinct layers of each of stack  420  and flap  430 , as described above in connection with  FIGS. 8 and 9 . To ensure that the stack and flap are properly integrated, layer  1002  can be used simultaneously as both layer  912  of periphery stack  420  ( FIG. 9 ) and layer  804  of flap  430  ( FIG. 8 ). Adhesive layer  1010 , which can correspond to adhesive layer  810  of flap  430  ( FIG. 8 ), can extend at least partially underneath periphery stack  420  along with layer  820  of flap  430  ( FIG. 8 ). 
     Device  500  can include several ports for interface with the electronic device. For example, device  500  can include one or more buttons or other control means (e.g., a sliding mechanisms), connectors (e.g., USB or 30-pin connectors, or a jack), speakers, sensors (e.g., proximity or IR sensors) or other interface elements that a user may need to access through pouch  400 . For example, pouch  400  can include connector opening  452 , button openings  452  and  454 , wheel opening  456 , and speaker openings  458 . Although the openings in pouch  400  were characterized, it will be understood that these openings could be used for any other interface element, and that one opening could be used for several interface elements. 
     Opening  450  can be formed in any suitable element of the case. In the example of  FIG. 4 , opening  450  has been made in flap  430 . Opening  450  can have any suitable size or use, including for example positioned and sized to let a connector pass through and engage a corresponding interface of device  500 . Opening  450  can be manufactured using any suitable approach, including for example die cutting before or after the assembly of flap  430 . Openings  452 ,  454  and  456  can have any suitable size or use, including for example a position and size corresponding to buttons or other interfaces for actuating device  500 . Because openings  452 ,  454 , and  456  can be relatively large (e.g., large enough to allow a user&#39;s finger to pass), the portions of periphery stack  420  near or around the openings can flare out when device  500  is inserted. To prevent the flare out, periphery stack  420  or back layer stack  410  (e.g., the stack having the openings) can include a stiffening layer that maintains the integrity and shape of the opening. For example, the stacks can include a supplemental polycarbonate layer (e.g., a polycarbonate disk around the edges of the openings) and corresponding adhesive layers in the layer stack (e.g., an additional polycarbonate layer instead of or adjacent to the rigid layer). 
     Openings  458  can include several holes through which audio waves can propagate. To ensure optical audio propagation, openings  458  can be substantially aligned with corresponding openings adjacent to a speaker of device  500 . Openings  458  can have any suitable size, including for example a larger number of small openings or a smaller number (e.g., one) of larger openings. When smaller openings are used, periphery stack  420  may be less prone to flaring out, as there is less material absent and therefore force is more evenly distributed. To ensure that the shape of pouch  400  remains intact, periphery stack  420  can include an additional layer of material (e.g., a softer material, such as an additional layer of microfiber or polyurethane). 
     Back layer stack  410  can include a substantially continuous surface to be placed in contact with a side of the device enclosure. For example, a side of the device opposite the display can be placed in contact with back layer stack  410 . In some embodiments, back layer stack  410  can extend beyond the edges of periphery stack  420  and include some or all of a hinge and cover of the case.  FIG. 11  is a schematic view of a base stack in accordance with one embodiment of the invention. Stack  1100  can include several distinct portions, including for example pouch portion  1110 , hinge portion  1120 , and cover portion  1130  all within the same piece of material. In particular, stack  1100  can be manufactured from at least one layer of material sized to include the pouch, hinge and cover portions. 
     Stack  1100  can distinguish the different portions of the stack using any suitable approach. In some embodiments, stack  1100  can include sections of harder material defining boundaries for the different portions. For example, stack  1100  can include hard element  1112  of pouch portion  1100 , hard element  1122  of hinge portion  1120 , and hard element  1132  of cover portion  1130 . The hard elements can have any suitable size, including for example elements that extend almost or substantially to the side boundaries of the stack. The space between the hard elements (e.g., space  1115  and space  1125 ) can include softer material such that the different hard elements can fold at least partially over each other along spaces  1115  and  1125 . The hard elements can be constructed from any suitable material including for example rigid layers (e.g., polycarbonate layers) providing a that are flexible for bending around an axis in the plane of the layers, but stiff and resisting bending around an axis that is not in the plane of the layers (e.g., perpendicular to the plane of the layers). 
     Each of pouch portion  1110 , hinge portion  1120  and cover portion  1130  can have any suitable size. For example, pouch portion  1100  can have substantially the same size as the periphery pouch (e.g., periphery pouch  420 ,  FIG. 4 ). In particular, the size of pouch portion  1100  can be selected based on the expected size of an electronic device to be placed within the pouch (e.g., width  1130  corresponds to a dimension of the device). Hinge portion  1120  can have any suitable width  1131 . For example, width  1131  can be selected to substantially match the thickness of the device plus the thickness of the periphery stack, such that cover portion  1130  can fold over the device and lie directing on the device display. In particular, spaces  1115  and  1125  can be distributed to ensure that cover portion  1130  can fold over the device and remain in place over the device while protecting the entire device (e.g., the cover portion does not remain partially open, and the portion of cover portion  1130  adjacent to space  1125  is substantially in contact with the device). 
     Cover portion  1130  can have any suitable length  1132  and width  1134 . In particular, length  1132  can be selected so that cover portion  1130  can at least cover a portion along the entire periphery of the periphery stack of the case (e.g., at least cover the ring of the periphery stack). Width  1134  can be selected such that it is less than or equal to width  1133  of the pouch portion. In some embodiments, width  1134  can be selected to be less than width  1133 , but at least enough to cover at least a portion along the entire periphery of the periphery stack of the case (e.g., at least cover the ring of the periphery stack). Width  1134  can be distributed within width  1133  in any suitable manner, including for example off-centered (e.g., such that the distance between the each side edge of the cover portion and the side edge of the corresponding pouch portion are different). In some embodiments, cover portion  1130  can include a fastening mechanism for retaining the cover over the periphery stack. The fastening mechanism can include, for example, a mechanical snap, a magnetic snap, hook and fastener material, or any other suitable fastening mechanism. 
       FIG. 12  is a cross-sectional view of base layer stack  1110  taken along line  12 - 12  and connected to a peripheral layer stack in accordance with one embodiment of the invention. Cross-section  1200  of base layer stack  1100  can include several layers constructed from different materials. In particular, base layer stack  1100  can include internal layer  1202  put in contact with the electronic device enclosure (e.g., electronic device  500 ). To prevent damage to the device, layer  1202  can be constructed from a soft material. Such materials can include, for example, a microfiber (e.g., polyester microfiber). 
     Layer  1202  can be coupled to rigid layer  1208  (e.g., a polycarbonate layer) by adhesive layer  1204 . In some embodiments, layer  1208  can extend through only portions of stack  1200  (e.g., the portions of the base layer stack that include rigid elements). To ensure a proper bond between layer  1208  and the remaining layers, adhesive layers  1204 ,  1205  and  1206  can be applied around layer  1208  (e.g., adhesive layers  1204  and  1206  on the top and bottom surfaces of layer  1208 , and layer  1205  between layers  1202  and  1210  where there is no rigid layer  1208 ). Layers  1204 ,  1205  and  1206  can be formed using any suitable adhesive, including for example a pressure or heat-sensitive adhesive (e.g., a polyurethane based adhesive). 
     On its outermost surface, base layer stack  1200  can include external layer  1212 . Layer  1212  can include any suitable property, including for example an aesthetically pleasing surface, a surface that is comfortable to the touch, resistant to stains, tears, or other damage, or has any other property. In one implementation, layer  1212  can be constructed from polyurethane. Because polyurethane is stretchable, stack  1100  can include layer  1210  for resisting the deformation by stretching of layer  1212 . For example, layer  1210  can include a polyester knit that resists to tension along the plane of the knit. Layer  1210  can be bonded to layer  1212  using any suitable approach, including for example using an adhesive layer (not shown), but pressure, or any other suitable approach. In some embodiments, an adhesive layer on the other side of layer  1210  (e.g., adhesive layer  1206 ) can traverse layer  1210  (because it is knit) and ensure that layer  1210  bonds to layer  1212 . 
     Stack  1200  can be assembled in any suitable manner. In some embodiments, each layer can be individually added and adhered or integrated in the stack in sequence. Alternatively, some or all of the layers can be overlaid, and a pressure or heat-based process can be applied to assemble the stack. The individual layers can be pre-cut and assembled, or alternatively can be assembled and once the stack crated, cut to a particular shape (e.g., die cut). 
     Base layer stack  1100  can be coupled to periphery stack  420  using any suitable approach. In some embodiments, adhesive layer  1220  can be placed between base layer stack  1100  and periphery stack  420  such that the edges of the stacks are connected. In some embodiments, individual layers of each stack can be visible along the edge of the case (e.g., knit layer  1210  and the corresponding knit layer of periphery stack  420  can be visible). In some embodiments, or one or more layers of each stack can stop before reaching the edge of the stack (e.g., similar to the fiberglass and polycarbonate layers, described above). For example, layer  1202  and its counterpart in the periphery stack (e.g., microfiber layers) can not extend to the edge of the stacks such that the adhesive layers of each stack (e.g., adhesive layer  1205 ) can be used to couple base layer stack  1100  to periphery stack  420 . 
     In some embodiments, base layer stack  1100  can include tab  1150  coupled to the back surface of the stack (e.g., the surface opposite the periphery stack, or the surface that is not placed in contact with the device). Tab  1150  can be positioned at any suitable distance from edges of base layer stack  1100 . For example, tab  1150  can be equidistant from the side edges of base layer stack  1100  (e.g., the sides that include the sides of cover portion  1130 ), such that distances  1160  and  1162  are the same. In some embodiments, distances  1160  and  1162  can be different, for example based on characteristics of pouch portion  1110  or cover  1130  (e.g., the placement of rigid elements, openings in the cover or pouch, or other physical attributes of the stack). Although only one tab  1150  is shown in  FIG. 11 , base layer stack  1100  can include several tabs distributed along the stack (e.g., distributed based on corresponding elements of the cover portion). 
     Tab  1150  can be positioned at any suitable distance from bottom edge  1112  of pouch portion  1110 . In particular, distance  1164  can be selected, along with width  1131  and length  1132  such that cover portion  1130  can be folded back over pouch portion  1110  and the edge of the cover portion inserted into tab  1150 . This can form a triangular prism that a user can place on hinge portion  1120  or on pouch portion  1130 .  FIGS. 13A and 13B  are end views of a folded over case defining a prism in accordance with one embodiment of the invention. Case  1300  can include pouch portion  1310 , hinge portion  1320 , and cover portion  1330 . Cover portion  1330  can be folded over pouch portion  1310  such that cover portion  1330  can be engaged in tab  1350 . Case  1300  can then define a prism-type shape by which the internal surface of pouch portion  1310  (e.g., the surface of pouch portion  1310  through which a device interface can be accessed) is exposed on an outer surface of the prism. 
     Tab  1350  can be placed on the back surface of pouch portion  1310  at any suitable position, including for example a position such that the prism defines angle  1352  between pouch portion  1310  and cover portion  1330 , and angle  1354  between pouch portion  1310  and hinge portion  1320 . Each angle  1352  and  1354  can be selected based on any criteria, including for example desired angles for performing particular operations with the device. In one implementation, angle  1352  can be selected such that a user can easily type on an interface of the device. In another implementation, angle  1354  can be selected so that the user can view content (e.g., media) displayed by the device. 
     Returning to  FIG. 11 , tab  1150  can be constructed using any suitable approach. In some embodiments, tab  1150  can be a component added to the surface of base layer stack  1100 . Tab  1150  can include periphery  1152  defining the structure of tab  1150  and enclosing an area of the tab. Tab element  1154  can extend from a side of periphery  1152  such that the cover can engage tab element  1154 . Tab element  1154  can be offset from the surface of base layer plate  1100  by gap  1156 , which can extend within the area defined by periphery  1152 .  FIG. 14  is a cross-sectional view of tab  1150  taken along line  14 - 14  in accordance with one embodiment of the invention. Cross-section  1400  of tab  1150  can include several layers constructed from different materials. In particular, cross-section  1400  can include softer materials to be placed in contact with the cover, and harder materials to ensure that the tab can retain the cover. In particular, tab  1150  can include outermost layer  1402 . Layer  1402  can include any suitable property, including for example an aesthetically pleasing surface, a surface that is comfortable to the touch, resistant to stains, tears, or other damage, or has any other property. In one implementation, layer  1402  can be constructed from polyurethane. Because polyurethane is stretchable, tab  1150  can include layer  1404  for resisting the deformation by stretching of layer  1402 . For example, layer  1404  can include a polyester knit that resists to tension along the plane of the knit. Layer  1404  can be bonded to layer  1402  using any suitable approach, including for example using an adhesive layer (not shown), but pressure, or any other suitable approach. In some embodiments, an adhesive layer on the other side of layer  1404  (e.g., adhesive layer  1406  or  1407 ) can traverse layer  1404  (because it is knit) and ensure that layer  1404  bonds to layer  1402 . 
     To provide stiffness to tab  1150  so that the tab can retain the cover when it is inserted in the tab, tab  1150  can include rigid layer  1410  (e.g., a polycarbonate layer) coupled to the other layers by adhesive layer  1406 . In some embodiments, layer  1410  can extend through only portions of tab  1150  (e.g., the portions of the tab that include rigid elements, such as tab element  1154  and periphery  1152 ). To ensure a proper bond between layer  1410  and the remaining layers, adhesive layers  1406 ,  1407  and  1408  can be applied around layer  1410  (e.g., adhesive layers  1407  and  1408  on the top and bottom surfaces of layer  1410 , and layer  1406  between layers  1404  and  1412  where there is no rigid layer  1410 ). Layers  1406 ,  1407  and  1408  can be formed using any suitable adhesive, including for example a pressure or heat-sensitive adhesive (e.g., a polyurethane based adhesive). 
     Tab  1150  can include internal layer  1412  that the cover can contact when it is folded into tab  1150 . To prevent damage to the cover, layer  1412  can be constructed from a soft material. Such materials can include, for example, a microfiber (e.g., polyester microfiber). Tab  1150  can then coupled to pouch portion  1320  using adhesive layer  1414 . 
     Tab  1150  can be assembled in any suitable manner. In some embodiments, each layer can be individually added and adhered or integrated in the stack in sequence. Alternatively, some or all of the layers can be overlaid, and a pressure or heat-based process can be applied to assemble the stack. The individual layers can be pre-cut and assembled, or alternatively can be assembled and once the stack crated, cut to a particular shape (e.g., die cut). 
       FIG. 15  is a flowchart of an illustrative process for assembling a case for protecting an electronic device in accordance with one embodiment of the invention. Process  1500  can begin at step  1502 . At step  1504 , the individual layers forming each stack of the case can be aligned. For example, each layer can be cut and aligned relative to the other layers. As another example, sheets of material can be overlaid with layers that do not extend through the entire stack (e.g., rigid layers such as polycarbonate layers or fiberglass layers). At step  1506 , the aligned layers can be assembled into stacks. The layers can be assembled using any suitable approach, including for example using heat and/or pressure-based processes or adhesive. In some embodiments, one or more cuts can be applied to the assembled stacks to provide openings for interfaces of a device to be placed in the case. 
     At step  1508 , the assembled stacks can be connected to form a case. For example, one or more layers of adhesive can be placed between the stacks to secure the stacks. As another example, a heat or pressure based process can be used to connect the assembled stacks. At step  1510 , the tab can be connected to the case (e.g., to the back of the base layer stack), and various cuts or other finishing processes can be performed. For example, the tab can be assembled to the stack via an adhesive, and the cuts in the flap or other portions of the periphery stack can be performed to allow access to device interface elements. In some embodiments, the external surfaces of the case can be finished (e.g., provide a stain resistance coating). In some embodiments, the edges of the case can be refined if necessary. Process  1500  can then end at step  1512 . 
     The previously described embodiments are presented for purposes of illustration and not of limitation. It is understood that one or more features of an embodiment can be combined with one or more features of another embodiment to provide systems and/or methods without deviating from the spirit and scope of the invention. The present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20140129
Publication Date: 20170912
Grant Date: 20170912
Priority Date: 20100106
Inventors: ROHRBACH MATTHEW D.
DIEP Vinh
Assignee: APPLE INC
CPC Classifications: [{"code": "A45C9/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C9/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1628", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C2013/025", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2200/15", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2200/15", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1628", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C2013/025", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1628", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C7/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C13/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C7/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C3/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C13/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C3/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C15/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C13/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1628", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C9/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C7/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2013/025", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C3/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2200/15", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C13/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C9/00", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 43037084