PATENT DOCUMENT

Publication Number: US-9485338-B2
Application Number: US-201414258951-A
Country: US
Kind Code: B2

Title: Features and manufacturing methods for a case for a portable electronic device

Abstract:
An accessory unit for use with an electronic device is described. Accessory unit includes a front flap and a rear cover. The rear cover includes a recessed portion that defines a chamber and a lip portion. The chamber is configured to receive a consumer electronic device, and the lip portion is configured to hold the consumer electronic device therein by an interference fit that exposes substantially all of a display portion of the consumer electronic product. The front flap can include segments formed from panels with folding regions therebetween, which allow the front flap to fold. Further, an end region of the front flap pivotally couples the front flap to the rear cover, such that the front flap may be moved between open and closed configurations. The front may include magnetic elements.

Claims:
What is claimed is: 
     
       1. A case for a portable electronic device having a housing, the case comprising:
 a rear cover comprising a shell formed from a first material and having a bottom wall and a plurality of sidewalls extending from the bottom wall, the bottom wall and the plurality of sidewalls cooperate to define a chamber configured to receive the portable electronic device such that the housing engages the bottom wall; and 
 a lip portion formed from a second material different from the first material and extending from the plurality of sidewalls, 
 wherein when the portable electronic device is inserted in the chamber, the plurality of sidewalls and the lip portion cooperate to provide an affirmative feedback indicating that the portable electronic device is fully secured within the chamber. 
 
     
     
       2. The case according to  claim 1 , further comprising a front flap attached to the rear cover, the front flap comprising a first segment having a first opening, a second segment having a second opening, and a bending region between the first segment and the second segment, wherein in a closed configuration the front flap engages the lip portion. 
     
     
       3. The case according to  claim 2 , further comprising an end region attached to the rear cover and the front flap, the end region adapted to allow the front flap to pivotally couple to the rear cover, the end region having an end segment embedded in the end region, the end segment configured to align the front flap with the chamber in the closed configuration. 
     
     
       4. The case according to  claim 2 , wherein during a receiving event of the portable electronic device, the lip portion comprises an edge that engages the housing such that the lip portion initially expands from an original position to an expanded position to accommodate the housing and snaps back to the original position in accordance with the affirmative feedback. 
     
     
       5. The case according to  claim 2 , further comprising an inner layer disposed on an inner surface the rear cover and an outer layer disposed on an outer surface of the rear cover, the outer layer separate from the inner layer. 
     
     
       6. The case according to  claim 5 , wherein an insertion of the portable electronic device defines an insertion configuration, and wherein the lip portion comprises an edge that is angled such that a portion of the inner layer is free of engagement with the portable electronic device during the insertion configuration. 
     
     
       7. The case according to  claim 6 , wherein the portion of the inner layer is positioned below the lip portion. 
     
     
       8. The case according to  claim 5 , further comprising an aperture region on a curved surface of the rear cover, the aperture region comprising:
 a first aperture in the outer layer; 
 a second aperture in the rear cover; and 
 a third aperture in the inner layer, the first aperture being concentric with the second aperture and the third aperture. 
 
     
     
       9. The case according to  claim 8 , wherein:
 the first aperture includes a first diameter, 
 the second aperture includes a second diameter, and 
 the first diameter is larger than the second diameter. 
 
     
     
       10. The case according to  claim 8 , wherein the third aperture is smaller than the first aperture and smaller than the second aperture. 
     
     
       11. The case according to  claim 8 , wherein:
 the shell positioned between the inner layer and the outer layer, the outer layer has a first thickness, 
 the shell has a second thickness, and 
 the second thickness is less than the first thickness at the aperture region. 
 
     
     
       12. The case according to  claim 1 , wherein the affirmative feedback comprises a snap that generates an audible sound. 
     
     
       13. The case according to  claim 1 , further comprising a front flap,
 wherein the front flap comprises a first segment, a second segment, and a folding region between the first segment and the second segment, the folding region formed from an inner layer the and an outer layer secured with the inner layer, wherein the inner layer and the outer layer surround the first segment and the second segment. 
 
     
     
       14. The case of  claim 1 , wherein when the portable electronic device is inserted in the chamber, the lip portion directly engages the housing to provide the affirmative feedback. 
     
     
       15. The case of  claim 14 , wherein the rear cover is formed from an opaque material. 
     
     
       16. A method for forming a case for a portable electronic device having a housing, the method comprising:
 forming a rear cover using a first material, the rear cover comprising a bottom wall and a plurality of sidewalls extending from the bottom wall, the bottom wall and the plurality of sidewalls cooperate to define a chamber configured to receive the portable electronic device such that the housing engages the bottom wall; and 
 forming a lip portion using a second material different from the first material, the lip portion extending from the plurality of sidewalls, wherein when the portable electronic device is inserted in the chamber, the plurality of sidewalls and the lip portion cooperate to provide an affirmative feedback indicating that the portable electronic device is fully secured within the chamber. 
 
     
     
       17. The method of  claim 16 , further comprising:
 engaging an interior region of a shell of the rear cover with a first layer; and 
 engaging an exterior region of the shell a second layer different from the first layer, wherein the first layer and the second layer combine to define a front flap configured to cover the rear cover. 
 
     
     
       18. The method of  claim 17 , further comprising forming an aperture region on a curved surface of the rear cover, the aperture region comprising:
 a first aperture in the first layer; 
 a second aperture in the shell; and 
 a third aperture in the second layer, the first aperture being concentric with the second aperture and the third aperture.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C §119(e) to U.S. Provisional Application No. 61/873,748, filed on Sep. 4, 2013, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The present disclosure relates generally to accessory units, and more particularly to accessory units for consumer electronic devices and related assemblies and methods. 
     BACKGROUND 
     As advancements are made in the field of consumer electronic devices, development of associated accessory units also occurs. In this regard, some accessory units such as cases are designed to protect consumer electronic devices. Other accessory units are configured to provide consumer electronic devices with increased functionality. While existing accessory units may function suitably for their intended purposes, further advancements may be desirable. For example, increased functionality or protection for the associated consumer electronic devices may be desirable. 
     Accordingly, a need for continued advancement in the field of accessory units may exist. 
     SUMMARY 
     In one aspect, a case for a portable electronic device having a housing and a display assembly carried by the housing is described. The case may include a recessed portion and a lip portion. The recessed portion may include a side wall. The lip portion may be integrally formed with the recessed portion. The recessed portion and the lip portion may cooperate to define a chamber. The lip portion may further include a resilient material and be configured to retain the portable electronic device within the chamber. The lip portion may further include an edge having a shape that defines an opening suitable for receiving the portable electronic device. While receiving of the portable electronic device into the chamber, the edge may directly engage the housing. The sidewall and the lip portion may cooperate to provide an affirmative feedback indicating that the portable electronic device is fully secured within the chamber. 
     In another aspect, a method of forming a rear cover configured to receive an electronic device is described. The method may include applying an adhesive to an inner portion of a shell and an outer portion of the shell. The shell may include a lip portion, and the shell may be configured to receive the electronic device. The method further includes applying a first layer to a central portion disposed on the inner portion of the shell. The first layer may be configured to engage the inner portion and the lip portion. The first layer may also include an outer peripheral region. The method further includes expanding the inner layer toward an inner surface of the shell. The inner surface extends around a perimeter of the shell. The method may further include applying a second layer to the outer portion of the shell. The second layer may include an outer peripheral region, and may be configured to engage the lip portion and the outer portion. The outer peripheral region of the second layer may be configured to engage the outer peripheral region of the inner portion. The method may further comprise curing the adhesive. 
     In another aspect, a method of forming a front cover for an electronic device is described. The may include providing a fabric layer having a top surface and a bottom surface opposite the top surface. The fabric layer may also include a first thickness measuring from a vertical distance between the top surface and the bottom surface. The method may further include positioning the fabric layer such that the fabric layer includes a first elevated portion and a second elevated portion. A non-elevated portion of the fabric layer may extend between the first elevated portion and the second elevated portion. The method may further include applying a first cut on the top surface at the first elevated portion thereby forming a first cut portion. The method may further include removing the first elevated portion. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  illustrates a perspective view of an accessory unit comprising a front flap and a rear cover wherein the front flap is in an open configuration according to an example embodiment of the disclosure; 
         FIG. 1B  illustrates a cross sectional view of the accessory unit shown in  FIG. 1A  in the open configuration; 
         FIG. 2A  illustrates a perspective view of the accessory unit of  FIG. 1A  with the front flap in a closed configuration; 
         FIG. 2B  illustrates a cross sectional view of the accessory unit of  FIG. 2A  with the front flap in a closed configuration; 
         FIGS. 3A-3C  illustrate cross-sectional side views various embodiments of shells; 
         FIGS. 3D-3G  illustrate cross-sectional side views schematically showing a method for forming a rear cover portion of an accessory unit; 
         FIGS. 4A-4D  illustrate a side cross sectional views showing various features relating to sidewalls of an accessory unit; 
         FIGS. 5A-5E  illustrate cross sectional views showing a method for skiving a piece of fabric; 
         FIG. 6  illustrates a block diagram representing a method for assembling an accessory unit; and 
         FIGS. 7A-7D  illustrate various embodiments of hybrid shells suitable for use as a shell within an accessory unit. 
     
    
    
     DETAILED DESCRIPTION 
     Exemplary applications of apparatuses, assemblies, systems, and methods according to the present disclosure are described in this section. These examples are being provided solely to add context and aid in the understanding of the disclosure. It will thus be apparent to one skilled in the art that the present disclosure may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the present disclosure. Other applications are possible, such that the following examples should not be taken as limiting. 
     Accessory units are commonly used in conjunction with consumer electronic devices. Some accessory units are configured to protect consumer electronic devices. For example, cases may be employed to partially or fully surround a consumer electronic device such that the consumer electronic device is protected from damage. By way of further example, stands for consumer electronic devices may be configured to prop up the consumer electronic devices such that they may be conveniently positioned for interaction therewith. Another accessory unit can take the form of a foldable cover that can be detachably connected to, for example, a tablet computer, and have a protective flap. An example of such is that of the SMART COVER®, which is produced by Apple, Inc. of Cupertino, Calif. This product is moveable between multiple configurations, including one configuration in which it functions as a cover and another configuration in which it functions as a stand. While the SMART COVER® and other accessory units may perform in accordance with their intended purposes, additional advancements in accessory units may be desirable. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-7 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. For the remainder of this discussion, an accessory unit suitable for use with an electronic device will be described. In particular, for simplicity and clarity, for the remainder of this discussion, the electronic device takes the form of a handheld electronic device such as a tablet computer. 
     In this regard,  FIGS. 1A-1B  illustrate an embodiment of an accessory unit  100  according to the present disclosure. As illustrated, the accessory unit  100  may comprise a front flap  200  and a rear cover  300 . The front flap  200  may include a plurality of segments  201   a ,  201   b ,  201   c  and a folding region  204  positioned between each of the segments. The folding regions  204  may be configured to allow segments  201   a ,  201   b , and  201   c  to fold with respect to each other. The front flap  200  may also include an end region  206 . The end region  206  pivotally couples the front flap  200  to the rear cover  300 . 
     In some embodiments, each of segments  201   a ,  201   b ,  201   c  can include one or more inserts disposed therein. For example, segments  201   a ,  201   b ,  201   c  can each include a pocket region where the inserts are placed, or alternatively, may be embedded within segments  201   a ,  201   b ,  201   c  (e.g., via insert molding). In embodiments using pockets, the pocket regions have a size and shape to accommodate corresponding inserts. The inserts can have various shapes but are usually shaped to correspond to the overall look of front flap  200  (e.g., rectangular). The inserts can provide structural support for front flap  200 . That is, the inserts can provide stiffness to the cover assembly. Accordingly, the inserts may be referred to as stiffeners. The inserts can be formed of rigid or semi-rigid material adding resiliency to front flap  200 . Examples of materials that can be used include plastics, fiber glass, carbon fiber composites, metals, and the like. Some inserts can be formed of resilient materials that further accommodate other components such as magnetic elements. Magnetic elements can interact with a magnetic sensor disposed within an electronic device (not shown) associated with accessory unit  100 . Magnetic elements also be arranged to form a magnetic attraction with an attractable magnetic element disposed with at least one insert. In some embodiment, attractable magnetic elements can be formed of steel, or other ferromagnetic material, and take the shape of a thin sheet incorporated within an insert. 
     Front flap  200  further includes folding regions  204  that are thinner segments  201   a ,  201   b ,  201   c  and do not include the inserts thereby allowing front flap  200  to fold and make front flap  200  easier to handle. In one embodiment, segments  201   b , and  201   c  can be substantially wider than segment  201   a  in size. In this way, a triangular support structure having appropriate angles can be formed by positioning segments  201   a ,  201   b ,  201   c  in a manner described in U.S. patent application entitled, “CONSUMER ELECTRONIC PRODUCT” by Lauder et al. filed Dec. 17, 2010, having application Ser. No. 12/971,536, now U.S. Pat. No. 8,344,836, which is incorporated herein by reference in its entirety. 
     One approach to forming at least one triangular support structure can include segment  201   a  having a plurality of magnets and arranged to fold with respect to segments  201   b  and  201   c  in such a way that at least one magnetic element within segment  201   a  is magnetically attracted to a magnetically active element within segment  201   c . In this way, segments  201   a  and segment  201   c  can be magnetically bound together forming a first triangular support structure. The triangular support structure can be used as a support structure for accessory unit  100 . Accordingly, any electronic component supported by accessory unit  100  can also be supported. For example, when used as a support, an electronic device having a display and supported by accessory unit  100  can be placed in such a way that visual content can be displayed at about 75 degrees in relation to a horizontal surface below accessory unit  100 . In another example, front flap  200  can be folded to form a second triangular support structure that can be used to position the electronic device in an orientation suitable for using the electronic device as a keyboard. It should be noted, however, that these are only representative examples of many other support structures that can be formed by front flap  200 . 
     While the flexible material of end region  206  allows it to pivotally couple front flap  200  to rear cover  300 , this may also cause misalignment between front flap  200  and rear cover  300  in a closed configuration. As shown in  FIG. 2B , a closed configuration refers to front flap  200  being substantially in contact with rear cover  300 . To ensure proper alignment between front flap  200  and rear cover  300  in a closed configuration, some embodiments include end panels  208  in end region  206 . End panels  208  may be configured to strengthen the end region  206  such that the end region  206  maintains alignment of outer edges  210   a - c  (collectively, “ 210 ”) of the front flap  200  with respect to the lip portion  304  of the rear cover  300 . End panels  208  could be made of fiberglass, steel, carbon fiber, plastic, or combination thereof. In some embodiments, end panels  208  can have a thickness that prevents them from showing through to a cosmetic surface of accessory unit  100 . In this way, end panels  208  can provide rigidity for the pivotal coupling between front flap  200  and rear cover  300  such that front flap  200  pivots about a longitudinal axis  212  without affecting a cosmetic appearance of accessory unit  100 . 
     The rear cover  300  can include a recessed portion  302 , also referred to as a bucket, and a lip portion  304 . The recessed portion  302  may include a plurality of sidewalls  306   a - d  (collectively, “ 306 ”) and a bottom wall  308  that define a chamber  310 . The recessed portion  302  may include one or more apertures  312   a - e  (collectively, “ 312 ”) and/or one or more embossed portions  314   a - b  (collectively, “ 314 ”). Embossed portion  314   b  illustrated in  FIG. 1A  may be employed for similar purposes with respect to one or more additional buttons on a consumer electronic device. Similarly, the apertures  312  may be employed to provide access to various components of the consumer electronic device such as audio, power, and data ports. Further, one of the apertures  312   c  may be configured to align with a camera lens of a consumer electronic device (not shown). In this regard, the aperture  312   c  may be oversized relative to the size of the camera lens in order to ensure that the camera lens is not blocked even when the consumer electronic device is not perfectly aligned in the rear cover  300 . In one embodiment, apertures  312  can be punched into a thermoplastic shell that provides structure to accessory unit  100 . A liquid crystal polymer fiber can be added around apertures  312  to reinforce apertures  312 . In one specific embodiment, a 70 micron thick layer of liquid crystal polymer fiber can be utilized to provide durability to apertures  312 . One specific type of liquid crystal polymer fiber that can be utilized for such a purpose is Vectran® fiber. 
     The lip portion  304 , including lip portions  304   a - d  as shown in  FIG. 1A , can be integrally formed with the recessed portion  302  and extend about an opening  316  of the chamber  310 . It should be noted that in alternate embodiments lip portion  304  can be a separate rigid frame member in contact with recessed portion  302 . As will be described in further detail below, the recessed portion  302  of the rear cover  300  may be formed from a flexible material. Additionally, the lip portion  304  may be formed from a material that is more rigid than the flexible material of the recessed portion  302 . In this regard, the lip portion  304  of the rear cover  300  may be configured to retain a consumer electronic device in the chamber  310 , as discussed in detail below. In some embodiments, the rigidness of lip portion  304  can be due substantially to a thickness of lip portion  304  with respect to recessed portion  302 . 
     As illustrated in  FIG. 2A , outer edges  210  of front flap  200  may contact lip portion  304  when the front flap  200  is in the closed configuration. Accordingly, front flap  200  may define a substantially linear configuration when moved to the closed configuration. In this regard, end panels  208  can be substantially coplanar with the other segments  201   a ,  201   b ,  201   c  and the folding regions  204  of the front flap  200  when the front flap  200  is in the closed (or folded) configuration. However, a portion of end region  206  adjacent the end panels  208  bends to enable the end region  206  to function as a hinge, as noted above. 
     In some embodiments, as illustrated in  FIG. 2A , lip portion  304  may extend outwardly beyond the outer edges  210  of front flap  200 . In this regard, lip portion  304  may function to protect a consumer electronic device received in the chamber  310  in rear cover  300  from damage to the edges of the consumer electronic device when dropped or otherwise subjected to impact. However, in other embodiments, the outer edges  210  of the front flap  200  and the lip portion  304  may extend to the same dimensions, or the outer edges  210  of the front flap  200  may extend beyond the lip portion  304 . When used as a structural element, lip portion  304  includes material having mechanical properties sufficient to retain the consumer electronic device within chamber  310  of rear cover  300 . Moreover, in addition to the ability to retain the consumer electronic product within chamber  310 , lip portion  304  also retains enough flexibility to allow the consumer electronic device to be inserted and removed from chamber  310  numerous times without undue exertion by an end-user, a potentially damaged accessory unit  100 , or the consumer electronic device. 
     The material(s) defining the accessory unit  100  may vary. In one embodiment, the entire accessory unit  100  may be formed from a single material. However, as noted above, in other embodiments, it may be desirable to form the accessory unit  100  from multiple materials to take advantage of differing material properties. 
     Accessory unit  100  may further include one or more magnetic elements  108  in front flap  200 . For example, magnetic elements  108  disposed within segment  201   a  can be configured to interact with an attachment feature of a consumer electronic device positioned within rear cover  300 . Magnetic elements  108  can be magnetically attracted to the attachment feature of the consumer electronic device when accessory unit  100  is in a closed configuration such that the front flap  200  is releasably retained in this configuration. The front flap  200  may further include a magnetic element  110  configured to interact with a magnetically sensitive circuit embedded in the consumer electronic device configured to detect the presence, absence, or change from presence to absence, or vice versa, of the magnetic element  110 . For example, the magnetically sensitive circuit may include a Hall Effect sensor. 
     Magnetic elements  108  and  110  of accessory unit  100  can be configured to provide various other types of functionality. For example, the Hall Effect sensor can respond to the presence (or absence) of the magnetic field by generating a signal. The signal can be used to alter an operating state of the consumer electronic device. Magnetic element  110  can be positioned on front flap  200  in a location that triggers the Hall Effect sensor to generate the signal when the cover is placed on or in proximity to a surface of the consumer electronic device. The signal can indicate that the front flap  200  is in a predetermined position relative to the consumer electronic device that can result in a change in an operating state of the consumer electronic device. The signal can also be used to alter the operating state to a state having functionality suitable for the consumer electronic device being fully covered. 
     In situations where the consumer electronic device includes a display, the functioning of the consumer electronic product can be altered in such a way that the display is prevented from displaying visual content. On the other hand, when the portion of front flap  200  having magnetic element  110  is removed to the point where the Hall Effect sensor no longer senses the magnetic field of magnetic element  110 , then the Hall Effect sensor can generate another signal. This other signal can result in the consumer electronic device entering a different operating state consistent with at least a portion of the display being uncovered and viewable. In this state, the functionality of the tablet computer can be altered such that the display is enabled to present visual content. It should be noted that the above described attachment feature, and the magnetically sensitive circuit are discussed in U.S. patent application entitled, “CONSUMER ELECTRONIC PRODUCT” by Lauder et al. filed Dec. 17, 2010 having application Ser. No. 12/971,536, now U.S. Pat. No. 8,344,836, which is incorporated herein by reference in its entirety. 
       FIG. 2B  shows accessory unit  100  in a closed configuration. Further, in other embodiments, rear cover  300  could be made with an adhesively formed base material, or alternative, rear cover could simply be an inner layer adhesively attached to an outer layer. In the embodiment shown in  FIG. 2B , rear cover  300  includes shell  118 . Shell  118  may be formed by a thermoforming process using plastic, compression molding, injection molding, or a combination thereof. Shell  118  could be made from any rigid material known in the art for making a case for an electronic housing device. In addition to shell  118 , rear cover  300  includes inner layer  102  is attached to an inner surface of shell  118 , and outer layer  104  is also attached to shell  118 . As shown  FIG. 2B , inner layer  102  and outer layer  104  generally terminate at one end near lip portion  304  of rear cover. Inner layer  102  and outer layer  104  extend through rear cover  300  to define an outer periphery of front flap  200 . Inner layer  102  and outer layer  104  generally terminate at another end near reinforcement element  116 . In some embodiment, reinforcement element  116  can be formed from a relatively rigid material such as plastic, steel, carbon fiber, fiberglass, etc. In the embodiment shown in  FIG. 2B , reinforcement element  116  includes an adhesive disposed between inner layer  102  and outer layer  104 . 
       FIGS. 3A-3G  show a process for forming rear cover portion of an accessory unit  100 . For simplicity, this set of figures omits front flap  200 .  FIGS. 3A-3C  show various embodiments of shell  400 . In  FIG. 3A , a thermoformed plastic shell  400  made of a single material is depicted. A recessed portion  402  of shell  400  can have a substantially uniform thickness, while a lip portion  404  can be integrally formed with recessed portion  402 . Lip portion  404  can be injection molded on to recessed portion  402 , thereby removing any need for a subsequent bonding operation. In another embodiment shown in  FIG. 3B , plastic recessed portion  402  is compression molded to a lip portion  406 . In some embodiments, lip portion  406  is made from reinforced glass fiber. Lip portion  406  can be constructed by overlaying a number of unidirectional glass fibers in a continuous loop and then forming them in accordance with a geometry of lip portion  406 . In  FIG. 3C , lip portion  406  also includes a substantial portion of sidewalls and accordingly, forms a substantial portion of the recessed portion of shell  400 . Portions of a shell  400  that include reinforced material (such as reinforced glass fiber) can substantially add to an overall stiffness of shell  400 . 
       FIG. 3D  shows a first assembly step, which depicts shell  400  as depicted in  FIG. 3A  and a first layer  410  (which may also be referred to as an inner layer). In some embodiments, shell  400  can be a thermoformed plastic shell, a compression molded shell, an injection molded shell, or a combination thereof. In some embodiments, first layer  410  is a microfiber layer; microfiber layer could further be a preformed microfiber layer. It should be understood that the embodiments shown in  FIGS. 3B and 3C  could also be used in the assembly steps shown in  FIGS. 3D-3G . First layer  410  can be a preformed microfiber layer. First layer  410  can be adhesively coupled to a central portion  409  of recessed portion  402 . In one embodiment, first layer  410  can be adhesively coupled to shell  400  by a thermoplastic adhesive, while in other embodiments a thermosetting adhesive can be utilized. In both cases, shell  400  and first layer  410  can be heated to activate the thermal adhesive.  FIG. 3E  shows a second step in which an expanding device is used to press peripheral portions  411  of first layer  410  around a lip portion  404  of shell  400 , thereby adhesively engaging the peripheral portions of first layer  410  about lip portion  404  and along sidewalls of shell  400 . Because first layer  410  is preformed to conform with an inside surface of shell  400 , undue stretching of first layer  410  can be controlled and avoided. In this way, pin holes can be prevented from forming in first layer  410 , thereby preventing adhesive and/or a portion of shell  400  from showing through first layer  410 . 
     In  FIG. 3F , once first layer  410  is in adhesive contact with shell  400  and while an expanding device (not shown) keeps the first layer  410  under tension, an exposed portion of shell  400  can be cooled at a controlled rate to establish desired characteristics in an adhesive coupling between first layer  410  and shell  400 . For example, in some embodiments, cooling can be varied to provide varying stiffness across recessed portion  402  and/or lip portion  404 . In  FIG. 3G , second layer  412  (also referred to as an outer layer) can be adhesively coupled to an exposed portion of shell  400 . Second layer  412  could be made of leather. In one embodiment, the adhesive coupling can be accomplished using a concave fixture to press second layer  412  against shell  400 . First end  413  and second end  414  of second layer  412  can be coupled to first end  416  and second end  417 , respectively, of first layer  410 . First layer  410  and second layer  412  can come together to form a substantially zero flange design. The phrase “zero flange design” refers to a bonded region of first layer  410  and second layer  412  that free of outward protrusion (with respect to shell  400 ) of first layer  410  or second layer  412 . In other words, the region where first layer  410  is bonded to second layer  412  extends from shell  400  a distance approximately similar to a thickness (width) of first layer  410  or second layer  412 ). The zero flange design further maintains the bonded relationship between first layer  410  and second layer  412 . An example of zero flange design is shown where second end  414  of second layer  412  bonds with first layer  410 . In some embodiments, a slight flange can be formed to increase surface area between the two layers, thereby improving adhesion. It should be noted that ideal fit and finish of accessory unit  100  is accomplished by tuning an amount of stretch in both first layer  410  and second layer  412 . Also, the adhesive may be cured by, for example, radiation (from a light source such as ultraviolet (UV) light) and/or a time lapse sufficient for the adhesive to bond first layer  410  and second layer  412  to shell  400 . Other cooling means are further discussed below. 
       FIG. 4A  shows a cross sectional view of a sidewall of rear cover  300  having consumer electronic device  500  disposed therein. This view shows how lip portion  304  can act via interference fit to retain consumer electronic device  500  in chamber  310 . When consumer electronic device  500  is inserted into rear cover  300 , lip portion  304  extends outward in a direction away from consumer electronic device  500 , then retracts to the original (resting) position once consumer electronic device  500  is fully received by the rear cover  300 . The interference fit can cause consumer electronic device  500  to snap into place within accessory unit  100  due to a geometry of lip portion  304  not conforming precisely to an outer surface of consumer electronic device  500 . In other words, the curvature of rear cover  300  may not completely correspond to the curvature of electronic device.  FIG. 4A  further illustrates a close-up showing relationship between lip portion  304  and chamfered portion  504  of electronic device  500 . Here, engaging region  515  of the inner layer  102  contacts consumer electronic device  500 . However, edge  305  of lip portion  304  is angled such that inner layer  102  does not contact consumer electronic device  500 . The area is shown as disengaging region  516 . Such a configuration contributes to the snap effect during inserting and extracting consumer electronic device  500  from accessory unit  100 . It should be understood this relationship between extends around the perimeter of the lip portion  304  and consumer electronic device  500 . 
     This feature allows a user to have affirmative confirmation (for example, by hearing a “snap”) that consumer electronic device  500  is secured within accessory unit  100 , or when consumer electronic device  500  is released/removed from accessory unit  100 . Also, lip portion  304  can avoid contacting display cover glass  502 . This allows all of display cover glass  502  to remain visible, which may be desirable in embodiments in which consumer electronic device  500  includes a display that extends near the edges of the top surface consumer electronic device  500 . 
     In particular, the curvature of rear cover  300  may not completely correspond to the curvature of electronic device. For example,  FIG. 4A  illustrates a close-up of the relationship between lip portion  304  and chamfered portion  504  of electronic device  500 . Here, engaging region  515  of the inner layer  102  contacts electronic device  500 . However, a lower section of lip portion  304  is angled such that inner layer  102  does not contact electronic device  500 . The area is shown as disengaging region  516 . Such a configuration contributes to the snap effect of inserting and extracting electronic device  500  from accessory unit  100 . It should be understood this relationship between extends around the perimeter of the lip portion  304  and electronic device  500 . 
       FIG. 4B  shows a cross sectional view of a sidewall of rear cover  300  that includes embossed portion  314   b . A tactile feel of embossed portion  314   b  can be enhanced by adding a filling member  506  suspended between inner layer  102  and outer layer  104 . Filling member  506  could include a plastic member other or a more flexible member such as silicone. In the embodiment shown in  FIG. 4B , embossed portion  314   b  can correspond to a volume control of an electronic device. A portion of shell  118  has been removed to allow user interaction with the volume control. In this way filling member  506  can provide a strong tactile feeling to a user manipulating the volume control. Inner layer  102  and outer layer  104  can cause plastic piece filling member  506  to hover in position and provide resistance in response to a user actuation. In some embodiments, filling member  506  can be surrounded by low durometer rubber during an insert molding operation to provide additional spring/flexibility for actuation of the volume control. In other embodiments, additional tactile enhancements can be made. For example, a portion of outer layer  104  that engages filling member  506  can be made thinner so that there is less compressible material (e.g, less outer layer  104 ) when a user actuates the volume control. A treatment can be applied to the leather layer to adjust a hardness of the leather layer above filling member  506 . A skiving method (discussed below) could also be used to remove a portion of outer layer  104 . 
       FIG. 4C  shows a cross sectional side view of a sidewall or rear cover  300  that includes an aperture  312   f  for coupling a data cable to data port  508  of electronic device  500  disposed within accessory unit  100 . Depending on the electronic device, aperture  312   f  could receive other members known in the art for coupling to an electronic device through an aperture of an accessory unit. Aperture  312   f  can have sidewalls  510  that extend normal from an outside surface of electronic device  500 . When compared with an aperture cut in a direction substantially parallel to a top surface of electronic device  500 , aperture  312   f  avoids sharp angles jutting out and having a higher potential of fraying or even interfering with use of data port  508 . Rather, aperture  312 , as shown in  FIG. 4C , is cut such that the circular wall is normal to the surface of electronic device  500 . This design leaves edges of aperture  312   f  less vulnerable to contact from external objects. While such an opening would normally require a three dimensional cutting path to be traced, a tapered cutter can be utilized to cut aperture  312   f  as depicted without complexities associated with a three dimensional cutting path.  FIG. 4D  shows another configuration of aperture  312   f . In this embodiment, a debossed aperture  312   f  is depicted. Here, shell  118  is made thinner near aperture  312   f  to provide an appearance of accessory unit  100  having a narrower width. In some embodiments, shell  118  can end prior to aperture  312   f  such that only inner layer and outer layers remain at the edge of aperture  312   f . In other embodiments, inner layer  102  can made thinner and/or end prior to aperture  312   f.    
     It should be understood that the depicted techniques can be applied to any of apertures  312  as depicted in  FIG. 1A . In contrast, apertures  312   e  (configured to audio from an electronic device to pass through accessory unit  100 ) can be formed using a different process. In one embodiment, apertures  312   e  can be drilled by a spindle head rotating at 80,000 rpm to create a substantially clean hole through rear cover  300 . In other embodiments, a spiral shaped cutter can be used to form apertures  312   e . The spiral shaped cutter can push chips towards a center portion of apertures  312   e , thereby forming a clean cut. 
       FIGS. 5A-5E  shows a series of illustrations describing a skiving method. Skiving can be applied by a skiving machine, to change characteristics of a fabric layer, and more specifically to change a material thickness of the fabric. A leather portion of front flap  200  may be too rigid along folding regions  204  (shown in  FIGS. 1A-2A ) for certain applications. This excessive rigidness may prohibit front flap  200  from easily folding to form a support structure. The skiving method offers a reliable method for removing material from front flap  200  to create, for example, folding regions  204 . 
       FIG. 5A  shows a template  602  configured to establish a skiving pattern. In some embodiments template  602  can be made of plastic and can includes protrusions  604 ,  606  that determine where material is to be removed. Although protrusions  604 ,  606  are depicted as being substantially the same size and shape, other sizes and shapes are possible and can serve different purposes. In other embodiments, there could be at least three protrusions. In  FIG. 5B , leather layer  608  is laid across template  602 , with the cosmetic side  609  contacting template  602 . By laying the cosmetic side  609  against template  602 , subsequent cutting operations do not substantially affect an exterior finish of leather layer  608 . In  FIG. 5C  a cutting operation is performed along cutting line  610 . The cutting operation can be performed by a thin slicing blade that cuts parallel to a top surface of template  602 .  FIG. 5D  shows leather layer  608  after the cutting operation. Because protrusions  604 ,  606  cause leather layer to curve gradually, a resulting thickness of leather layer  608  also varies gradually (corresponding to protrusions  604 ,  606 ) to provide a smooth thickness transition. Finally,  FIG. 5E  shows leather layer  608  removed from template  602 . It should be noted that in addition to increasing flexibility in folding regions  204 , this skiving method can be used to provide space to embed various items beneath leather layer  608 . For example, flexible circuits, wiring, and even magnetic elements could be partially or completely hidden by such a technique. 
       FIG. 6  shows a block diagram  700  illustrating a method for assembling an accessory unit. In a first step  702 , a shell and front flap segment inserts are provided. In one embodiment the shell can be a thin walled thermoformed plastic shell and the segment inserts can be glass fiber. In other embodiments, the shell can be formed by compression molding, or a combination of thermoforming and compression molding. In step  704 , the shell and front flap segment inserts can be positioned between an outer layer and an inner layer. Segment inserts may include magnetic elements, filling elements (such as a plastic piece or silicone), or a combination thereof. In some embodiments, magnetic elements are formed inside the segments inserts, and accordingly, are disposed between the inner layer and the outer layer in conjunction with the segment inserts. 
     In step  706 , the outer layer and inner layer are adhesively coupled together around both the shell and the front flap segments. In some embodiments, a complex press can be utilized that seals the outer layer and inner layer around the shell and front flap in a single bonding (or laminating) operation. In other embodiments, the microfiber layer is first adhesively bonded to an inside surface of the shell. The adhesive bond can be established by a thermoplastic or thermosetting adhesive. One advantage of a thermosetting adhesive is that lower setting temperatures can be used and an applicator can be utilized to spread the adhesive at varying thicknesses thereby generating regions of greater and lesser rigidity. In addition, the leather layer is not subject to higher heat that is required to activate other adhesives. 
     Subsequent to bonding the microfiber layer to a bottom portion of the shell, a spreading element can be utilized to adhere peripheral portions to sidewalls of the shell, including a top side of a lip portion of the shell as well as the sidewalls of the shell. After the microfiber is pressed against the shell the shell, the shell can be cooled to cause the adhesive to properly set. Cooling means may include running coolant through the tool (spreading element), cooling the tool (which extracts heat from the microfiber/shell configuration), using air jets in the tool to push air onto the microfiber/shell configuration, switching out the heated tool with a cool tool, or a combination thereof. Next, the leather layer is adhered to an opposite side of the shell. Subsequently, the leather layer and microfiber seal around the front flap segment inserts and various other internal components of the accessory unit. In step  708 , a machining operation can be applied to form apertures and embossments along a surface of the accessory unit to provide easy access to controls on a compatible consumer electronic product. 
       FIGS. 7A-7D  show various alternative hybrid shell embodiments. The hybrid shell embodiments each include a shell formed by compression molding at least two different materials together. In this way different characteristics can be provided to different portions of the shell. Each of the following embodiments can be formed during a single compression molding operation. In  FIG. 7A  shell  800  is made from substantially stiff material such as glass fiber or a carbon fiber weave. Portions  802  and  804  can correspond to an input/output openings that can be areas of high strain. In this way the potential strain on the cover can be ameliorated. In  FIG. 7B  shell  810  is made from substantially flexible material, such as a thermoplastic. Regions  812  and  814  can correspond to edge areas to firm up a feel of the edge portions of the accessory unit. In some embodiments this can prevent the accessory unit from having a floppy edge feel. In other words, the accessory unit feels rigid and robust when held by a user. In  FIG. 7C , shell  820  is made from a substantially flexible material and having an embedded attraction plate  822  made from a magnetically attractable material such as steel. By embedding attraction the plate  822  within shell  820 , magnetic elements within the front flap can attract to the attraction plate  822 , such that the front flap is secured to the shell  820  during, for example, use of an electronic device.  FIG. 7D  shows a shell  830  having a stiff outer periphery  832  that can be formed from, for example, glass fiber. Outer periphery  832  can include both a lip portion of shell  830  and at least sidewalls of shell  830 , such that a protected electronic device is firmly seated within the accessory unit. The shells described in  FIGS. 7A-D  may include an outer layer (such as leather) disposed on an outer surface of the shell. It should be understood that the outer layer is sufficiently thin and/or the magnetic attraction is sufficiently strong such that front flap attracts to shell. 
     Indicia, such as a logo or symbol, may be disposed on the front flap and/or the rear cover. Indicia can be formed by removing a portion of a surface of the leather layer corresponding to a shape of the logo. Unfortunately, the consistency or uniformity of an underlying layer of leather can vary in accordance with a grain or other individual characteristic of the leather. To compensation, in some embodiments, the underlying layer can be treated with water or steam to provide a particular color for the indicia. Variations in temperature, time and/or operating pressure can affect the color or colors obtained. To further create indicia with a more uniform appearance, a dye or ink can be applied to the indicia. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140422
Publication Date: 20161101
Grant Date: 20161101
Priority Date: 20130904
Inventors: BALAJI SANTHANA KRISHNAN
QIAN AMY
MOOLSINTONG PINIDA J.
Assignee: APPLE INC
CPC Classifications: [{"code": "A45C11/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0216", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T83/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/0448", "inventive": false, "first": false, "tree": "[]"}, {"code": "B26D3/281", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/0448", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0216", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T83/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B26D3/281", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T83/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0216", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T83/0448", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B26D3/281", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 52583975