PATENT DOCUMENT

Publication Number: US-9872545-B2
Application Number: US-201615087868-A
Country: US
Kind Code: B2

Title: Accessory covers for mobile phones or other consumer electronic devices with button assembly

Abstract:
A durable, accessory cover assembly for a computing device, such as a cellular phone or a tablet computer. The accessory cover includes a frame, a first covering portion, and a second covering portion. The first covering can be composed of a wear-resistant material, such as leather; whereas, the second covering can be composed of a pliable particulate-absorbing material, such as microfiber. The first covering can be configured to seamlessly cover an external bottom surface of the frame, four external lateral surfaces of the frame, and four internal later surfaces of the frame, as well as an overlap region of an internal top surface of the frame. The second covering can be configured cover a majority of the surface area of the internal top surface of the frame, where it abuts the first covering along an annular region.

Claims:
What is claimed is: 
     
       1. A button assembly for an accessory case that releasably secures an electronic device that include a device button, the button assembly comprising:
 a first cover layer; 
 a button comprising a convex feature that extends into the first cover layer, the button further comprising a concave feature located opposite the convex feature; 
 a second cover layer extending over and at least partially into the button along the concave feature, wherein an applied force to the button facilitates an actuation of the device button when the button is positioned over the device button. 
 
     
     
       2. The button assembly of  claim 1 , wherein the second cover layer statically positions the button at least partially out of a cavity defined by the first cover layer and the second cover layer. 
     
     
       3. The button assembly of  claim 2 , further comprising:
 a compressible material configured to align the button with the cavity and transfer a force of the actuation to the device button, the compressible material conforming to at least the concave feature. 
 
     
     
       4. The button assembly of  claim 1 , wherein the second cover layer is positioned between the button and the device button when the electronic device is positioned in the accessory case. 
     
     
       5. The button assembly of  claim 1 , further comprising a frame positioned between the first cover layer and the second cover layer, the frame having an opening, wherein the button is positioned in the opening and wherein a gap separates the button from the first cover layer, the second cover layer, and the frame. 
     
     
       6. The button assembly of  claim 1 , wherein the button is connected to the second cover layer and disconnected from the first cover layer. 
     
     
       7. The button assembly of  claim 1 , wherein the applied force causes the concave feature to provide the actuation of the device button. 
     
     
       8. A device cover for an electronic device, the device cover comprising:
 a frame that includes a bottom wall and sidewalls perpendicular to the bottom wall, the sidewalls combining with the bottom wall to define a receptacle that receives the electronic device, wherein the sidewalls include a sidewall having an aperture; 
 a cover disposed over a portion of the frame; 
 a button that is separate from the cover and held within the aperture and hidden by the cover, wherein an applied force to the cover in a location corresponding to the button actuates the button to depress a device button of the electronic device when the electronic device is within the receptacle. 
 
     
     
       9. The device cover of  claim 8 , wherein:
 the frame defines a lip formed on an edge of the sidewall, 
 the frame includes a first thickness, and 
 the lip includes a second thickness greater than the first thickness. 
 
     
     
       10. The device cover of  claim 9 , wherein the cover comprises:
 a first cover layer that covers the sidewall and the lip; and 
 a second cover layer coupled to the first cover layer and covering the button. 
 
     
     
       11. The device cover of  claim 8 , further comprising:
 a compressible material surrounding at least two surfaces of the button within the aperture. 
 
     
     
       12. The device cover of  claim 8 , wherein the button includes:
 a convex feature that extends away from the device button and causes the cover to extend away from the device button; and 
 a concave feature located opposite the convex feature, the concave feature positioned between the convex feature and the device button when the electronic device is in the receptacle. 
 
     
     
       13. The device cover of  claim 8 , wherein the cover comprises a first cover layer coupled to a second cover layer by a coupling portion located at the bottom wall. 
     
     
       14. The device cover of  claim 8 , wherein the aperture defines a gap that surrounds at least four surfaces of the button. 
     
     
       15. An accessory device for an electronic device, the accessory device comprising:
 a frame that includes a bottom wall and sidewalls that combine with the bottom wall to define a receptacle that receives the electronic device, wherein the sidewalls include a sidewall having a cavity; 
 a first cover that covers an external surface of the frame; 
 a second cover that covers an internal surface of the frame including the receptacle; 
 a button disposed within the cavity and separated from the frame, the first cover, and the second cover by a gap; and 
 a filler material positioned in the gap and surrounding the button within the cavity, wherein the button is configured to glide through the cavity when the first cover receives a pressing force at a location corresponding to the button. 
 
     
     
       16. The accessory device of  claim 15 , wherein the button comprises:
 a convex feature engaging the first cover; and 
 a concave feature engaging the second cover. 
 
     
     
       17. The accessory device of  claim 15 , wherein the button comprises a protruding button having a first convex feature and a second convex feature opposite the first convex feature. 
     
     
       18. The accessory device of  claim 17 , wherein the first convex feature engages the first cover and wherein the second convex feature engages the second cover. 
     
     
       19. The accessory device of  claim 18 , wherein the frame includes a lip extending in a direction toward the cavity and covered by the first cover, and wherein the lip includes a greater thickness than that of the sidewall. 
     
     
       20. The accessory device of  claim 15 , wherein the button is separated from the first cover and the second cover by a gap.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of U.S. patent application Ser. No. 14/258,977, filed Apr. 22, 2014, entitled “ACCESSORY COVERS FOR MOBILE PHONES OR OTHER CONSUMER ELECTRONIC DEVICES,” which claims priority to U.S. Provisional Patent Application No. 61/875,630, filed Sep. 9, 2013, entitled “ACCESSORY COVERS FOR MOBILE PHONES OR OTHER CONSUMER ELECTRONIC DEVICES,” and U.S. Provisional Patent Application No. 61/873,769, filed Sep. 4, 2013, entitled “ACCESSORY COVERS FOR MOBILE PHONES OR OTHER CONSUMER ELECTRONIC DEVICES,” the contents of which are incorporated by reference herein in their entireties for all purposes. 
    
    
     TECHNICAL FIELD 
     The present disclosure generally relates to accessory covers for mobile phones, tablet computers, and other consumer electronic devices. 
     BACKGROUND 
     Modern consumer electronic devices continue to evolve at an alarming rate. For instance, devices such as cellular phones, tablet computers, and media player devices routinely realize technological advancements while at the same time achieving various form factor advantages pertaining to physical size, device usability, etc. As these apparatuses become more powerful, and in many scenarios, more compact in structure, it becomes increasingly important for consumers to employ improved instrumentalities for protecting the sensitive electronic components and display units of their devices. 
     At present, a subset of device covers are principally directed to protecting consumer electronic devices by providing for a bulky, overbuilt cover i.e., a weighty hard-shell accessory case, which can be suitably configured to withstand the shock of an accidental impact. Such an impact can occur when the device is dropped or when the device is otherwise struck by a rigid surface. In this scenario, a heavy-duty cover can be configured to prevent a glass device display from being cracked or shattered upon impact. However, this type of device cover typically effectuates cumbersome device usage and/or manipulation that the average consumer would deem to be annoying or not user-friendly. 
     Another subset of device covers are primarily intended to prevent scratches and abrasions to the exterior of a device, as well as to provide for grip and traction when the device is being handled by a user. Many of these insubstantial covers are made from inexpensive, fragile plastics, neoprene, or some other fabric that does not significantly lessen the effects of a blunt force impact to a covered cellular phone or tablet computing device. Moreover, aesthetic fabric covers are often loosely fit to the device, i.e., a device can simply slip inside the cover, such that the cover can become misaligned over the device, or even irreparably stretched with extended use. 
     While these accessory covers can function suitably for their intended purposes for a limited period of time, further advancements are desirable to protect and enhance the extended usability of valuable consumer electronic devices. Specifically, there remains a need for new protective covers that are made from a substantially durable material, which are capable of facilitating tactual interactions with various hardware components of an underlying, covered device. 
     SUMMARY 
     Accordingly, embodiments of the present disclosure include an accessory cover assembly configured for a specific computing device. In one embodiment, the accessory cover assembly includes a frame formed as a receptacle for the specific computing device. Additionally, the accessory cover assembly includes a first covering portion. The first covering portion covers an external bottom surface of the frame, a plurality of external lateral surfaces of the frame, a plurality of internal lateral surfaces of the frame, and a portion of an internal top surface of the frame. The accessory cover assembly also includes a second covering portion that covers a larger portion of the internal top surface of the frame than the first covering portion. The second cover portion abuts the first covering portion. Moreover, the first covering portion of the accessory cover assembly seamlessly covers a portion of at least six surfaces of the frame. 
     In another embodiment, a method of fabricating an accessory cover assembly for a portable computing device is set forth. The method of fabricating an accessory cover assembly includes a step of forming disposing a first and second covering on a frame having a shape suitable for receiving a portable computing device. The frame includes an external bottom surface, a plurality of external lateral surfaces, a plurality of internal lateral surfaces, and an internal top surface. The method further includes a step of disposing a first covering of the accessory cover assembly onto an external bottom surface of the frame, a plurality of external lateral surfaces of the frame, a plurality of internal lateral surfaces of the frame, and a portion of an internal top surface of the frame. Next, a second covering of the accessory cover assembly is disposed on a second portion of the internal top surface such that an edge of the second covering abuts an edge of the first covering an annular abutment region. Finally, the first covering is coupled to the second covering at the annular abutment region. 
     In yet another embodiment, a cutting assembly for manufacturing a material inlay of an accessory cover assembly for a portable computing device is set forth. The cutting assembly includes a support block with a recessed area configured to house a frame of the accessory cover. The frame includes an external bottom surface, a plurality of external lateral surfaces, a plurality of internal lateral surfaces, and an internal top surface. The recessed area of the frame supports the external bottom surface and at least one of the external lateral surfaces. The cutting assembly also includes a retaining plug configured to secure the material inlay disposed on the internal top surface and at least one internal lateral surface of the frame creating a gap between the material inlay disposed within the recessed area of the support block and the retaining plug. The cutting assembly further includes a rotating cutting device configured to cut the material inlay disposed on the internal lateral surface. The cutting device is further configured to fit within and translate within the gap during a cutting procedure. During a cutting operation the cutting device can translate in the same direction as a rotation of the cutting blade of the cutting device. This configuration prevents a portion of the material inlay from becoming misaligned during the cutting procedure. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The presented drawings are intended for illustrative purposes and primarily serve to provide a few examples of possible structures and arrangements for the disclosed accessory covers that are described in further detail within the Detailed Description. The drawings should not to be construed as being all-inclusive. Notably, several changes can be made to the subject matter depicted in the corresponding figures by one having ordinary skill in the art without departing from the spirit and the scope of the disclosure. 
         FIG. 1  illustrates a perspective view of an accessory cover for a cellular phone according to an embodiment of the disclosure. 
         FIG. 2  illustrates a cross-sectional perspective view of the accessory cover depicted in  FIG. 1  including an identified area of interest in accordance with some embodiments. 
         FIG. 3  illustrates a cross-sectional view of the identified area of interest of the accessory cover depicted in  FIG. 2  according to an embodiment of the disclosure. 
         FIG. 4  illustrates a cross-sectional view of the identified area of interest of the accessory cover depicted in  FIG. 2  according to an embodiment of the disclosure. 
         FIG. 5  illustrates a cross-sectional view of a portion of the accessory cover depicted in  FIG. 1  including a floating button assembly according to an embodiment of the disclosure. 
         FIG. 6  illustrates a cross-sectional view of the identified area of interest of the accessory cover depicted in  FIG. 2  according to another embodiment of the disclosure. 
         FIG. 7  illustrates a cross-sectional view of a portion of the accessory cover depicted in  FIG. 1  including a button assembly according to an embodiment of the disclosure. 
         FIG. 8  illustrates a flow diagram of a fabrication procedure of an accessory cover assembly according to an embodiment of the disclosure. 
         FIG. 9  illustrates a cross-sectional perspective view of the accessory cover depicted in  FIG. 1  including an identified area of interest in accordance with some embodiments of the disclosure. 
         FIG. 10  illustrates a cross-sectional view of the identified area of interest of the accessory cover depicted in  FIG. 9  according to an embodiment of the disclosure. 
         FIG. 11  illustrates an accessory cover cutting assembly including an exploded view depicting cutting and translational forces applied by a cutting device according to an embodiment of the disclosure. 
         FIG. 12  illustrates a cross-sectional view of a portion of the cutting assembly of  FIG. 11  depicting the cutting device according to an embodiment of the disclosure. 
         FIG. 13  illustrates a cross-sectional view of a portion of the cutting assembly of  FIG. 11  depicting exploded views of the cutting device according to various embodiments of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Exemplary applications of accessory cover assemblies according to the present disclosure are described in this section. Various examples are provided to add context to, and aid in the understanding of, the subject matter of this disclosure. It should be apparent to one having ordinary skill in the art that the present disclosure can be practiced without some or all of these specific details described herein. Further, various modifications and/or alterations can be made to the subject matter described herein and illustrated in the corresponding figures to achieve similar results or similar advantages, without departing from the spirit and scope of the disclosure. 
     For the remainder of this discussion, accessory cover assemblies that are suitable for use with specific computing device will be described. In particular, for the remainder of this discussion the computing device can take the form of a handheld computing device such as a cellular phone or a tablet computer. 
     This disclosure describes various embodiments of an accessory cover for a computing device, such as a cellular phone, which can be securely joined with the device for protection. The accessory cover assembly can act as a material sheath that envelops a durable, rigid frame in such a manner that it entirely wraps around a lip of the frame and continues along the internal lateral surfaces of the frame without a seam or break in a singular piece of durable material. In this configuration, the accessory cover assembly is substantially resistant to picking and other forms of wear along the edges and interior lateral surfaces of the accessory cover assembly. This is particularly beneficial, as the edges and interior lateral surfaces of the accessory cover assembly generally receive the most wear, such as in a scenario where a designated computing device is repeatedly inserted into, and/or removed from the accessory cover assembly i.e., as depicted in  FIG. 1 . 
     In an exemplary embodiment the material sheath can include a first covering portion and a second covering portion that are joined or otherwise coupled to each other along a single annular seam or abutment. The first covering portion of the accessory cover assembly can be made from a single piece of wear-resistant material which is configured to substantially cover an exterior portion of the frame. In one aspect, the first covering portion can be configured to cover a bottom external surface of the frame, all four external lateral surfaces of the frame, all four internal lateral surfaces of the frame, and at least a portion of the internal top surface of the frame. 
     Further, in various implementations, the first covering portion and/or the second covering portion of the accessory cover assembly can be affixed to the corresponding frame surfaces with an adhesive to prevent movement or slippage of the first and second covering portions over any surface of the rigid case. 
     The second covering portion of the accessory cover assembly can be made from a single piece of scratch resistant and/or particulate-absorbing material which can be configured to substantially cover the internal top surface of the frame. Further, in some embodiments either the first covering portion or the second covering portion can be composed of a material having shock absorbing properties, e.g., such as a foam material. In one implementation, the second covering portion can be configured to cover a portion of the internal top surface of the frame in such a manner that the second covering portion directly abuts the first covering portion at and/or on top of the internal top portion of the frame. This abutment or joint between the two covering portions can occur along an annular region encircling a majority of the surface area of the internal top portion of the frame. 
     In various embodiments, described further herein, the first covering portion of the accessory cover assembly can be joined to the second covering portion of the accessory cover assembly along the annular abutment region via a single seam and/or an adhesive coupling. Further, the accessory cover assembly can be composed from similar or dissimilar material types, such that first covering material can be different than that of the second covering material. A multi-material composition of the accessory cover assembly can be arranged to provide a number of distinct advantages over types of cover assemblies which utilize only one contiguous material type, such as plastic. 
       FIG. 1  depicts the coupling  100  of accessory cover assembly  104  with a particular computing device  102  according to various embodiments of the present disclosure. The accessory cover assembly  104  can be configured to receive a specific model of a computing device  102 . In this regard, the accessory cover assembly  104  can act as a protective receptacle that can securely retain the computing device  102 , after insertion. 
     Additionally, the accessory cover assembly  104  can be adapted with any number of apertures, openings, or thin, pliable covering portions that can allow for, but are not limited to, any of the following: accessory plug-ins, speaker output, microphone input, touch-screen display access and viewing, camera input, switch or button access and/or manipulation, viewing of device aesthetics, etc. These custom-crafted features of the accessory cover assembly  104  must be specifically manufactured to accommodate for the unique characteristics of the computing device  102  as designed by the device&#39;s manufacturer. In some embodiments, the placement/positioning of various apertures, openings, and/or pliable covering portions can ensure proper alignment with various device hardware features, e.g., such as a forward-facing and/or a rearward-facing camera. 
     In some configurations, various apertures or openings of the accessory cover assembly  104  can be formed by laser ablation. In this regard, a laser can remove material from the accessory cover assembly  104  to define aperture patterns there through. Additionally, laser ablation techniques can also be employed to remove material from a desired partial depth through the accessory cover assembly  104  to thin portions of the cover and/or to make portions of the cover more pliable for user manipulations. 
       FIG. 2  represents a cross-sectional perspective view  200  of the accessory cover assembly  104  depicted in  FIG. 1 , which includes an identified cross-sectional area of interest  202 , i.e., the area encompassed by a dotted rectangle, which can be representative of various implementations of the accessory cover assembly  104  that are described in further detail herein. In various embodiments, the cross-sectional area of interest  202  of the accessory cover assembly  104  can correspond to the related cross-sectional views  300 ,  400 , and  600 , respectively shown in  FIGS. 3, 4, and 6 . It should be understood that the cross-sectional views  500  and  700 , depicted in  FIGS. 5 and 7  correspond to a different cross-sectional area of interest  202  of the accessory cover assembly  104  that is located in an area designated for covering a device button or switch. 
     The accessory cover assembly  104  can have a first covering portion  208  that extends over the edges of a frame  212 , and a second covering portion  206  that extends over a majority of an internal bottom surface of the frame  212 . The first covering portion  208  can extend over the internal bottom surface of the frame  212  creating an overlap region  210 . In this way, the overlap region  210  is defined by the abutting edges of the first covering portion  208  and the second covering portion  206 . 
     In  FIG. 2 , a computing device  102  can be inserted into the accessory cover assembly  104 , and a lip  204  that is positioned along the upper periphery of the accessory cover assembly  104  can be configured to tightly slip over a topside edge or corner of the computing device  102  in response to a downward force being applied to the computing device  102  during insertion. In this regard, a consumer may be able to simply and easily press their computing device  102  into its protective accessory cover with minimal applied force, such that it achieves snap a snap-fit configuration against the lip  204 . Advantageously, the lip  204  of the accessory cover assembly  104  is positioned to protrude over, and on top of, the topside edge of the computing device  102  to prevent it from accidentally ejecting out of the accessory cover assembly  104  during use or drops. 
       FIG. 3  illustrates a cross-sectional view  300  of the identified area of interest  202  of the accessory cover assembly  104  of  FIG. 2  according to an implementation of the disclosure. As depicted, the cross-sectional view  300  of the accessory cover assembly  104  includes, but is not limited to, a frame  212  (which may also be referred to as a “case” or a “shell”), a first covering portion  208 , a second covering portion  206 , and a coupling portion  308  (also referred to as a “joint”). 
     In various implementations, the frame  212  of the accessory cover assembly  104  can be composed of any one of, or combination of: fiberglass, steel, carbon fiber, plastic, nylon, or other suitable rigid or semi-rigid material types. A laser ablation can remove portions of a frame  212  of the accessory cover assembly  104 , while allowing one or more other portions of the frame  212  of the accessory cover assembly  104  to remain intact at its original thickness. The material composition of the frame  212  can be selected to define its function, relating to its inherent material properties. For example, during a press-fit or snap-fit action, a user inserting or extracting his or her computing device  102  from the accessory cover assembly  104  may be able to more readily detach, or securely position, his or her device  102  within the accessory cover assembly  104  based on the selected material composition of the frame  212  of the accessory cover assembly  104 . 
     In an embodiment, the first covering portion  208  of the accessory cover assembly  104  can be positioned over and/or on top of an external bottom surface  316  of the frame  212  in a manner such that the external bottom surface  316  of the frame  212  can be completely covered by the first covering portion  208 . Further, the first covering portion  208  can also be simultaneously positioned over and/or on top of an external lateral surface  310  of the frame  212  such that the external lateral surface  310  of the frame  212  can be completely covered by the first covering portion  208 . 
     The first covering portion  208  can be simultaneously positioned over and/or on top of an internal top surface  314  of the frame  212  in a manner such that the internal top surface  314  of the frame  212  can be completely covered by the first covering portion  208 . Lastly, the first covering portion  208  can be simultaneously positioned over and/or on top of at least a portion of an internal top surface  314  of the frame  212  such that the internal top surface  314  of the frame  212  can be completely covered by the first covering portion  208 . 
     In an embodiment, the second covering portion  206  of the accessory cover assembly  104  can be positioned over and/or on top of an internal bottom surface of the frame  212  in a manner such that the internal bottom surface of the frame  212  can be substantially covered by the first covering portion  208 . For example, the second covering portion  206  can be configured to cover the entire surface area of the internal bottom surface of the frame  212 , except for an overlap region  210 . The overlap region  210  is a segment of the first covering portion  208  that extends over a portion of the internal top surface  314  of the frame  212 . The overlap region  210  terminates at an edge of the first covering portion  208  where the second covering portion  206  abuts the first covering portion  208  at a coupling portion  308 . 
     In an exemplary implementation, the first covering portion  208  of the accessory cover assembly  104  can be composed of a durable non-fabric material, such as leather, e.g., Nubuck leather, imitation leather, or suede. In other implementations, the first covering portion  208  can be composed of a durable fabric material, such as microfiber, woven or non-woven fabrics, or a polymer-based film, e.g., polyurethane film or thermoplastic polyurethane film. The material selected for the first covering portion  208  can be configured to be substantially wear-resistant and sufficiently resilient enough to withstand various anticipated impacts, scuffs, abrasions, as well as natural elements i.e., heat, cold, rain, snow, etc. 
     In some embodiments, the second covering portion  206  of the accessory cover assembly  104  can be composed of a fabric material, such as microfiber, woven or non-woven fabrics, or a polymer-based film, e.g., polyurethane film or thermoplastic polyurethane film. Alternatively, the second covering portion  206  can be composed of a durable non-fabric material, such as leather, imitation leather, or suede. Alternatively, the second covering portion  206  can also be composed of a fabric material, such as microfiber, woven or non-woven fabrics, or a polymer-based film, e.g., polyurethane film or thermoplastic polyurethane film. Additionally, in some embodiments either the first covering portion  208  or the second covering portion  206  can be composed of a material having shock absorbing properties, e.g., such as a foam material. 
     In some scenarios, consistent with the above-mentioned material options for the first covering portion  208  and the second covering portion  206 , the accessory cover assembly  104  can be composed of both a non-fabric material and a fabric material, i.e., dissimilar material types. In other scenarios, the accessory cover assembly  104  can be composed entirely of a non-fabric material type(s), or alternatively, entirely of a fabric material type(s). 
     Regardless of the various possible material arrangements for the first covering portion  208  or the second covering portion  206 , it should be understood that a whole piece of material associated with the first covering portion  208  can be configured to entirely wrap around a lip  204  of the frame  212  and then continue along an internal lateral surface  312  of the frame  212  without a seam or break. The lip  204  of the frame  212  is at a distal end of the lateral surface of the accessory cover assembly  104  and extends above and over an internal top surface  314  of the accessory cover assembly  104 . 
     The accessory cover assembly  104  can advantageously configured to be substantially resistant to picking and abrasion along all edges of the accessory cover assembly  104 . Further, by pulling the first covering portion  208  down over the internal lateral surface(s)  312  of the frame  212 , the accessory cover assembly  104  can also be substantially resistant to picking abrasions that could otherwise be caused by apertures cut through the internal lateral surface  312  and external lateral surface  310  of the frame  212 , a scenario which could occur if the coupling portion  308  were positioned above or directly over one or more frame  212  apertures. 
     In various embodiments, the coupling portion  308  of the accessory cover assembly  104  can be positioned above the internal top surface  314  of the frame  212  a preset, optimal distance inward from the internal lateral surfaces  312  of the frame  212  so as to reduce wear to the coupling portion  308  when a device  102  is inserted into and removed from the accessory cover assembly  104 . In various implementations, the coupling portion  308  can join the first covering portion  208  to the second covering portion  206  using any suitable adhesive, e.g., glue, epoxy resin, or double-sided tape, or stitching implement, such as a nylon thread having relatively high tensile strength. Further, in some scenarios, a seam tape can be applied over the coupling portion  308  as an additional adhesive that can be employed to further reduce wear and/or abrasions at the coupling portion  308 . 
     In some implementations, the coupling portion  308  of the accessory cover assembly  104  can be annular in shape, such that the coupling portion  308  is located entirely around, and on top of, a periphery region of the internal top surface  314  of the frame  212 . In this configuration, there may only be one connected coupling for the accessory cover assembly  104 , which is where the first covering portion  208  abuts and/or joins with the second covering portion  206 . Once coupled via the coupling portion  308 , the first covering portion  208  and second covering portion  206  can be configured to envelop the entire frame  212 . 
       FIG. 4  shows a cross-sectional view  400  of the identified area of interest  202  of the accessory cover assembly  104  depicted in  FIG. 2  according to an embodiment of the disclosure. In this implementation, the first covering portion  208  can be physically joined to the frame  212  along its entire interior surface area with an adhesive  410 . Similarly, the second covering portion  206  can be physically coupled to the frame  212  along its entire interior surface area with the adhesive  410 . In various embodiments, the adhesive  410  can be applied to the surface area(s) of any combination of, or all of the first covering portion  208 , the second covering portion  206 , and the frame  212 . 
     As described above, the adhesive  410  can pertain to any suitable adhesive, including, but not limited to, glue, epoxy resin, double-sided tape, etc. The adhesive  410  can adhere or couple the first covering portion  208  and/or the second covering portion  206  to the frame  212 . The adhesive  410  can advantageously prevent slippage or misalignment of the first covering portion  208  and the second covering portion  206  over the frame  212 . This can facilitate continued use of the accessory cover assembly  104  over a relatively lengthy duration, as compared to other accessory cover assemblies that are loosely fit to the computing device  102 . 
     Additionally, the accessory cover assembly  104  can include an adhesive coupling portion  408  that can include any suitable adhesive, including, but not limited to, glue, epoxy resin, double-sided tape, etc. The adhesive coupling portion  408  can be positioned above the internal top surface  314  of the frame  212  a set distance in from the internal lateral surfaces  312  of the frame  212  to reduce wear to the coupling portion  308  when a device  102  is inserted into and removed from the accessory cover assembly  104 . 
     In certain implementations, the adhesive(s) employed by the adhesive  410  and/or in the adhesive coupling portion  408  can comprise a thermoplastic adhesive, such as a thermoplastic urethane adhesive, or a thermoplastic nylon adhesive. Thermoplastic adhesives can be melted in order to glue together multiple layers of material together. Furthermore, thermoplastic adhesives can form structural elements on the surfaces of the frame  212  to create a more rigid frame  212 . 
       FIG. 5  represents a cross-sectional view  500  of a portion of the accessory cover assembly  104  depicted in  FIG. 1  including an auxiliary floating button  510  according to an implementation of the disclosure. In this configuration, a portion of the frame  212  can be configured to include an aperture  512  (also referred to as an “opening”) that is specifically positioned over an anticipated location of a device button (not shown), i.e., at a time when the computing device  102  is positioned within the accessory cover assembly  104 . The aperture  512  can enable a corresponding device button of the computing device  102  to be actuated by a user when the computing device  102  is positioned within its accessory cover assembly  104 . 
     To enhance tactile manipulation of the device button of the computing device  102  through the aperture  512 , auxiliary floating button  510  can be configured to reside within aperture  512 , creating a gap  514  between the wrapped layers of the first covering portion  208  of the accessory cover assembly  104 . In various implementations, the auxiliary floating button  510  can be coupled to the first covering portion  208  on an internal lateral region and external lateral region of relative to the frame  212  with an adhesive, such as the adhesive  410  described above and shown on the cross-sectional view  400  of the accessory cover assembly  104  in  FIG. 4 . In other embodiments, the auxiliary floating button  510  is not coupled to the first covering portion  208  on both sides, thereby allowing for less restricted movement of the auxiliary floating button  510  within the gap  514 . Moreover, in other embodiments, the first covering portion  208  (or the second covering portion  1006  in  FIG. 10 ) can be permanently embossed or debossed such that the material of the first covering portion  208  is raised or sunk to receive the auxiliary floating button  510  and give the user a better sense of where the auxiliary floating button  510  is located. 
     It should be understood, that the auxiliary floating button  510  could be coupled to the accessory cover assembly  104 , within the aperture  512 , by any other suitable joining means, without departing from the spirit and scope of the disclosure. It should also be appreciated that the first covering portion  208  and the second covering portion  206  of the accessory cover assembly  104 , as depicted in  FIG. 5 , can be similarly adhered to the frame  212  via the adhesive  410 . In the illustration of  FIG. 5 , the adhesive  410  has been omitted for clarity in order to focus on the physical positioning and structure of the auxiliary floating button  510  within the aperture  512 . 
     In an embodiment, when an external surface of the first covering portion  208 , positioned directly over the auxiliary floating button  510  and aperture  512 , is pressed by a device user, the auxiliary floating button  510  can effectuate an actuation of a corresponding button of the device  102 . In this artificially enhanced configuration, a user pressing the button of the device  102  through the accessory cover assembly  104  can achieve a more vivid sense of contact with the underlying control components of device  102 . In some implementations, a gap  514  within the aperture  512 , between the frame  212  and the auxiliary floating button  510 , can be filled with a compressible and/or nonstick filler or material to further prevent the auxiliary floating button  510  from being misaligned within the accessory cover assembly  104 . In other embodiments, the gap  514  within the aperture  512  can be hollow, and filled with air or fluid. 
       FIG. 6  illustrates a cross-sectional view  600  of the identified area of interest  202  of the accessory cover assembly  104  depicted in  FIG. 2  according to another embodiment of the disclosure. In this embodiment, the frame  602  of the accessory cover assembly  104  can be coated with a protective sealant  604 , such as a silicon or rubber sealant material, that can provide for grip or traction, as well as, shock absorption when the device  102  is dropped or otherwise exposed to some force of impact. In various implementations, the covering material or layer of the protective sealant  604  can be applied to the frame  602  by dipping the frame into a viscous liquid sealant material or by spraying the frame with one or more coatings of a suitable protective sealant material type. 
       FIG. 7  shows a cross-sectional view  700  of a portion of the accessory cover assembly  104  depicted in  FIG. 1  including another button assembly according to an implementation of the disclosure. In this configuration, a portion of the frame  602  can be configured to include an aperture  704  that is specifically positioned over an anticipated location of a device button, i.e., when the computing device  102  is positioned within the accessory cover assembly  104 . The aperture  704  can enable a device button of the computing device  102  to be actuated by a user. 
     To effectuate the manipulation of the button of device  102  through the aperture  704 , a protruding button portion  702  can be fabricated to reside within the aperture  704 , between the protective sealant  604  disposed on opposite sides of a lateral surface of the frame  602 . The aperture  704  can include a gap or space filled with air or fluid. In various implementations, the protruding button portion  702  can be composed of a similar material as the protective sealant  604 , and of a varying thickness from a remainder of the protective sealant  604  coating that is applied to the frame  602 . In other embodiments, the protruding button portion  702  can be composed of a different material than the protective sealant  604 . Alternatively, the protruding button portion  702  can encapsulate some form of auxiliary button to provide additional thickness and a more realistic button press experience to a user. 
       FIG. 8  depicts a flow diagram  800  of a fabrication procedure of an accessory cover assembly  104  according to an embodiment of the disclosure. The fabrication process can result in the production of an accessory cover assembly  104  similar to those depicted in  FIGS. 1 through 5 , and described above. At block  802  a frame  212  can be formed from a suitable material type in a specific shape to house a specific computing device. Next, at block  804 , a first covering portion  208  of the accessory cover assembly  104  can be disposed, i.e., adhered to, on an external bottom surface  316  of the frame  212 . Then, at block  806 , the first covering portion  208  can be disposed on, i.e., adhered to, a plurality of external lateral surfaces  310  of the frame, i.e., on all four external lateral sides of the frame  212 . 
     Subsequently, at block  808 , the first covering portion  208  can be disposed on, i.e., adhered to, a plurality of internal lateral surfaces  312  of the frame  212 , i.e., on all four internal lateral sides of the frame  212 . Next, at block  810 , the first covering portion  208  can be disposed on, i.e., adhered to, at least a portion of an internal top surface  314  of the frame  212 . Then, at block  812 , a second covering portion  206  of the accessory cover assembly  104  can be disposed on, i.e., adhered to, a majority of a surface area of the internal top surface  314  of the frame  212  such that the second covering portion  206  abuts the first covering portion  208  thereon. Thereafter, at block  814 , the first covering portion  208  and the second covering portion  206  can be coupled, i.e., adhered to each other and/or stitched together, along an annular abutment region. The annular abutment region is a region where the outside edges of the second covering portion  206  abut the first covering portion  208 . 
       FIG. 9  illustrates a cross sectional view  900  of the accessory cover assembly  104  depicted in  FIG. 1  including an identified area of interest  902 , i.e., the area encompassed by a dotted rectangle, which can be representative of various implementations of the accessory cover assembly  904  that are described in further detail herein. In various embodiments, the cross sectional area of interest  902  of the accessory cover assembly  104  can correspond to the related cross sectional view  1000  shown in  FIG. 10 . Further, the related cutting assemblies  1100 ,  1200 , and  1300 , for producing the accessory cover assembly  104  depicted in the cross sectional views  900  and  1000  of  FIGS. 9 and 10  are depicted in each of  FIGS. 11, 12, and 13 . 
       FIG. 10  illustrates a cross-sectional view  1000  of the identified area of interest  902  of the accessory cover assembly  104  of  FIG. 9  according to an embodiment of the disclosure. As depicted, the cross-sectional view  900  of the accessory cover assembly  104  includes, but is not limited to, a frame  1002 , a first covering portion  1004 , a second covering portion  1006 , and a coupling portion  1008 . 
     In various implementations, the frame  1002  of the accessory cover assembly  104  can be composed of any one of, or a combination of: fiberglass, steel, carbon fiber, plastic, nylon, or other suitable rigid or semi-rigid material types. Further, the first covering portion  1004  of the accessory cover assembly  104  can be composed of a durable non-fabric material, such as leather, e.g., Nubuck leather, imitation leather, or suede. In other implementations, the first covering portion  1004  can be composed of a durable fabric material, such as microfiber, woven or non-woven fabrics, or a polymer-based film, e.g., polyurethane film or thermoplastic polyurethane film. 
     In an embodiment, the second covering portion  1006 , or also referred to as material inlay herein, of the accessory cover assembly  104  can be composed of a fabric material, such as microfiber, woven or non-woven fabrics, or a polymer-based film, e.g., polyurethane film or thermoplastic polyurethane film. Alternatively, the second covering portion  1006  can be composed of a durable non-fabric material, such as leather, imitation leather, or suede. In some scenarios, material options for the first covering portion  1004  and the second covering portion  1006  of the accessory cover assembly  104  can be composed of both a non-fabric material and a fabric material, i.e., dissimilar material types. In other scenarios, the accessory cover assembly  104  can be composed entirely of a non-fabric material type(s), or alternatively, entirely of a fabric material type(s). 
     In various embodiments, the coupling portion  1008  of the accessory cover assembly  104  can be positioned a specified distance below a lip  204  of the frame  1002  so as to reduce wear to the coupling portion  1008  when a device  102  is inserted into and removed from the accessory cover assembly  104 . In various implementations, the coupling portion  1008  can join the first covering portion  1004  to the second covering portion  1006  using any suitable adhesive, e.g., glue, epoxy resin, or double-sided tape, or stitching implement, such as a nylon thread having relatively high tensile strength. 
     In some embodiments, the second covering portion  1006  of the accessory cover assembly  104  can be formed using a bladder tool. For example, a layer of second covering portion  1006  can be positioned above a preheated accessory cover assembly  104 . The bladder tool uses a balloon-like feature that is inflated into the second covering portion  1006 . As a result, the second covering portion  1006  stretches and bonds to the preheated accessory cover assembly  104 . Once bonded, the cutting assembly  1100  is used to cut any excess second covering portion  1006   b  off the perimeter of the accessory cover assembly  104 . 
     In some scenarios, the coupling portion  1008  of the accessory cover assembly  104  can be annular in shape, such that the coupling portion  1008  is located entirely around, a periphery region of the internal lateral surface  312  of the frame  212 . In this configuration, there may only be one connected coupling  1008  that spans a perimeter of the accessory cover assembly  104 . Once the first covering portion  1004  and second covering portion  1006  are connected, they can be configured to envelop the entire frame  1002 . 
     It should be understood, in accordance with some embodiments, that the accessory cover assembly  104  depicted in  FIG. 10  can alternatively be configured to include a button assembly, as discussed above with respect to  FIG. 5 . For example, the auxiliary floating button  510  (of  FIG. 5 ) can be suitably positioned between the first covering portion  1004  on an external lateral side of the frame  1002 , and the second covering portion  1006  on the opposing internal lateral side of the frame  1002 . 
       FIG. 11  illustrates a cutting assembly  1100  including an exploded view  1106   b  depicting cutting force F 1  and translational force F 2  applied to the frame  1002  by a cutting device  1106   a  according to some embodiments. In one implementation, the cutting assembly  1100  can include a support block  1102  having a substantially rectangular shape, and including a recessed area  1110  that is configured to house both the frame  1002  of the accessory cover assembly  104  and a retaining plug  1104 . 
     In some embodiments, the support block  1102  and/or the retaining plug  1104  can be composed of a rigid metal material, including, but not limited to, steel, aluminum, or any other suitable metal alloy. In other embodiments the support block  1102  and/or the retaining plug  1104  can be composed of a rigid non-metal material. In some scenarios, the retaining plug  1104  can be configured to fit within the recessed area  1110  of the support block  1102 , on top of the frame  1002 , in such a manner as to secure the second covering portion  1006  to the frame  1002  during cutting actions of the cutting assembly  1100 , e.g., when the cutting device  1106   a - b  of the cutting assembly  1100  applies both a cutting force F 1  and a translational force F 2  to the second covering portion  1006  covering the frame  1002 . 
     As would be appreciated by those skilled in the art, the cutting assembly  1100  can be associated with a computer numerical control (CNC) milling machine, and the cutting device  1106   a - b  can be a rotating drill-like implement that has a material cutting blade disposed at a distal end thereof. In some embodiments, a material cutting blade of the cutting device  1106   a - b  can be configured and shaped to cleanly slice through a fabric or non-fabric material of the second covering portion  1006  without damaging or cutting through a portion of the frame  1002  at substantially high rotational speeds, e.g., on the order of several thousands of rotations per minute (rpm) along a single cut path  1108 . 
     In various implementations, the cutting device  1106   a - b  of the cutting assembly  1100  can be configured to fit within a recessed area  1110  between a lateral surface of the retaining plug  1104  and a lateral surface  312  of the support block  1102 . The shape of the recessed area  1110  can mirror that of the internal lateral side walls of the support block  1102 . During a cutting action, the cutting device  1106   a - b  can traverse along a cut path  1108  around the entire circumference of the recessed area to arrive back at its origin. In this manner, the cutting device  1106   a - b  can complete the cut path  1108  by translating within the recessed area in the direction of the cut path  1108 . As a result of this patterned movement, the cutting device  1106   a - b  can apply a translational force F 2  to a surface of the second covering portion  1006  being cut. 
     At the same time the cutting device  1106   a - b  applies the translational force F 2  to a surface of the second covering portion  1006  being cut, the cutting blade of the cutting device  1106   a - b  can apply a cutting force F 1  to the same surface of the second covering portion  1006 , in the same direction (e.g., the blade rotation direction at the point where it touches the second covering portion  1006  during a cutting action), as depicted in the exploded view diagram of the cutting device  1106   a - b . In this arrangement, the translational force F 2  and cutting force F 1  can act to mitigate problematic pulled misalignment of the second covering portion  1006  during cutting actions. This misalignment problem could otherwise be compounded by the fact that the second covering portion  1006  can be fixed to the frame  1002  with an adhesive that can melt at the temperatures generated by the cutting blade of the cutting device  1106   a - b  as it slices through the second covering portion  1006 . 
     At  FIG. 12  illustrates a cross-sectional view of a portion of the cutting assembly  1200  of  FIG. 11  by depicting the cutting device  1204  according to an embodiment of the disclosure. In this arrangement, the cutting blade  1202  of the cutting device  1204  can be positioned within the recessed area, between the support block  1102  and the retaining plug  1104 , a specified distance  1206  down from the top surface of the frame  1002 . For example, the cutting device  1204  can be positioned a set distance below the lip  204  of the frame  1002 , to cut the second covering portion  1006  to a specified length. In some implementations, by varying the depth that the cutting device  1204  is inserted within the recessed area, the cutting blade  1202  can be positioned to cut the second covering portion  1006   a - b  at any suitable location along an internal lateral surface  312  of the frame  1002 , or alternatively, along an internal top surface  314  of the frame  1002 . 
     As depicted in  FIG. 12 , the cutting blade  1202  of the cutting device  1204  is shown as already having performed a cutting action, and as a result, a cuttant or excess portion of the second covering portion  1006   b  has been cut/severed from a remaining portion of the second covering portion  1006   a . During cutting, the cutting blade  1202 , frame  1002 , and cutting device  1204  can be cooled with air, or some other gas, or fluid coolant. After the cutting device  1204  circumscribes an entire circumference of the recessed area  1110  in a single rotation around the recessed area  1110 , the excess portion of the second covering portion  1006   b  can be removed from the frame  1002  and discarded. In certain embodiments, the recessed area  1110  between the support block  1102  and the retaining plug  1104  can act as a guide for the cutting device  1204  during various cutting actions. In scenarios where a CNC milling machine is being used as the cutting device  1204 , a physical cutting guide may be less necessary to aid precision cutting actions as compared to other manually implemented machining embodiments. 
     In some embodiments, that cutting blade  1202  of the cutting device  1204  can be configured to cut through the second covering portion  1006  and the first covering portion  1004  at the same time (e.g., in a scenario where these covering are overlapped during fabrication) to produce the best joint. In this scenario, the cut edges of the second covering portion  1006  and the first covering portion  1004  can be arranged to line up evenly at all points along an annular abutment region defined by the cut edges. In some embodiments, the first covering portion  1004  can be adhered to the frame  1002  and cut by the cutting device  1204  before the second covering portion  1006  is cut by the cutting device. In some embodiments, the second covering portion  1006  can be adhered to the frame  1002  and cut by the cutting device  1204  before the first covering portion  1004  is cut by the cutting device  1204 . 
       FIG. 13  illustrates a cross-sectional view of a portion of the cutting assembly  1100  of  FIG. 11  by depicting exploded views of alternative cutting devices and/or cutting blades  1302  according to various embodiments of the disclosure. In some scenarios, the cutting device  1304  can be attached to a milling machine and/or a drill via a spline. Further, the cutting device  1304  can be configured in such a manner that its cutting blade  1302  is positioned either at a distal end of a spindle portion of the cutting device  1304 , or alternatively, at any position between the distal end of the spindle portion and an upper spline portion of the cutting device that connects the cutting device  1304  to a milling machine and/or a drill. The location of the cutting blade  1302  determines how much of the excess portion of the second covering portion  1006   b  is discarded and how much of the remaining portion of the second covering portion  1006   a  is left on the frame  1002  after cutting is complete. 
     In some embodiments, the cutting blade  1302  of the cutting device  1304  can be configured to have any number cutting edge(s) and or blade shapes e.g., such as the cutting blade alternatives depicted in exploded views  1302   a  and  1302   b , to better cut a particular material type of the second covering portion  1006   a - b  at a specified location along an internal lateral surface  312  of the frame  1002  or along the internal top surface  314  of the frame  1002 . The angles at the edge of the cutting blades  1302  depicted in exploded views  1302   a  and  1302   b  can vary for different applications to provide a more or less invasive incision. Further, the cutting device  1304  can be arranged to angle the cutting blade or blades  1302  at any number of suitable cutting angles, e.g., at a 45, 60, or 90 degree cutting angle, etc., to provide for a suitable cut location and/or a suitable material edge and/or shape e.g., where the second covering portion  1006   a  is cut to have an angled edge that mates with a complimentary angled edge of the first covering portion  1004 . 
     Additionally, in some scenarios, the cutting device  1304  can be configured in such a manner that its cutting blade  1302  is positioned at a distal end of the spindle portion of the cutting device  1304 , e.g., as depicted in exploded view of the cutting blade  1304   a , such that the cutting blade  1302  can meet flush with a top internal surface of the covered frame  1002  during a cutting action. The cutting blade  1302  can be attached to the cutting device  1304  with a single screw that tightens completely within a screw recess of the cutting device (as detailed the view of cutting blade  1304   a  in  FIG. 13  so as to ensure a flush cut with no damage to the second covering portion  1006  or frame  1002 . In some embodiments, the cut depth D 2  can be programed into a CNC milling machine to eliminate or substantially reduce abrasions or cuts to the surface of the frame  1002  at a specified cut location. A variable of precision would need to be employed to keep a cutting blade length D 1  from exceeding a desired cut depth D 2  during a single circumferential cutting operation. 
     Although the foregoing disclosure has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described disclosure can be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the disclosure. Certain changes and modifications can be practiced, and it is understood that the disclosure is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims.

Metadata:
Filing Date: 20160331
Publication Date: 20180123
Grant Date: 20180123
Priority Date: 20130904
Inventors: SARTEE JARED A.
ROHRBACH MATTHEW DEAN
ESCHNER ADAM K.
QUINTERO JULIO C.
SMITH, IV HARRY W.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T409/304032", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T409/30868", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49888", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C3/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49888", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/30868", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/304032", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C3/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49888", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/30868", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/304032", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C2228/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23C3/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 52581638