PATENT DOCUMENT

Publication Number: US-9756914-B2
Application Number: US-201514609403-A
Country: US
Kind Code: B2

Title: Case for a portable electronic device

Abstract:
A case for an electronic device is disclosed. The case may include several layers. An inner layer may be made from a rigid material such as plastic. An outer layer is molded to an exterior portion of the inner layer. A fabric layer formed from a material such as microfiber is adhesively secured to an interior layer of the inner layer, the inner layer opposite the exterior layer. The inner layer may further include a recessed portion that receives a camera trim made from an opaque material. In this regard, when the electronic device is positioned within the case, the camera trim improves image capturing of a camera of the electronic device by blocking reflected light from a camera flash emitted by the electronic device.

Claims:
What is claimed is: 
     
       1. A case for an electronic device, the case comprising:
 a first layer having an indented region; 
 a second layer attached with the first layer, the second layer comprising an opening, wherein the indented region is in a location corresponding to the opening; and 
 a third layer attached with the second layer and comprising a protrusion, the third layer further comprising a first extension that extends from the protrusion and through the opening and engages the indented region, and a second extension and a third extension, the second extension and the third extension extending through the opening to engage the first layer. 
 
     
     
       2. The case as recited in  claim 1 , further comprising a fourth layer, wherein the first layer comprises a recessed portion that receives the fourth layer. 
     
     
       3. The case as recited in  claim 2 , wherein the first layer comprises a second opening in the recessed portion, and wherein the fourth layer comprises an opening concentric with respect to the second opening. 
     
     
       4. The case as recited in  claim 3 , wherein the second layer is fully covered by the first layer and the third layer. 
     
     
       5. The case of  claim 1 , wherein the second layer comprises a second opening and a cut out portion defined by a material removal region, the cut out portion surrounding the opening, and wherein the third layer extends through the second opening and into the cut out portion such that the third layer interlocks with the second layer. 
     
     
       6. The case of  claim 1 , wherein a force to the protrusion causes the extension to move toward the first layer at the indented region. 
     
     
       7. A case for an electronic device having a camera, the case comprising:
 a first layer having a size and shape defining an interior region that is configured to receive the electronic device, the first layer having a first opening; 
 a second layer attached with the first layer, the second layer comprising a recessed portion in a location corresponding to the camera when the electronic device is inserted into the interior region, the recessed portion including a second opening; and an intermediate layer disposed in the recessed portion, the intermediate layer having a third opening, wherein the first opening, the second opening, and the third opening define a through hole. 
 
     
     
       8. The case of  claim 7 , further comprising a third layer attached with the second layer and defining an exterior region, the third layer having a fourth opening aligned with the first opening, the second opening and the third opening such that the through hole is further defined by the fourth opening that extends from the exterior region to the interior region. 
     
     
       9. The case of  claim 8 , wherein the second layer comprises a lip region that secures the electronic device, and wherein the third layer covers the lip region. 
     
     
       10. The case of  claim 7 , wherein the intermediate layer is covered by the first layer and the second layer. 
     
     
       11. The case of  claim 7 , wherein the intermediate layer is positioned around the camera, when the electronic device is positioned in the interior region, to block reflected light emitted from the electronic device when the camera captures an image. 
     
     
       12. A case for an electronic device, the case comprising:
 a first layer; 
 a second layer having a rear wall and sidewalls that combine with the rear wall to define an internal cavity that receives the electronic device, the sidewalls having a lip region extending inward along the sidewall in a direction toward the internal cavity, the second layer further comprising an opening and a cut out portion, the cut out portion defined by a material removal region and surround the opening; and 
 a third layer covering the sidewalls and the lip region, the third layer extending through the opening and into the cut out portion such that the third layer interlocks with the second layer, 
 wherein the third layer covers an exterior portion of the sidewall and wraps around the lip region and terminates at an interior region of the sidewall. 
 
     
     
       13. The case of  claim 12 , wherein:
 the second layer comprises a planar surface at the lip region, 
 the third layer covers the planar surface to secure the second layer with the third layer. 
 
     
     
       14. The case of  claim 12 , wherein the second layer further comprises a second opening, and wherein the third layer comprises an extension that passes through the second opening and engages the first layer. 
     
     
       15. The case of  claim 14 , wherein the third layer further comprises a second extension and a third extension, the second extension and the third extension passing through the second opening and engaging the first layer. 
     
     
       16. The case of  claim 12 , further comprising an intermediate layer positioned in a recessed portion of the second layer, wherein:
 the first layer includes a first opening, 
 the second layer includes a second opening aligned with the first opening, 
 the intermediate layer includes a third opening aligned with the second opening, and 
 the first opening, the second opening, and the third opening define a through hole from the exterior region to the interior region. 
 
     
     
       17. A case for an electronic device, the case comprising:
 a first layer having an indented region; 
 a second layer attached with the first layer, the second layer comprising an opening, wherein the indented region is in a location corresponding to the opening; and 
 a third layer attached with the second layer and comprising a protrusion, the third layer further comprising an extension that extends from the protrusion and through the opening and engages the indented region, 
 wherein the second layer comprises a second opening and a cut out portion defined by a material removal region, the cut out portion surrounding the opening, and wherein the third layer extends through the second opening and into the cut out portion such that the third layer interlocks with the second layer. 
 
     
     
       18. The case as recited in  claim 17 , wherein the third layer further comprises a second extension and a third extension, the second extension and the third extension extending through the opening to engage the first layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This is a continuation of International Application PCT/US15/13563, with an international filing date of Jan. 29, 2015, entitled “Case for a Portable Electronic Device,” published as WO 2016/036407 on Mar. 10, 2016, which claims the benefit of priority under 35 U.S.C §119(e) to U.S. Provisional Application No. 62/045,480, filed on Sep. 3, 2014, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate generally to an accessory for portable electronic devices. In particular, the present embodiments relate to a case capable of receiving a portable electronic device and provide protection thereto. 
     BACKGROUND 
     A case can be configured to receive an electronic device. The case may offer means for protecting the device in a drop event and/or provide an aesthetic appearance to the device. 
     SUMMARY 
     In one aspect, a method for forming a case for an electronic device is described. The method may include securing a first layer to a second layer. In some embodiments, the first layer includes a first aperture. Also, the second layer may include a recessed portion and a second aperture within the recessed portion. Further, the second layer may include a sidewall having a third aperture. The method may further include securing an intermediate layer within the recessed portion. In some embodiments, the intermediate layer includes a third aperture approximately concentric with respect to the first aperture and the second aperture. The method may further include securing the second layer to a third layer. In some embodiments, the third layer may include a first protrusion and a second protrusion. The first protrusion and the second protrusion may be positioned within the third aperture. 
     In another aspect, a case for an electronic device is described. The case may include a first layer having a first aperture. The first layer may be configured to engage the electronic device. The case may further include a second layer having a sidewall having a second aperture. The second layer may further include a recessed portion and a third aperture positioned within the recessed portion. The case may further include an intermediate layer positioned within the recessed portion. In some embodiments, the intermediate layer includes a fourth aperture. The case may further include a third layer formed on an exterior portion of the second layer. In some embodiments, the third layer includes a sidewall having a protrusion. In some cases, the first aperture, the third aperture, and the fourth aperture may be approximately concentric with respect to each other. In some cases, the protrusion is positioned within the second aperture. The protrusion may include extension which extends through an aperture of the second layer to engage the first layer. Also, adhesive layers may be used, for example, to secure the first layer to the second layer or secure the intermediate layer to the second layer. 
     In another aspect, a method for forming a case for an electronic device is described. The method may include forming a first aperture in a first layer. The method may further include molding a second layer in a mold cavity. In some embodiments, molding the second layer includes: molding a recessed portion into the second layer, and forming a second aperture in the recessed portion. In some cases, the second aperture is concentric with respect to the first aperture. The method may further include positioning an intermediate layer within the recessed portion. The method may further include adhesively securing the first layer to the second layer. The method may further include adhesively securing the intermediate layer to the second layer. The method may further include molding a third layer to the second layer. In some embodiments, the third layer includes a third protrusion concentric with the first protrusion and the second protrusion. 
     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. 1  illustrates an embodiment of a case fully assembled and configured to receive an electronic device; 
         FIG. 2  illustrates an exploded view of an embodiment of a case showing the various layers of the case; 
         FIG. 3  illustrates a cross sectional view showing an expandable member configured to assemble a case having a first layer, adhesive layer, second layer, and a third layer, in accordance with the described embodiments; 
         FIG. 4  illustrates an embodiment of an expandable member expanding from a first volume to a second volume such that a first layer is actuated toward an adhesive layer, and both the first layer and the adhesive layer are actuated toward the sidewalls of a second layer; 
         FIG. 5  illustrates the embodiment shown in  FIG. 4 , further showing a removal tool cutting a portion of a first layer of the case; 
         FIG. 6  illustrates a cross sectional view of an embodiment of a case having cuts in portions of an aperture in the second layer, the cuts defining a material removal region; 
         FIG. 7  illustrates a cross sectional view of a case having a third layer with a protrusion with features configured to improve the ability to depress a control input when the electronic device is positioned with case, in accordance with the described embodiments; 
         FIG. 8  illustrates a process by which a first layer of a case can be re-bonded to a second layer by a tool, in accordance with the described embodiments; 
         FIG. 9  illustrates a cross sectional view of an enlarged portion of an embodiment of a case positioned within a mold device; 
         FIG. 10  illustrates an enlarged portion of an embodiment of a case in a mold device having void regions; 
         FIG. 11  illustrates the enlarged view of the case shown in  FIG. 10 , with the mold member removed; 
         FIG. 12  illustrates the enlarged view shown in  FIG. 11 , with a portion of the extension removed; 
         FIG. 13  illustrates the enlarged view of the case shown in  FIG. 12 , with the excess material removed from the third layer; 
         FIG. 14  illustrates an embodiment of a second layer positioned within a mold member; 
         FIG. 15  illustrates a portion of a mold member removed from the second layer after a liquid (e.g., non-cured plastic) used to form the second layer is poured into mold member and cured; 
         FIG. 16  illustrates a process for forming a recessed portion in the second layer during the formation (e.g., curing) of the second layer, in accordance with the described embodiments; 
         FIG. 17  illustrates a cross sectional view taken across the  17 - 17  line shown in  FIG. 16 ; 
         FIG. 18  illustrates a plan view of an embodiment of an electronic device positioned within a case, with the case allowing for access to various features of the electronic device; 
         FIG. 19  illustrates a plan view of the embodiment of the electronic device in  FIG. 18  positioned within the case; and 
         FIG. 20  illustrates a flowchart showing a method for forming a case for an electronic device, in accordance with the described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to a case configured to receive an electronic device. The case offers protection to the electronic device against scratching, and in some cases, protects against damage to the electronic device that may occur from a drop event. Unlike typical cases, the embodiments of the case shown and described herein include several features. For example, the case may include a first layer, a second layer, and a third layer, all of which are formed individually. The second layer may form the general shape of the case and be formed from a rigid material such as plastic to provide support and protection to the electronic device. Also, a region of the second layer may be formed by an undercut molding process. Further, the second layer may include a recessed portion that receives a camera trim. In this manner, when the electronic device uses a camera to capture an image, the camera trim prevents extraneous camera flash generated from the electronic device from entering through the camera, thereby improving image capture. The camera trim is generally formed from an opaque material. 
     The first layer may be positioned on an interior portion of the second layer and formed from relatively soft materials such as microfiber, or another material that does not scratch an electronic device. The third layer may be formed on an exterior portion of the second layer by a molding process, such as over molding. The third layer may be formed from materials such as an elastomeric silicone, including liquid silicone rubber (“LSR”). Also, the third layer may be one of several colors. 
     These and other embodiments are discussed below with reference to  FIGS. 1-20 . 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. 
       FIG. 1  illustrates an embodiment of case  100  fully assembled and configured to receive an electronic device, such as a mobile telecommunications device (e.g., smartphone) or a tablet computing device. Case  100  may include first layer  102  positioned on an interior portion of a second layer (not shown). In some embodiments, first layer  102  is a formed from a fabric, such as microfiber. Also, case  100  may further include third layer  106  formed on an exterior portion of the second layer. In some embodiments, third layer  106  is made from an elastomeric material, such as silicone. When silicone is used, the silicone may be a liquid silicone rubber (“LSR”). In some embodiments, the silicone is a gum silicone, such as a heat cure rubber (“HCR”). Further, third layer  106  may be combined with the second layer by an over molding process. In other words, once the second layer is molded (or formed by another means), the second layer may be positioned in a molding tool, such as a pair of mating molds. Then, a silicone-based material is added to the molding tool such that the material flows around an exterior portion of the second layer and cures around the exterior portion. Also, first layer  102  may include features which improve lamination of first layer  102  to other layers. This will be further discussed. 
     Also, case  100  may include apertures and protrusions on various portion of case  100  which allow a user to operate the electronic device when the device is positioned within case  100 . For example, case  100  may include first sidewall  108  having first protrusion  110  and second protrusion  112 . In some embodiments, first protrusion  110  and second protrusion  112  are formed during a stamping process. In the embodiment shown in  FIG. 1 , first protrusion  110  and second protrusion  112  are formed during a molding process, such as an over molding process. Generally, first protrusion  110  and second protrusion  112  may be positioned on any sidewall of case  100  in a location corresponding to a control input (e.g., button) or inputs of an electronic device. Also, first protrusion  110  and second protrusion  112  may provide a protective cover to the control inputs to protect against environmental conditions.  FIG. 1  further shows second sidewall  114  including third protrusion  116  which may correspond to yet another input of the electronic device. 
     First sidewall  108  may also include aperture  118  configured to allow access to a switch or an additional control input of the electronic device. Aperture  118  may be positioned on any sidewall of case  100  in a location corresponding to a switch or button of the electronic device. 
     Case  100  may also include rear portion  120  on which the electronic device may be positioned. As shown in  FIG. 1 , rear portion  120  includes aperture  122  which may be positioned to allow a camera built into an electronic device to capture an image of the environment surrounding the electronic device. Similar to the protrusions and other apertures previously described, aperture  122  may generally be in any position on rear portion  120  that corresponds to the positioning of the camera within the electronic device such that the camera may capture an image. 
     Case  100  may further include chin portion  126  associated with a region of case  100  that allows access to features of an electronic device, such as a jack to receive for an audio accessory (e.g., headphones) as well as a jack that receives a power cord in order to supply power to the electronic device. Further, chin portion  126  may be designed around a speaker grill to allow the electronic device to emit audio sounds, such as music or a ring tone, without disruption from case  100 . Despite chin portion  126  generally being a region free of material, first sidewall  108 , second sidewall  114 , and third sidewall  124  may collectively retain an electronic device while also allowing for flexibility to insert and remove the electronic device. The sidewalls, coupled with rear portion  120  and chin portion  126 , define an interior cavity that receives the electronic device. 
       FIG. 2  illustrates an exploded view of case  200  showing various layers, in accordance with the described embodiments. Case  200  may include, for example, first layer  202 , adhesive layer  232 , second layer  252 , and third layer  282 . First layer  202  may be a relatively smooth layer free of rough surfaces or edges, and configured to engage the electronic device when positioned within case  200 . In some embodiments, first layer  202  is a fabric layer, such as microfiber. First layer  202  further includes several sidewalls, such as first sidewall  204 , second sidewall  206 , and third sidewall  208 . In some embodiments, first sidewall  204  includes preformed features. In the embodiment shown in  FIG. 2 , first sidewall  204  includes first protrusion  210  and second protrusion  212 , both of which are formed during a molding process. Also, in some embodiments, first sidewall  204  includes first aperture  214  that may be formed by a material removal process such as a computer numeric control (“CNC”) tool, a die cut tool, or a laser cutting tool. First protrusion  210 , second protrusion  212 , and first aperture  214  are generally formed in locations corresponding to control input features of an electronic device, such as a button or switch. Second sidewall  206  may also include third protrusion  216  formed in a manner similar to that of first protrusion  210  and second protrusion  212 . Also, first layer  202  includes rear portion  220  configured to receive a rear portion of an electronic device. Rear portion  220  may include second aperture  222  formed in rear portion  220  in a location that corresponds to a camera of an electronic device. Also, first layer  202  may include chin portion  224  located in a region associated with several interface features of an electronic device to receive an accessory such as an audio jack, a power jack, or a microphone. Chin portion  224  may further define an opening for a speaker grill of the electronic device. Chin portion  224  may be formed in a manner that exposes the aforementioned interface features. Also, in some cases, first layer  202  includes dimensions which extend beyond chin portion  224 . In these, when the layers shown in  FIG. 2  are assembled, a laser cutting tool may be used to remove excess material such that an outer peripheral portion of first layer  202  is substantially co-planar, or flush, with respect to chin portion  281  of second layer  252 . 
     In order to secure an outer region of first layer  202  to second layer  252 , adhesive layer  232  may be positioned between first layer  202  and second layer  252 . Adhesive layer  232  may include an adhesive surface on both a first portion  234  and a second portion  236  opposite the first portion  234 . First portion  234  and second portion  236  generally refer to exterior surfaces of adhesive layer  232 . This also includes sidewalls  240 , such as first sidewall  244 . In some embodiments, adhesive layer  232  includes a pressure sensitive adhesive (“PSA”). In some embodiments, adhesive layer  232  is an assembly adhesive or assembly laminate. Also, adhesive layer  232  is configured to conform to the shape and design of first layer  202  and second layer  252 . This includes, for example, first sidewall  244 , first protrusion  246 , second protrusion  248 , and first aperture  250 . Also, second aperture  251  may be concentric, or approximately concentric, with respect to second aperture  222  and also have similar dimensions. However, in some cases, second aperture  251  of adhesive layer  232  includes larger dimensions. In this manner, adhesive layer  232  will not flow into second aperture  222  or third aperture  266  (of second layer  252 ). 
     Second layer  252  may be positioned between first layer  202  and third layer  282 , and may be formed from rigid materials, such as plastic. Other materials used to form second layer  252  include nylon  12 , polycarbonate (including EX-CEL© polycarbonate), or a combination thereof. Generally, second layer  252  is relatively rigid as compared to first layer  202  and third layer  282 . As a result, second layer  252  may provide the overall structural backbone of case  200 . In order to form second layer  252 , these materials may be in a molten or liquid state and poured in a mold cavity which may combine with a second mold feature. Also, the mold cavity and second mold feature may combine to form an undercut molded region (shown later) first sidewall  254 , second sidewall  256 , and third sidewall  258 . Undercut molding may form, for example, a lip region of second layer  252  near a top portion of the sidewalls that prevents second layer  252  from being directly removed from the mold cavity and/or second mold feature. 
     Second layer  252  includes various features, some of which are preformed and some of which are formed from a material removal process. For example, first sidewall  254  includes first aperture  260  and second aperture  262 , both of which are formed during the molding process for second layer  252 . In other words, the mold cavity and/or second molded feature can include a shape configured to preform first aperture  260  and second aperture  262  during a curing process of second layer  252 . However, in other embodiments, first aperture  260  and second aperture  262  are formed from a material removal process, such as die cutting, or CNC cutting. First aperture  260  may include dimensions capable of receiving features such as first protrusion  210  and second protrusion  212 . Second aperture  262  may be aligned with other features such as first aperture  250  as well as include dimensions capable of receiving a control input (e.g., switch, button) to the electronic device. Second sidewall  256  includes third aperture  263  that may be formed by any means previously described for first aperture  260  and second aperture  262 . 
     In some embodiments, second layer  252  further includes recessed portion  264  having third aperture  266 . Recessed portion  264  may be formed during the molding process of second layer  252 , and will be discussed later. Also, as shown in  FIG. 2 , recessed portion  264  may extend at least partially into third sidewall  258 . However, in other embodiments, recessed portion  264  is fully enclosed by rear portion  270  of second layer  252 . While third aperture  266  may be formed during the molding process of second layer  252  and recessed portion  264 , in the embodiment shown in  FIG. 2 , third aperture  266  is die cut in a subsequent step. Also, third aperture  266  may be concentric, or approximately concentric, with respect to second aperture  222  and also have similar dimensions. 
     Also, recessed portion  264  may be configured to receive intermediate layer  272 . In some embodiments, intermediate layer  272  is used as a camera trim configured to prevent reflected light from, for example, a camera flash event during an image capture of the camera previously described. In this regard, intermediate layer  272  is generally opaque and includes a dark color, such as black. However, in a particular embodiment, intermediate layer  272  is opaque but white in color. This assists in reflecting light incident on case  200  such that intermediate layer  272  is less visible (or not visible) when, for example, third layer  282  includes a pink and/or fluorescent color, as the material or materials used to form those colors are relatively transparent. Although intermediate layer  272  is shown generally as a four-sided figure, intermediate layer  272  could include any number of sides, or intermediate layer  272  could be circular. Accordingly, recessed portion  264  and adhesive layer  276  can also include a shape corresponding to the shape of intermediate layer  272 . 
     Intermediate layer  272  may include aperture  274  that may be concentric, or approximately concentric, with respect to third aperture  266  and also have similar dimensions. In order to secure intermediate layer  272  to recessed portion  264 , adhesive layer  276  may be used. Adhesive layer  276  includes an adhesive on multiple surfaces. Also, adhesive layer  276  includes aperture  278  that may be concentric, or approximately concentric, with respect to third aperture  266  and aperture  274 , and also have similar dimensions. However, in some cases, aperture  278  of adhesive layer  276  includes larger dimensions. In this manner, adhesive layer  276  will not flow into third aperture  266  or aperture  274 . Generally, adhesive layer  276  may be formed from any material previously described for adhesive layer  232 . Also, in some embodiments, adhesive layer  276  is foam adhesive. 
     First layer  202  and adhesive layer  232  are both designed to be positioned within interior cavity  268  of second layer  252 . Moreover, second layer  252  is designed to be positioned within an interior cavity  298  of third layer  282 . In some embodiments, third layer  282  is formed over second layer  252  during an over molding process in which second layer  252  is placed within a mold cavity (not shown) having dimensions larger than second layer  252 . Further, the mold cavity is configured to receive a liquid and allow this liquid form to flow or extend around an exterior portion of second layer  252 . A curing process of the liquid forms third layer  282 . The mold cavity may further include protrusions which correspond to several protrusions of third layer  282 , such as first protrusion  290  and second protrusion  292  located on first sidewall  284 . In other words, the protrusions of third layer  282  may be formed during the over molding process. Similarly, second sidewall  286  may include third protrusion  293 . The mold cavity may also include other features which allow for openings, such as first aperture  294  and second aperture  296 , such that the openings of third layer  282  may be formed during the over molding process. Also, second aperture  296  may be configured to be concentric with respect to second aperture  222  of first layer  202  as well as third aperture  266  of second layer  252 . 
     In some embodiments, third layer  282  is a thermoplastic elastomer (TPE). In the embodiment shown in  FIG. 2 , third layer  282  is a silicone-based material, such as LSR. In some embodiments, third layer  282  is selected from several colors, including, red, blue, green, yellow, or a combination thereof. In other embodiments, third layer  282  is selected from black, gray, white, or a combination thereof. Also, not shown, in some embodiments, an additional layer, such as a coating, may be formed over third layer  282 . The coating may cover or mask certain blemishes associated with the manufacturing process of case  200 . The coating may include materials such as TPE, nitrile rubber, silicone, or a combination thereof. It will be appreciated that any features, geometries, and/or orientations previously described may be present in the foregoing embodiments. 
     When adhesively securing layers, it is relatively less complex to adhesively secure flat or level surfaces. However, non-linear or curved surfaces may require more complexity. FIGS.  3 - 5  illustrate an assembly process for forming case  200 , and in particular, adhesively securing layers in locations associated with the non-linear surfaces, such as sidewalls.  FIG. 3  illustrates a cross sectional view of case  200  having first layer  202 , adhesive layer  232 , second layer  252 , and third layer  282 . Expansion member  300  may be placed within an interior portion of case  200 , and in particular first layer  202 , and expanded across a rear portion (e.g., rear portion  220 , shown in  FIG. 2 ). Expansion member  300  may also be referred to as a bladder, and further, is generally a non-rigid member. Expansion member  300  may be configured to expand when filled with a liquid or gas, or when a gas is heated. As shown in  FIG. 4 , expansion member  300  is expanded from a first volume to a second volume greater than the first volume such that first layer  202  is actuated toward adhesive layer  232 , and both first layer  202  and adhesive layer  232  are actuated toward the sidewalls of second layer  252 . In this manner, case  200  may include non-linear surfaces (e.g., sidewalls) with layers adhesively secured in a desired manner. 
     Once first layer  202  is adhesively secured to second layer  252 , expansion member  300  may be removed. When first layer  202  includes excess material, it can also be removed by a removal tool.  FIG. 5  illustrates removal tool  302  cutting a portion of first layer  202 . In some embodiments, removal tool  302  is a laser cutting tool. In the embodiment shown in  FIG. 5 , removal tool  302  is a CNC tool capable of cutting around the outer peripheral portion of first layer  202 . 
     While an over molding process may promote adhesion between layers (such as second layer  252  and third layer  282 ,  FIG. 2 ), additional techniques may be incorporated to further promote adhesion.  FIG. 6  illustrates a cross sectional view of an enlarged portion of an embodiment of case  200  having cuts in second layer  252 . For example, first aperture  260  includes a cut that defines a material removal region  310  of second layer  252  extending around the outer peripheral portion of first aperture  260 . As a result, during the over molding process of molding third layer  282  to second layer  252 , third layer  282  may flow into the material removal region  310 . This allows for improved lamination of third layer  282  to second layer  252 . Although  FIG. 6  shows relief cuts for first aperture  260 , these relief cuts may be used in other apertures, such as third aperture  266 . In some embodiments, a removal tool (not shown) may be used to create the material removal region  310 . The removal tool may be a CNC tool. In other embodiments, the mold member used to form second layer  252  include indentions that define the material removal region  310 . 
     Also, second layer  252  may include lip region  322  that provides added securing means for an electronic device within case  200 . In some embodiments, lip region  322  is machined by a removal tool previously described. In the embodiment shown in  FIG. 6 , lip region  322  is created by a molding process (e.g., when molding second layer  252 ). As shown, lip region  322  includes a relatively flat surface as opposed to the curved surface of lip region  322  in other locations. Accordingly, a portion of third layer  282  may also be relatively flat. This relatively flat region of both third layer  282  and lip region  322  define a mechanical interlock which further increases adhesion between third layer  282  and second layer  252 . Also, during the molding process of third layer  282 , several slides may be inserted into the molding tool and engaged with first sidewall  254 . A clearance region between the slides and second layer  252  can contribute to forming the flat region of lip region  322 . 
     A case may also accommodate an electronic device having control input, such as a button, which can be depressed in order to send a signal to the electronic device.  FIG. 7  illustrates a cross sectional view of an enlarged portion of an embodiment of case  400  having third layer  482  with protrusion  490  with features configured to improve the ability to depress a control input (e.g., button) when the electronic device is positioned with case  400 . For example, first layer  402  may be de-bossed, or indented, by tool  430  into a location proximate to protrusion  490 . Tool  430  may also be referred to as a stamping tool as first layer  402  is pressed in a manner such that first layer  402  engages several locations of protrusion  490 , including first extension  492 , second extension  494 , and third extension  496 . As shown, first extension  492 , second extension  494 , and third extension  496  extend through an aperture of second layer  452 . These extensions may be formed by a material removal tool, such as a CNC tool, subsequent to an over molding process previously described. Alternatively, the mold cavity used for an over molding process used to mold third layer  482  to second layer  452  may include a geometry that allows third layer  482  (prior to curing) to flow in a manner forming first extension  492  and second extension  494 . Also, first extension  492  and second extension  494  provide for additional surface area on which third layer  482  is molded to second layer  452 , thereby promoting adhesion. Also, rather than forming or cutting parts or materials in a precise manner (e.g., within precise tolerances), the over molding process allows third layer  482  to simply flow around second layer  452 . Further, the use of tool  430  removes the need to form an indention in first layer  402 , thereby reducing the need to rely on precise tolerances. This allows parts to be formed as they may which reduces manufacturing times and associated costs. 
     Third extension  496  when secured to first layer  402  in a manner shown in  FIG. 7  allows for improved functionality of case  400 . For example, when an electronic device is positioned within case  400 , the number of “false triggers” may be reduced when depressing protrusion  490  in order to press a control input, such as a button, of the electronic device. In other words, a force applied to protrusion  490  may be more directly transferred to first layer  402  as well as a control input (e.g., button) of the electronic device. Further, the force required to depress the control input within case  400  may be reduced. Also, although not shown, in some embodiments, adhesive layer  432  is positioned between first layer  402  and the extensions (e.g., first extension  492 , second extension  494 , and/or third extension  496 ). 
       FIG. 8  illustrates a process by which a first layer of a case can be re-bonded to a second layer of the case by a tool in order to further secure the layers of the case, in accordance with the described embodiments. Tool  440  may be used to provide a re-bond operation of first layer  402  in order to ensure first layer  402  is adhesively secured to second layer  452 . As shown, tool  440  may traverse in a direction toward and away from first layer  402 . Tool  440  may engage first layer  402  to ensure first layer  402  engages adhesive layer  432 , and both first layer  402  and adhesive layer  432  engage second layer  452 . This ensures a good finish, particularly in instances of bonding to a non-linear surface. 
       FIG. 9  illustrates a cross sectional view of an enlarged portion of an embodiment of case  500  positioned within a mold device  510 . Case  500  is shown upside down. In some embodiments, mold device  510  includes first mold member  512  and second mold member  514 . In order to over mold third layer  582  to second layer  552 , first mold member  512  engages second mold member  514 . However, in some cases, it may be difficult align first mold member  512  to second mold member  514  with absolute precision. In other cases, first mold member  512  and second mold member  514  may be misaligned due to tolerances within first mold member  512  and/or second mold member  514 . In either event, a mismatch can occur between first mold member  512  and second mold member  514 . This mismatch may be on the order of approximately 100 micrometers. However, despite this relatively small mismatch, third layer  582 , prior to curing, can flow into this mismatch area between first mold member  512  and second mold member  514 , giving case  500  the appearance of a lip  584  which is generally undesirable. As a result, either a rework operation may be required, or alternatively, case  500 , which also includes second layer  552  which has already been molded, may be discarded. 
       FIGS. 10-12  illustrate an over molding process of an embodiment of case  600  in a modified mold device  610 .  FIG. 10  illustrates an enlarged portion of an embodiment of case  600  in mold device  610  having first mold member  612  and second mold member  614 . Here, first mold member  612  and second mold member  614  include first void region  622  and second void region  624 , respectively. First void region  622  and second void region  624  each may include a thickness  628  approximately in the range of 40 to 60 micrometers. In this manner, when an over molding process forms third layer  682  to second layer  652 , third layer  682  can flow into first void region  622  and second void region  624 . As a result, in addition to lip  684  forming around case  600 , extension  686  is also formed. However, this technique provides a structure requiring relatively simple steps to remove. This technique is found to be advantageous when the mismatch between first mold member  612  and second mold member  614  is approximately 50 micrometers or less. 
       FIG. 11  illustrates the enlarged view of case  600  shown in  FIG. 10 , with the mold member removed. As a result of the first and void regions, excess material, such as extension  686 , intentionally formed may be more easily removed. As shown, tool  650  may be used to remove extension  686 . In some embodiments, tool  650  is a blade.  FIG. 12  illustrates the enlarged view of case  600  shown in  FIG. 11 , with a portion of extension  686  removed. This remaining excess material  688  of third layer  682  may be referred to as “flash” material which may be removed by tool  660 , such as a grinding or sanding tool.  FIG. 13  illustrates the enlarged view of case  600  shown in  FIG. 12 , with the excess material removed from third layer  682 . Any resultant portion evidencing a mismatch may be hidden or masked by subsequent processes. 
       FIGS. 14 and 15  illustrate a process for forming a recessed portion (such as recessed portion  264  shown in  FIG. 2 ).  FIG. 14  illustrates an embodiment of second layer  752  positioned within mold member  710 . Mold member  710  may include first member  712 , second member  714 , and third member  716 , which, when acting in concert, can form a recessed portion.  FIG. 15  illustrates mold core  720  removed from second layer  752  after a liquid (e.g., non-cured plastic) used to form second layer  752  is poured into mold member  710  and cured. When mold core  720  is removed, first member  712 , second member  714 , and third member  716  are configured to extend inward toward a central region of second layer  752 . As a result, an indention or bossed portion (not shown) below each of first member  712 , second member  714 , and third member  716  may force the liquid to traverse in a direction toward the central portion of second layer  752  to define recessed portion  764 . When second layer  752  cures, first member  712 , second member  714 , and third member  716  may be removed from second layer  752  and recessed portion  764  remains. Forming recessed portion  764  in this manner has several advantages. For example, a material removal process, which may include a CNC tool, is not required which removes additional tolerance requirements. Also, a portion of recessed portion  764  may be formed on a portion of a sidewall of second layer  752 . Conventional techniques for forming recessed portion  764 , which may include a material removal tool, must fit into tight spaces, which may be cumbersome and difficult. However, using mold member  710 , the liquid simply flows in all areas not occupied by the mold member  710 , including first member  712 , second member  714 , and third member  716 , making it easier to mold features into non-linear spaces. 
     After second layer  752 , including recessed portion  764 , is formed, third layer  782  is formed on second layer  752  in an over molding process previously described, as shown in  FIG. 16 . Also, case  700  may undergo a die cutting process to form apertures, such as aperture  766  within recessed portion  764 .  FIG. 17  illustrates a cross sectional view taken across the  17 - 17  line shown in  FIG. 16 . Recessed portion  764  may include a thickness  770  that depends on the electronic device being used with case  700 . 
       FIGS. 18 and 19  illustrate a portion of electronic device  810  positioned within case  800 . The features of case  800  described herein may be included in previous embodiments of a case.  FIG. 18  illustrates a plan view of electronic device  810  positioned within case  800 , with case  800  allowing for access to various features of electronic device  810 . For example, case  800  may include a non-linear region  802  similar to a U-shape design that allows a user to plug in an accessory into first jack  812  and/or second jack  814 . In addition, electronic device  810  may include speaker grill  816  configured to allow sound to escape electronic device  810 . The non-linear region  802  of case  800  allows for sufficient retention of electronic device  810  within case  800  while not interrupting access to the device, or disrupting the sound emitted from the device. 
       FIG. 19  illustrates an alternate view of electronic device  810  positioned within case  800 . From this view, the non-linear region (shown in  FIG. 18 ) is generally not visible. Also, in some embodiments, a lower portion or edge of electronic device  810  is substantially co-planar, or flush, with respect to a lower portion of case  800 . 
       FIG. 20  illustrates a flowchart  900  showing a method for forming a case for an electronic device, in accordance with the described embodiments. In step  902 , a first layer is secured to a second layer. Securing means may include an adhesive layer. In some embodiments, the first layer includes a first aperture and the second layer includes a recessed portion and a second aperture within the recess portion. Also, in some embodiments, the second layer may further include a sidewall having a third aperture. In step  904 , an intermediate layer is secured within the recessed portion. The intermediate layer may include a fourth aperture approximately concentric with respect to the first aperture and the second aperture. In step  906 , the second layer is secured to the third layer. In some embodiments, the third layer includes a first protrusion and a second protrusion. In an optional step  908 , a coating may be applied to the third layer. In some embodiments, the coating includes a combination of polyurethane and silicone, and may be referred to as a slip coat. The coating may be useful for several purposes, such as improving the feel of the case, reducing an accumulation or buildup of particulates of dust, lint, or other contaminants, and improving the resistance to abrasion. 
     Also, in some embodiments, the first protrusion and the second protrusion are positioned within the third aperture. In order to assemble the various layers together, an expandable member may be inflated or expanded to force the layers together. Also, some apertures of the second layer may include a relief configured to receive a portion of the third layer formed during an over molding process. Also, the first protrusion and/or the second protrusion may each include extensions that engage both the first layer and the second layer. 
     In another embodiment, a second layer may be molded by means such as injection molding. Then, a silicone layer is over molded to an exterior portion of the second layer. In some cases, prior to over molding the silicon layer, a coating or “primer” is added to the second layer in locations where the silicone layer is over molded to the second layer. Then, any additional, unwanted portions of the silicone layer (e.g., flash) may be removed. Then, a coating (previously described) is applied to the silicone layer. Then, a camera trim (e.g., intermediate layer) is adhesively secured to an interior portion of the second layer. Then, a microfiber layer (e.g., first layer) is adhesively secured to the interior portion of the second layer. 
     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 targeted 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: 20150129
Publication Date: 20170912
Grant Date: 20170912
Priority Date: 20140903
Inventors: BAKER JOHN J.
SIAHAAN EDWARD L.
Assignee: APPLE INC
CPC Classifications: [{"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C2011/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55401042