ELECTRONIC DEVICE COVER AND METHOD OF MAKING SAME

• US 20100200456A1
• Filed: 02/05/2010
• Published: 08/12/2010
• Est. Priority Date: 02/06/2009
• Status: Active Grant

• Current Assignee: ideo Plastics Inc.
• Original Assignee: ideo Plastics Inc.
• Inventors: Parkinson, Kevin
• Granted Patent: US 8,644,011 B2
• Time in Patent Office: Days
• US Class Current: 206/701
• CPC Class Codes: B29C 2045/14147 using pins or needles penetrating through the insert
• CPC Class Codes: B29C 2045/14155 using vacuum or suction
• CPC Class Codes: B29C 2045/14327 anchoring by forcing the material to pass through a hole in the article
• CPC Class Codes: B29C 33/485 cores or mandrels collapsible mandrels for shaping tube ends B29C57/02; collapsible mandrels for winding and joining B29C53/824
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29K 2021/003 Thermoplastic elastomers
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/3431 Telephones, Earphones
• CPC Class Codes: B29L 2031/3437 Cellular phones
• CPC Class Codes: G06F 1/1626 with a single-body enclosure integrating a flat display, e.g. Personal Digital Assistants [PDAs]
• CPC Class Codes: G06F 2200/1633 Protecting arrangement for the entire housing of the computer
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

A water-resistant cover consisting of three components: a soft, form-fitting shell, a plastic slider and a plastic end cap. The shell does not inhibit the functionality of peripheral controls and includes fully integrated polycarbonate windows that are thermally and mechanically bonded to the shell in the molding process, the windows being adapted to the specific contour and profile of the device and to protect the device'"'"'s screen while not inhibiting the functionality of a touch-screen, keypad or acoustic devices. The slider is slidably connected to the cover for closing the audio jack aperture in the shell with a double closure to maintain a water-resistant seal when not in use. The end cap closes the cover with reciprocal seals that are molded into both components and the cap is easily removed for access to a data port or charger and is enhanced with water-resistant acoustic vents that provide sound clarity to speakers or microphones.

Claims

1. A protective cover for an electronic device having a viewing screen, said cover comprising:

a shell defining an enclosure with an opening at one end and having a shape corresponding to the shape of said electronic device for receiving said electronic device within said enclosure, said shell being formed of a soft, elastomeric material;

a protective membrane integrally connected to said soft shell, providing a viewing window through which said viewing screen may be viewed when said electronic device is inserted into said shell; and

a rigid end cap removably connectable to said open end of said soft sleeve to fully encase said electronic device when inserted into said shell.

2. The protective cover of claim 1 wherein said protective membrane is thermally and mechanically bonded to said shell.

3. The protective cover of claim 2 wherein said protective membrane having a plurality of perforations.

4. The protective cover of claim 3 wherein said shell being made of a thermoplastic elastomer or a thermoplastic rubber.

5. The protective cover of claim 4 wherein said thermoplastic elastomer or thermoplastic rubber fills said plurality of perforations to form said mechanical bond between said shell and said protective membrane.

6. The protective cover of claim 5 wherein said protective membrane is a polycarbonate resin thermoplastic.

7. The protective cover of claim 1 further comprising an aperture in said shell corresponding to an input area of said electronic device and an elongated guide slot in said shell adjacent to said aperture, said aperture being sealable by way of a rigid slider slidable within said guide slot from an open position wherein said aperture is open, to a closed position wherein said aperture is sealed.

8. The protective cover of claim 7 wherein said slider closes said aperture with a double internal and external seal to maintain a water-resistant seal about the aperture when in the closed position.

9. The protective cover of claim 8 wherein said slider having an internal sealing element and an external sealing element joined by a central column.

10. The protective cover of claim 9 wherein said slider further comprises a protrusion extending from said external sealing element, said protrusion inserting into said aperture when said slider is in the closed position.

11. A method of manufacturing a protective cover for an electronic device having a viewing screen comprising the step of:

thermally and mechanically bonding a protective membrane to a soft outer shell.

12. The method of claim 11 further comprising the steps of:

preparing a mold having a first portion and a second portion, said mold having a shape corresponding substantially to, and slightly larger than, the shape of said electronic device;

positioning said protective membrane into said first portion, said protective membrane having a plurality of perforations about its outer edge;

positioning a mandrel into said first portion adjacent said protective membrane, said mandrel shaped to correspond to the shape of said electronic device;

connecting said second portion to said first portion thereby enclosing said protective membrane and mandrel within said mold;

injecting an elastomeric material into said mold, said elastomeric material surrounding said mandrel and thermally and mechanically bonding to said protective membrane.

13. The method of claim 12 further comprising the step of:

prior to positioning of said protective membrane into said first portion, affixing a removable decal to a first side of said protective membrane, said removable decal shaped and sized to fit within a registration cavity defined in said first portion of said mold to ensure proper positioning of said protective membrane.

14. The method of claim 13 further comprising the step of:

applying vacuum pressure inside said registration cavity to hold said protective membrane in place during the injection molding.

15. The method of claim 14 wherein said mandrel having placement pins to further aid in the proper alignment of said protective membrane.

16. The method of claim 15 wherein said mold and said mandrel having a non-stick coating.

17. The method of claim 13 wherein prior to positioning of said protective membrane into said first portion, applying a removable protective mask to a second side of said protective membrane opposite said first side.

18. The method of claim 12 further comprising the step of removing said mandrel from said mold, said mandrel surrounded by said protective cover, and removing said cover from said mandrel.

19. The method of claim 18 further comprising the step of connecting an acoustic vent to a corresponding aperture in said cover, said aperture positioned to correspond to an audio related element of said electronic device.

20. The method of claim 19 further comprising molding a rigid end cap for connecting with an open end of said cover.