Case for an electronic device and manufacturing methods for making a case

Patent metadata

Field	Value
Publication number	US-9419669-B2
Application number	US-201414443040-A
Country	US
Kind code	B2
Filing date	Aug 27, 2014
Priority date	Sep 4, 2013
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

Abstract

An accessory unit includes a front flap and a rear cover. The rear cover includes a recessed portion that defines a chamber and a lip that extends about an opening of the chamber. The chamber is configured to receive a consumer electronic device, and the lip is configured to hold the consumer electronic device therein. The rear cover can include a shell formed from glass fiber reinforced plastics and a lip formed from a thermoplastic. The front flap may include segments formed from panels with folding regions therebetween, which allow the front flap to fold. Further, an end region of the front flap hingedly couples the front flap to the rear cover, such that the front flap may be moved between open and closed configurations. Methods of manufacturing the accessory unit are also disclosed.

First claim

What is claimed is:

1. An accessory unit for an electronic device, the accessory unit comprising:
a front flap comprising:
a plurality of segments, and
a first layer and a second layer separate from the first layer, the first layer and the second layer combining to 1) cover the plurality of segments and 2) fold in regions between the plurality of segments, the first layer and the second layer further defining an end region; and

a rear cover coupled with the front flap at the end region to define a hinge, the rear cover comprising:
a shell forming a sidewall and a recessed region configured to receive the electronic device, wherein the first layer covers the sidewall and the recessed region,
a opening in the shell, and
a rigid filler disposed within the opening and covered by the second layer such that a force exerted on the second layer is at least partially transferred to the rigid filler and to a button of the electronic device; and

a lip mechanically disposed along a periphery of the shell and formed from a material more rigid than the shell, the lip configured to retain the electronic device within the recessed region of the shell, wherein the front flap is configurable between a closed configuration in which the front flap at least partially covers the opening to the recessed region and an open configuration in which the opening to the recessed region is at least partially uncovered.

2. The accessory unit as recited in claim 1 , wherein the end region comprises a first rigid stiffener and a second rigid stiffener, the first rigid stiffener and the second rigid stiffener spanning the end region, and wherein the end region is located between the front flap and the rear cover.

3. The accessory unit as recited in claim 2 , wherein the first rigid stiffener and the second rigid stiffener comprise steel.

4. The accessory unit as recited in claim 2 , the first rigid stiffener and the second rigid stiffener further comprising magnets, wherein the magnets are oriented such that the magnets attract each other when the accessory unit is placed in the closed configuration.

5. The accessory unit as recited in claim 2 , wherein the first layer and the second layer combine to cover the first rigid stiffener and the second rigid stiffener.

6. The accessory unit as recited in claim 1 , further comprising a unidirectional fiber included within the lip and spanning a periphery of the lip.

7. The accessory unit as recited in claim 6 , wherein the unidirectional fiber comprises Kevlar.

8. The accessory unit as recited in claim 1 , wherein the opening comprises a chamfered opening configured to align with a camera of the electronic device.

9. The accessory unit as recited in claim 8 , wherein the shell comprises a first thickness, and wherein the shell further comprises a second thickness at the opening, the second thickness less than the first thickness.

10. The accessory unit as recited in claim 1 , wherein the first layer and the second layer combine to fully cover the plurality of segments and the shell.

11. The accessory unit as recited in claim 1 , wherein the plurality of segments comprises a segment having a reinforcement bar that reinforces an outer edge of the front flap.

12. The accessory unit as recited in claim 1 , wherein in the closed configuration, the front flap engages the first layer in a location corresponding to the lip.

13. A method for forming an accessory unit configured to receive an electronic device having a button, the accessory unit comprising a rigid shell having an opening, the method comprising:
positioning a fill material within the opening; and
disposing an inner cosmetic layer and an outer cosmetic layer over opposite sides of the rigid shell, wherein the fill material is covered by the outer cosmetic layer such that a force exerted on the outer cosmetic layer in a location corresponding to the fill material is at least partially transferred to the button when the electronic device is disposed in the accessory unit.

14. The method as recited in claim 13 , wherein the fill material is enclosed by the inner cosmetic layer and the outer cosmetic layer.

15. The method as recited in claim 13 , wherein the fill material causes a protruding region of the outer cosmetic layer, the protruding region defining a button region of the accessory unit.

16. A button assembly for depressing a button of an electronic device disposed in an accessory unit, the button assembly comprising:
a shell comprising an opening;
a fill material disposed in the opening;
an inner cosmetic layer covering an interior region of the shell; and
an outer cosmetic layer covering an exterior region of the shell opposite the interior region, wherein the inner cosmetic layer and the outer cosmetic layer combine to cover the fill material, and wherein in response to a force exerted on the outer cosmetic layer in a location corresponding to the fill material, the fill material transfers a forced to depress the button.

17. The button assembly as recited in claim 16 , wherein the opening comprises a chamfered opening, and wherein the fill material comprises a rigid filler extending along the chamfered opening.

18. The button assembly as recited in claim 17 , wherein the opening comprises a through hole surrounded by a blind hole, and wherein the opening comprises a over-molded material disposed in the through hole and the blind hole.

19. The button assembly as recited in claim 18 , wherein the over-molded material causes a protruding region of the outer cosmetic layer.

Assignees

• Apple Inc

Inventors

• Smith Samuel Gilkison
• Balaji Santhana Krishnan
• Sartee Jared A
• Qian Amy
• Moolsintong Pinida J

Classifications

• B32B37/182

  one or more of the layers being plastic · CPC title

• B32B38/0004

  Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence) · CPC title

• H04B1/3888 Primary

  Arrangements for carrying or protecting transceivers · CPC title

• B32B37/1284

  Application of adhesive · CPC title

• G05G1/02

  Controlling members for hand actuation by linear movement, e.g. push buttons · CPC title