Cell phone case and method of manufacturing the same by blending an additive with a polymer

Abstract

A cell phone case including an additive for providing desired properties of the cell phone case. The additive can be a fragrance for improving a scent of the cell phone case. The additive can also include a antimicrobial agent to create an antimicrobial device effective in reducing or eliminating bacteria on a surface of the cell phone case.

Claims

1. A method for manufacturing a cell phone case comprising the steps of: (a) blending a fragrance into a base material formed of a pre-polymer plastic to form a blended polymer compound, the blended polymer compound is blended with the fragrance using heat and high compression mixing simultaneously at a temperature in the range of 350 degrees F. to 475 degrees F. and at a pressure in the range of 0 to 1500 psi to form a blended polymer compound, the blended polymer compound results in the fragrance being infused or trapped in the polymer; and (b) molding the blended base material by injection molding to form the cell phone case, wherein after step (b) further comprising the step of surface treatment by means of flame or corona treatment of the surface of the cell phone case, wherein the surface treatment improves attraction or retention of microbes to the cell phone case.

2. The method of claim 1 wherein said fragrance is a fragrance oil for polymer.

3. The method of claim 1 further comprising blending an antimicrobial agent into the base material in step (a).

4. The method of claim 2 wherein said antimicrobial agent is a silver cation.

5. A method for manufacturing a cell phone case comprising the steps of: (a) blending an antimicrobial agent into a base material formed of a pre-polymer compound, the pre-polymer compound is blended with the antimicrobial agent using heat and high compression mixing simultaneously at a temperature in the range of 350 degrees F. to 475 degrees F. and at a pressure in the range of 0 to 1500 psi to form a blended polymer compound, the blended polymer compound results in the antimicrobial agent being infused or trapped in the polymer; and (b) molding the blended base material by injection molding to form the cell phone case, wherein after step (b) further comprising the step of surface treatment by means of flame or corona treatment of the surface of the cell phone case, wherein the surface treatment improves attraction or retention of microbes to the cell phone case.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a perspective view of a cell phone case including antimicrobial and/or fragrance in accordance with the teachings of the present invention.

(2) FIG. 1B is a rear view of the cell phone case.

(3) FIG. 1C is a side view of the cell phone case.

(4) FIG. 1D is a bottom view of the cell phone case.

(5) FIG. 1E is a top view of the cell phone case.

(6) FIG. 2 is a flow diagram of a method for manufacturing a cell phone case including antimicrobial and/or fragrance in accordance with the teachings of the present invention.

DETAILED DESCRIPTION

(7) Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.

(8) FIGS. 1A-1D illustrate cell phone case 10 in accordance with the teachings of the present invention. Cell phone case 10 includes housing 11 formed of at least one wall 14 extending from rear surface 16. Housing 11 is generally rectangular. While housing 11 is illustrated herein as being generally rectangular in shape, those skilled in the art will recognize that the housing 11 could be manufactured in numerous different shapes.

(9) Cell phone case 10 can have a size to cover a cell phone or personal data assistant. For example the cell phone can be a smart phone, such as for example an IPHONE manufactured by Apple or a Galaxy manufactured by Samsung. Cell phone case 10 can include camera opening 22, screen opening 24, ring/silent switch opening 25, volume button opening 26, headset jack opening 27, power cord opening 28, sleep/wake opening or button 29 which correspond to features of a cell phone received within cell phone case 10. It will be appreciated that openings of cell phone case 10 can be arranged dependent on the features of the cell phone received in the cell phone case.

(10) Surface 40 of cell phone case 10 can be a textured surface. For example, surface 40 can include a plurality of micro-pores extending into surface 40 to create the textured surface. The textured surface can have a depth up to about 0.0015 inches.

(11) Cell phone case 10 can be formed of a polymer. Cell phone case 10 can be formed of a plastic or thermoplastic material formed from the polymerization of polyurethane or olefins. Suitable polyolefins include polyethylene and polypropylene. An additive can be added to the plastic or thermoplastic material. In one embodiment, the additive can be added to a polyolefin used for injection molding of the cell phone case. A suitable thermoplastic material is polyurethane having about 60 to about 80 durometer. A flexible or rigid plastic material can be co-molded, over molded or insert molded with the plastic material.

(12) Cell phone case 10 can be formed of polyurethane. The polyurethane can be a thermosetting or thermoplastic material. Thermoplastic materials that can be used to form cell phone case 10 include ethylene vinyl acetate and nylon.

(13) A fragrance additive can be added to the plastic or thermoplastic material when forming cell phone case 10. The fragrance additive can comprise a fragrance and a solvent. Example fragrances include fruity, citrus, floral, powdery, aromatic, oriental, green and woody. A fragrance additive can be a fragrance oil for polymer. Example fragrance oil for polymers are manufactured by Agilex Fragrance, Piscataway N.J. The fragrance additive can be used in an amount of about 1% to about 5% by weight of the composition of the plastic or thermoplastic material. Preferably, the fragrance additive is used in an amount of about 2% by weight of the composition of the plastic or thermoplastic material.

(14) Antimicrobial agents can be added to the plastic or thermoplastic material when forming cell phone case 10. The antimicrobial agents can comprise metal antimicrobial agents including silver, gold, platinum, copper, zinc or palladium. The antimicrobial agents can include metal cations. The preferred metal ion is silver ion. The antimicrobial agent can be provided in an effective amount capable of interacting with a colony of microbes for suppressing colonization or killing of the colony. Example microbes include bacteria of methicillin-resistant staphylococcus aureus (MRSA). The antimicrobial agents can be used in an amount of about 1% to about 5% by weight of the composition of the plastic or thermoplastic material. Preferably, the antimicrobial agent is used in an amount of about 2% by weight of the composition of the plastic or thermoplastic material.

(15) The fragrance agent is blended into a plastic pre-polymer before molding of the plastic material into cell phone case. The antimicrobial agent is blended into a plastic pre-polymer before molding of the plastic material into cell phone case. Both the fragrance and the antimicrobial agent can be blended into a plastic pre-polymer before molding of the plastic material into cell phone case.

(16) A colorant can be added to the plastic material for cell phone case 10.

(17) A method for manufacturing cell phone case including fragrance and/or antimicrobial 100 is shown in FIG. 2. Fragrance is infused in a polymer prior to molding and the antimicrobial is added to the polymer prior to molding.

(18) In block 102, the base material is blended with a fragrance and/or microbial agent. Example suitable microbial agents include silver, silver nano-particles, additives of silver such as are manufactured by Biomaster Antimicrobial Technology. The amount of the microbial agent used can be selected to increase the dielectric constant of the base material not to exceed the percolation threshold of the base material. An increased dielectric constant attracts negatively charged microbes providing improved ability of the base material to attract the microbes. The amount of microbial agent can be in the range of about 1% to about 25%.

(19) The base material, such as a pre-polymer compound is blended with the fragrance and/or microbial agent using heat and high compression mixing simultaneously, thereby causing the microbial agent to be evenly distributed throughout the polymer compound. Blending in this manner retains the microbial agent between the polymer strand structures. The base material can blended at a temperature in the range of about 350 degrees F. to about 475 degrees F. at a pressure in the range of about 0 to about 1500 psi.

(20) In block 104, the blended base material is molded by injection molding to form cell phone case 10. A flexible plastic material can be co-molded with the base material. The cavity used in the injection mold can be selected to be larger than the desired product for providing pressure reduction and voids in the formed product to achieve a reduced density of the product. The cavity used in the injection mold can have a runout area allowing for a pressure drop, to maximize the foaming action and providing a pressure reduction and voids in the formed product to achieve a reduced density of the product.

(21) In block 106, the molded product of the cell phone case is surface treated to raise the surface tension that holds microbes to the cell phone case to improve retention of microbes. For example, the molded cell phone case can be flame treated or treated with corona discharge. Surface treatment can also include silk screening and sputter coating of a biologically active or electrically active agent. Surface treatment can also include hydrophilization spot coating to enhance the capability to absorb and retain moisture.

(22) It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention.