METHOD FOR MAKING A CASE FOR A MOBILE DEVICE WITH A SCREEN

Abstract

A method of making a case for a mobile device with a screen. The method comprising 3D printing of the case in a partially finished form on a support surface in a configuration in which rear wall (1) and sidewalls (2-5) lie alongside one another on the surface, and folding the sidewalls up relative to the rear wall to at least partially create a cavity for the device. Separate corner portions (10, 11) may be provided to connect the sidewalls. The invention also extends to a 3D printed blank from which the case is formed.

Claims

1. A method of making a case for a mobile device with a screen, the case having a rear wall and a plurality of upstanding sidewalls forming a cavity for the device, in use; the method comprising: 3D printing of the case in a partially finished form on a support surface in a configuration in which the rear wall and sidewalls lie alongside one another on the surface; and folding the sidewalls up relative to the rear wall to at least partially create the cavity.

2. A method according to claim 1, further comprising 3D printing a living hinge at an interface between the rear wall and an adjacent side wall.

3. A method according to claim 1, further comprising the step of joining adjacent sidewalls to one another via corner portions.

4. A method according to claim 3, wherein the corner portions are separate components which connect to adjacent sidewalls.

5. A method according to claim 4, wherein the corner portions are 3D printed.

6. method according to claim 4, wherein the corner portions are snap fitted into place.

7. A method according to claim 4, wherein each corner portion comprises an inner segment and an outer segment.

8. A method according to claim 7, wherein the inner segment is made of a material which is softer than the other segment,

9. A method according to claim 1, wherein the support surface is glass.

10. A method according to claim 1, wherein the support surface is heated.

11. A method according to claim 1, wherein the support surface has recessed or protruding features which form a pattern or texture on the outer face of the side walls and/or the rear wall.

12. A blank of material foldable to form a case for a mobile device, the blank comprising a rear wall for the device and a plurality of sidewalls extending in substantially the same plane as the rear wall, a hinge being provided between the rear wall and each respective sidewall about which the sidewalls can be pivoted into a finished configuration in which they extend transversely to the rear wall to define a cavity to receive, in use, a mobile device.

13. A case for a mobile device with a screen, comprising a blank according to claim 12 in the configuration in which sidewalls extend transversely to the rear wall, adjacent sidewalls being joined by a corner portion to support the sidewall in the upstanding configuration.

Description

[0024] An example of a method of making a case for a mobile device with a screen will now be described with reference to the accompanying drawings:

[0025] FIG. 1 is a plan view of a case on a support prior to full assembly in the form in which it is 3D printed;

[0026] FIG. 2 is a cross section through line II in FIG. 1

[0027] FIG. 3 is a perspective view showing the partially assembled case.

[0028] FIG. 4A is a perspective view of an outer corner segment; and

[0029] FIG. 4B is a perspective view of an inner corner segment in the opposite direction to the view of FIG. 4A.

[0030] The part formed case is formed by 3D printing in the form shown in FIG. 1 onto a flat surface S which is a heated glass surface. Any suitable 3D printing technique may be employed. However, preferably, the 3D printing is fused deposition modelling (FDM), selective laser sintering (SLS) or stereolithography (SLA).

[0031] The case comprises a rear wall 1 with a top side wall 2, bottom side wall 3 and lateral side walls 4, 5. As shown in FIG. 1, sidewalls 2-5 are printed in a configuration in which are supported by the surface S. This could be an entirely planar surface, or may be provided with features such as ridges and recesses which provide surface detail on the outer faces of the walls 1-5.

[0032] Conveniently, the sidewalls 2-5 are printed to be co-planar with the rear wall 1. However, the surface S could be inclined to a small extent in these regions such that the rear walls are produced in a plane which is angled with respect to the plane of the rear wall.

[0033] The 3D printing process occurs by gradually building up layers of plastic by printing these into the surface S. As will be appreciated from the consideration of FIG. 1, the maximum depth to be printed would be the maximum thickness of the thickest wall 1-5.

[0034] The printed material is precisely deposited by the printer in order to form external features on the walls of the devices such as buttons not shown in FIG. 1 as these are formed on the rear face of the case.

[0035] The 3D printing process also allows for the formation of infill patterns in the form of recesses 6 in the inner face of the rear wall 1. These reduce the mass and material cost of the case as well as producing impact protection features in the form of localised air cushions in the vicinity of a recess 6.

[0036] This method is particularly suited for forming orifices 7 in the sidewalls where this is done by simply not printing in these areas. Also, features on the internal faces on the sidewalls 2-5 such as ribs 8 can also be easily produced by 3D printing.

[0037] It is useful to form the ribs 8 in a softer material than the remainder of the case in order to provide enhanced impact absorption. With the above described method, the rear wall and the bulk of the side walls 2, 4, 5 can be printed from a first material while a second material can then be used to print the ribs 8. If the walls were printed directly in an upstanding configuration, numerous changes of material would be required as both materials would be repeatedly used in the same layers.

[0038] The interfaces between the rear wall 1 and the sidewalls 2-5 have living hinge 9 (best shown in FIG. 2) about which each of the sidewalls can be folded up to formed a cavity.

[0039] Adjacent sidewalls are connected by corner components 10 shown in FIGS. 3, 4A and 4B. These can moulded or 3D printed.

[0040] As shown in FIGS. 4A and 4B, the corner component 10 comprises an inner segment 11 an outer segment 12. The corner component could, instead, be made of a single piece. The inner segment 11 is generally formed of a softer cushioning material, for example, FlexShock®. This may be provided with inwardly projecting ribs (not shown) to enhance the cushioning effect. The outer segment 12 is made of a harder material such as TPU which is provided with locking ridges 13 at either end in order to snap fit onto the corners of the case to hold the side walls of the case together to maintain the case in its assembled configuration.

[0041] The inner segments 11 are fitted in place on the four corners of the printed component. The side walls 2-5 are then folded up along with the living hinges 9 and the outer segments 12 are then snapped into place in order to retain the finished case in place. FIG. 3 shows the positional relationship of the outer segments 12 in relation to the unfolded case. In practice, however, the side walls 2-5 are folded up before these are put into place.

[0042] As an alternative to or in addition to the snap fit connection of the corner components 10 an adhesive may be used to hold these in place.

[0043] Cases are generally required to provide the best impact resistance in the corner regions. Thus, the use of separate corner portions 10 can be advantageous as it allows different materials or structures to be used in these corner regions. Although the corner portions have a greater depth than the main 3D printed portion shown in FIG. 1, they can be produced relatively quickly because they are much smaller components such that the layers can be built up more quickly.