Abstract
A cover for forming a watertight enclosure enclosing an electronic device having a display includes: (a) a first member comprising: (i) a protective membrane operable to transmit touchscreen-type user input to the display; and (ii) a sealing mount attached to the protective member, the sealing mount defining a registration profile extending along the entire perimeter of the protective membrane, the sealing mount defining a stanchion projecting parallel and spaced-apart from the registration profile; and (b) a second member comprising: (iii) a rigid plastic frame; and (iv) a shell over-molded to the frame, the shell being made of a soft and elastomeric material and defining a compression profile extending along the entire perimeter of the shell, the shell at its compression profile being dimensioned for interlocking with the sealing mount at its registration profile so as to removably form a watertight seal between the first and second members.
Claims
1. A cover for forming a watertight enclosure enclosing an electronic device having a display, the cover comprising: (a) a first member comprising: (i) a protective membrane operable to transmit touchscreen-type user input to the display; and (ii) a sealing mount attached to said protective member, said sealing mount defining a registration profile extending along the entire perimeter of said protective membrane, said sealing mount defining a stanchion projecting parallel and spaced-apart from said registration profile; and (b) a second member comprising: (iii) a second-member frame made of a rigid plastic material; and (iv) a shell over-molded to said second-member frame, said shell being made of a soft and elastomeric material, said shell defining a compression profile extending along the entire perimeter of said shell, said shell at said compression profile being dimensioned for interlocking with said sealing mount at said registration profile so as to removably form a watertight seal between said first and second members.
2. The cover of claim 1 wherein said protective membrane is made of a material selected from the group consisting of: glass, and plastic.
3. The cover of claim 2 wherein said registration profile comprises a core made of rigid plastic and an overlay portion made of silicone, said overlay portion being overmolded to said core, said core and said stanchion being integral to each other.
4. The cover of claim 2 wherein said sealing mount is made solely of silicone.
5. The cover of claim 4 wherein said sealing mount is thermally and chemically bonded to said protective membrane.
6. The cover of claim 1 wherein said first member comprises a first acoustic membrane attached to said protective membrane at a border region of said protective membrane, said first acoustic membrane comprising: (i) an annular foam gasket, and (ii) a membrane member disposed adjacent to said annular foam gasket, and wherein said first acoustic membrane is operable to isolate sound and is dimensioned for alignment with an earpiece speaker of the electronic device, said gasket being operable to guide sound therethrough, said membrane member being selected from the group consisting of a waterproof member and a hydrophobic member.
7. The cover of claim 6 wherein said second member comprises a second acoustic membrane attached to said shell, said second acoustic membrane being operable to isolate sound, said second acoustic membrane comprising a second waterproof membrane member and at least one annular wall projecting from said second waterproof membrane member, said at least one annular wall being operable to guide sound therethrough, and wherein said second acoustic membrane is dimensioned for alignment with a mouthpiece microphone of the electronic device.
8. The cover of claim 7 wherein at least one of said first member and said second member comprises a third acoustic membrane being operable to isolate sound, said third acoustic membrane comprising a third waterproof membrane member and at least one annular wall projecting from said third waterproof membrane member, said at least one annular wall being operable to guide sound therethrough, and wherein said third acoustic membrane is dimensioned for alignment with an auxiliary microphone of the electronic device.
9. The cover of claim 8 wherein said second member defines a sound-isolation chamber dimensioned for placement into fluid communication with a speakerphone-mode speaker of the electronic device, said sound-isolation chamber being dimensioned to isolate sound emitted from said speakerphone-mode speaker and transmit said sound from the speakerphone-mode speaker into an acoustic chamber defined by the cover, said acoustic chamber extending between a rear side of the electronic device and at least one of said first member and said second member when the watertight enclosure is formed.
10. The cover of claim 1 wherein said second-member frame is translucent.
11. The cover of claim 10 wherein said second-member frame comprises a camera-flash frame, said camera-flash frame comprising a partition for acoustically isolating an auxiliary-microphone portion of said camera-flash frame from an acoustic chamber defined by the cover, said partition being over-molded to said second-member frame.
12. The cover of claim 11 wherein said second-member frame contiguously defines a first lens dimensioned for alignment with a rear-facing camera of the electronic device and contiguously defines a second lens dimensioned for alignment with a rear-facing flash of the electronic device, said camera-flash frame encasing said first and second lenses, said first and second lenses being operable to protect the rear-facing camera and the rear-facing flash.
13. The cover of claim 12 wherein said partition of the camera-flash frame is thermally and chemically bonded to said second-member frame.
14. The cover of claim 1 wherein said second member further comprises a rigid plastic cap attached to said shell such that an exterior portion of said rigid plastic cap protrudes outwardly from said shell and an interior portion of said rigid plastic cap engages a toggle switch of the electronic device when the watertight enclosure is formed.
15. The cover of claim 14 wherein said rigid plastic cap is thermally and chemically bonded to said shell.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings and wherein:
(2) FIG. 1a is a front perspective view of a cover according to a first embodiment of the invention, showing a front portion of the cover connected to a back portion of the cover to form a waterproof enclosure for an electronic device;
(3) FIG. 1b is a rear perspective view of the cover shown in FIG. 1a, showing the back portion connected to the front portion to form the waterproof enclosure;
(4) FIG. 2a is a perspective view of the front portion shown in FIG. 1a, showing a protective membrane, a border on the protective membrane, a sealing mount, a sound isolating, acoustic membrane for the earpiece speaker, and a waterproof membrane for over the electronic device's home button;
(5) FIG. 2b is a perspective view of an alternate configuration of the front portion, showing the protective membrane having a silkscreen-made border at the top and bottom perimeter of the protective membrane, a sealing mount, a sound isolating, acoustic membrane for the earpiece speaker, and a waterproof membrane for over the home electronic device's button;
(6) FIG. 2c is an exploded view of the sound isolating, acoustic membrane shown in FIGS. 2a and 2b, showing a perforated metal screen, hydrophobic material and a foam gasket;
(7) FIG. 2d is an exploded view of the reverse side of the front portion shown in FIGS. 2a and 2b, showing the sound isolating, acoustic membrane and the waterproof membrane for over the home electronic device's button;
(8) FIG. 2e provides a partial view of the front portion shown in FIGS. 2a and 2b, showing a registration profile of the compression seal in the sealing mount;
(9) FIG. 2f provides a cross-sectional view of the front portion shown in FIGS. 2a and 2b, showing the protective membrane, the registration profile and a stanchion on the perimeter of the sealing mount;
(10) FIG. 2g is a perspective view of the removable transparent film overlay on the silicone substrate applied to the reverse side of the protective membrane;
(11) FIG. 2h is a perspective view of the reverse side of the front portion absent the removable transparent film overlay, showing the plastic border, a transparent film dimensioned to be adhesively applied to the reverse side of the plastic border, the relationship between the transparent film and the plastic border being shown in exploded view, and the waterproof membrane for over the home electronic device's button;
(12) FIG. 2i is a perspective view of an alternate configuration of the front portion absent the removable transparent film overlay, showing the protective membrane having a silkscreen-made border at the top perimeter of the protective membrane, a hydrophobic or waterproof, acoustic membrane for the earpiece speaker, and a waterproof membrane for over the home electronic device's button;
(13) FIG. 3a is an exploded perspective view of the back portion shown in FIG. 1b, showing a hard, translucent plastic frame, a soft, elastomeric shell having a power toggle switch enclosure that is molded into the soft, elastomeric shell, and lenses for camera and flash apertures that are integrated with the translucent frame;
(14) FIG. 3b is a cross-sectional view of the back portion shown in FIG. 1b, showing the hard, translucent plastic frame over-molded with the soft plastic shell;
(15) FIG. 3c is a perspective view of the back portion shown in FIG. 1b, showing a hard plastic cap for the ring/silent toggle switch, volume switch enclosures, lanyard receptacle and respective seals in closed positions for the headphone jack port and charging port of the electronic device;
(16) FIG. 3d is a cross-sectional view of the back portion of FIG. 1b, showing the hard plastic cap for the ring/silent toggle switch protruding through the soft shell;
(17) FIG. 3e provides a perspective view of the back portion shown in FIG. 1b, showing the inner side of the back portion having a compression profile of the compression seal in the soft shell, the sound-isolation chamber for bottom speakerphone-mode speaker, the sound isolating, acoustic membrane for the mouthpiece microphone and the annular seal for headphone jack aperture;
(18) FIG. 3f is an exploded perspective view of the front and back portions shown in FIGS. 1a and 1b, showing the seals for the headphone jack port and charging port of the electronic device;
(19) FIG. 3g is an exploded perspective view of the sound isolating, acoustic membrane employed in the back portion shown in FIG. 3e, showing a flanged silicone membrane and a perforated metal screen;
(20) FIG. 4a is an exploded partial view of the back portion shown in FIG. 1b, showing a flash frame having a partition for the camera and flash apertures and a sound isolating, acoustic membrane on the partition of the frame consisting of a perforated metal screen and a flanged silicone membrane;
(21) FIG. 4b is a partial view of the back portion shown in FIG. 1b, showing the outer side of the back portion and showing a flash frame and lenses covering the rear-facing camera and rear-facing flash apertures for a rear-facing camera and flash of the electronic device;
(22) FIG. 4c is a partial view of the back portion shown in FIG. 1b, showing the inner side of the back portion and showing lenses for the rear-facing camera and flash of the electronic device, the partition in the camera frame and the flanged silicone membrane covering the aperture in the partition for the electronic device's auxiliary microphone;
(23) FIG. 5a is a front perspective view of a cover according to a second embodiment of the invention, showing a top portion connected to an end-cap to form a waterproof enclosure for the electronic device, the cover having a protective membrane with a waterproof membrane for covering the electronic device's home button and molded enclosures for the silent/ring toggle switch and volume control buttons;
(24) FIG. 5b is a rear perspective view of the cover shown in FIG. 5a, showing the end-cap connected to the top portion to form the waterproof enclosure, the cover having a hard plastic, translucent frame that is over-molded by a soft, elastomeric shell, a molded enclosure for the power toggle button and a camera-flash frame with lenses for covering the electronic device's camera and flash;
(25) FIG. 6a is a perspective view of the top portion and end-cap shown in FIG. 5a, showing the end-cap disconnected from the top portion, in which the top portion has a sealing mount with a female profile for a compression seal molded into the hard plastic frame and a locking mechanism compression release molded into the soft shell, the end-cap has a male profile for a compression seal and registration latches for the locking mechanism, and respective seals for the headphone jack port and charging port of the electronic device are in closed positions;
(26) FIG. 6b is a perspective exploded view of the top portion shown in FIG. 5a, showing a thin, ellipsoidal convexity molded into the protective membrane for being situated over the electronic device's earpiece speaker, enclosures for the electronic device's ring/silent toggle and volume switches molded into the soft shell and a home-button membrane;
(27) FIG. 6c is an exploded view of the top portion shown in FIG. 5a, showing a protective membrane, a hard plastic frame forming a congruous sealing mount with receptacles for a compression locking mechanism and integrated lenses for camera and flash apertures, and a soft shell;
(28) FIG. 6d is a cross-sectional view of the top portion shown in FIG. 6a, showing the protective membrane and the hard, translucent plastic frame over-molded with the soft plastic shell;
(29) FIG. 6e is a cross-sectional view of a cut-out of the top portion shown in FIG. 6a, showing a hard plastic cap protruding through the shell to form an enclosure for the electronic device's ring/silent toggle switch;
(30) FIG. 7a is a front perspective view of the cover shown in FIG. 5a, showing the respective seals for the headphone, jack port and charging port of the electronic device that are in the end-cap in their opened positions;
(31) FIG. 7b is a perspective and exploded view of the end-cap shown in FIG. 6a, showing a hard plastic outer member having male profile registration seals and latches, which over-molds and encases a soft, elastomeric inner member having a sound-isolation chamber for the bottom speaker, an annular seal for a headphone jack aperture and a sound isolating, acoustic membrane consisting of a flanged silicone membrane and a perforated metal screen;
(32) FIG. 8a is a partial view of the top portion shown in FIG. 5b, showing an outer side of the top portion and showing a camera frame for the rear-facing camera and flash of the electronic device;
(33) FIG. 8b is a partial view of the top portion shown in FIG. 5b, showing an inner side of the top portion and showing a partition of the camera frame; and
(34) FIG. 8c provides a perspective view of the top portion shown in FIG. 5b, showing an exploded view of a sound isolating, acoustic membrane for the auxiliary microphone of the electronic device, the sound isolating, acoustic membrane being located in the center of the partition in the camera-flash frame and consisting of a flanged silicone membrane and a perforated metal screen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
(35) The first and preferred embodiment of an electronic device cover is shown in FIGS. 1a to 4c. The embodiment of the electronic device cover shown in the drawings corresponds to a specific personal digital device (not shown in any of the drawing figures), however it is understood that the actual positioning and availability of the features of the cover further described below can be customized for any electronic device (not shown).
(36) Referring to FIGS. 1a and 1b, the cover 1 comprises a front portion 2 and a back portion 10 having a back, sides, and an open front through which an electronic device (not shown) can be inserted into the cover 1 prior to connectively sealing the front portion 2 to the back portion 10 to create a waterproof enclosure encasing the electronic device.
(37) Referring to FIG. 2a, the front portion 2 comprises a protective membrane 3 with a plastic border 4 attached to a hard plastic and silicone sealing mount 8, a sound isolating, acoustic membrane 7 for the electronic device's earpiece speaker (not shown), and a waterproof membrane 25 for covering the electronic device's home button (not shown). The protective membrane 3 is positioned so as to correspond to the position of the screen of the electronic device (not shown) to be placed in the cover 1. The protective membrane 3 is adapted to allow viewing of the electronic device's screen (not shown), and use thereof in the case of touch screens. The inner perimeter of the sealing mount 8, which frames the outer perimeter of the protective membrane 3, is angled at 45° to maximize the contact area on the electronic device's touch-screen display (not shown).
(38) FIG. 2b is an alternative embodiment of the front portion 2 whereby the border 4 on the protective membrane 3 is silkscreened and the sealing mount 8 is manufactured from only silicone. The sealing mount 8 is chemically and thermally adhered to the protective membrane 3 during the manufacturing process.
(39) Referring to FIGS. 2a, 2c and 2d, the protective membrane 3 incorporates a sound isolating, acoustic membrane 7 extending across the earpiece-speaker aperture of the front portion 2. The sound isolating, acoustic membrane 7 comprises a three-layer composition of perforated metal screen 7a, hydrophobic material 7b and a foam gasket 7c, which is then adhesively attached to the protective membrane 3. The gasketed, acoustic membrane 7 guides and maximizes the transmission of sound emitted from the speaker (not shown) through the cover 1. Some embodiments do not include the perforated metal screen 7a. The plastic border 4 on the protective membrane 3 features apertures for the earpiece speaker (not shown), forward-facing camera lens (not shown), sensors (not shown) and the home button (not shown) of the electronic device.
(40) Referring again to FIG. 2d, the home button (not shown) on the electronic device is designed so that it scans, reads and recognizes fingerprints but it also relies on bio-electromagnets (electromagnetic fields produced by living cells, tissues or organisms). The cover 1 provides an ultra-thin, waterproof, tear-resistant home-button membrane 25 conducive to “fingerprint recognition” or digital authentication technology. In the first embodiment, the home-button membrane 25 allows for fingerprint recognition by the electronic device (not shown) via the electronic device's home button through the home-button membrane 25. The home-button membrane 25 is adhesively attached to the interior side of the plastic border 4 and has been embossed to form-fit to the curvature or concavity of the home button (not shown).
(41) FIG. 2e depicts the registration profile 9 of the compression seal located on the reverse or interior side of the front portion 2.
(42) Referring to FIG. 2f, the protective membrane 3 is adhered to the sealing mount 8. The registration profile 9 on the sealing mount 8, which encompasses the perimeter of the sealing mount 8, is manufactured from hard plastic that has been over-molded with silicone and has been fully integrated with the hard plastic core of the registration profile 9 during the molding process. The sealing mount 8 further incorporates a stanchion 14 around the perimeter of the sealing mount 8. The stanchion 14 inhibits the sealing mount 8 from distorting or bending, thereby protecting the integrity of the protective membrane 3 and preventing the sealing mount 8 from dislodging from the soft plastic shell 12 during an impact. Alternatively, as depicted in FIG. 2b the entire sealing mount 8, registration profile 9 and stanchion 14 may be manufactured entirely of silicone and may be fully integrated with the protective membrane 3 during the molding process.
(43) Referring to FIG. 2g, the front portion 2 includes a silicone substrate applied to the inside surface of the protective membrane 3. The silicone substrate allows the protective membrane 3 to chemically adhere to the electronic device's screen (not shown). The front portion 2 includes a transparent film 6 applied over the silicon substrate on the inner side of the protective membrane 3. The transparent film 6 prevents the protective membrane 3 from adhering to the electronic device's screen, thereby allowing the front portion 2 to be easily removed from the electronic device (not shown). Thus, a user may decide to not remove the transparent film 6 before enclosing the electronic device by the cover 1 such that the cover 1 removably encloses the electronic device, or the user may decide to remove the transparent film 6 before enclosing the electronic device by the cover 1 such that the cover 1 more securely encloses the electronic device (not shown).
(44) As can be seen in FIG. 2h, the plastic border 4 includes a separate, transparent film 5 adhesively applied to the inward-facing side of the plastic border 4 to protect the forward-facing camera lens and sensors without inhibiting functionality of the forward-facing camera and sensors. The transparent film 5 covers apertures in the front portion 2 related to the forward-facing camera lens and sensors. The home-button membrane 25 is adhesively attached to the interior side of the plastic border 4 and has been embossed to form-fit to the curvature or concavity of the home button (not shown).
(45) FIG. 2i is an alternate embodiment of the front portion 2 (FIGS. 2b and 2h), seen from its reverse side, whereby the border 4 on the protective membrane 3 is silkscreened and the acoustic membrane 7 for the electronic device's earpiece speaker (not shown) is a single layer hydrophobic or waterproof membrane 7b.
(46) Referring to FIGS. 1b and 3a to 3g, the back portion 10 of the cover 1 comprises a hard translucent frame 11 that is over-molded with a soft durometer shell 12. The shell 12 typically has a durometer in the range of 60 Shore A to 90 Shore A, such that the shell 12 is soft relative to the translucent frame 11. The translucent frame 11 contains cut-outs that provide access to the protrusions and contours of the shell 12. The protrusions and contours of the soft shell 12 correspond to the positions of the electronic device's features and peripheral controls. The soft shell 12 includes a power toggle switch enclosure 12a, volume switches enclosures 12b and ring/silent toggle switch cap 15.
(47) FIG. 3a depicts the lenses 22, for the rear facing camera and flash apertures, which are integrated with the translucent frame 11.
(48) FIG. 3b shows by cross-sectional view the frame 11 over-molded by the soft shell 12.
(49) Referring to FIG. 3c, a seal 19 on the outer side of the back portion 10 closes the headphone-jack aperture of the frame 11 with a waterproof seal when a headphone jack (not shown) is not in use. Similarly, seal 20 is operable to close a charging-port aperture of the frame 11 corresponding to the charging port (not shown) of the electronic device. Seals 19 and 20 are hingedly connected to the frame 11 and both are shown in the closed position. The shell 12 also features a molded receptacle 12c for a removable lanyard.
(50) Referring to FIG. 3d, the shell 12 incorporates a hard plastic cap 15 that is contoured to fit over the electronic device's ring/silent toggle switch (not shown), thereby allowing the switch to be toggled by means of leveraged actuation. The cap 15 is partially over-molded by the shell 12 so that the cap 15 partially protrudes through the shell 12. The toggle switch cap 15 is thermally and chemically incorporated to the soft shell 12 during the injection molding process. The outward protrusion of the cap 15 advantageously facilitates toggling of the electronic device's ring/silent toggle switch by providing a mechanical advantage to reduce the extent of finger pressure required to toggle the electronic device's ring/silent toggle switch (not shown).
(51) Referring again to FIG. 3e, a sound-isolation chamber 17 insulates the speakerphone-mode speaker (not shown) of the electronic device and is fully incorporated into the frame 11 of the back portion 10. The sound-isolation chamber 17 isolates sound emitted from the electronic device's speakerphone-mode speaker and transmits it from the speaker into the acoustic chamber space of the cover 1. When the electronic device is being encased by the cover 1, the acoustic chamber in the first embodiment extends between the rear side of the electronic device and an inner side of the back portion 10. The acoustic chamber advantageously facilitates the emission of sound from the electronic device's speakerphone-mode speaker via acoustic resonance in the back portion 10. The soft shell 12 at its inner side incorporates a molded annular seal 16 for the headphone-jack aperture to create a watertight seal when a headphone jack (not shown) is inserted through the headphone-jack aperture and a sound isolating, acoustic membrane situated over the electronic device's bottommost microphone (not shown).
(52) Referring again to FIGS. 2e, 2f and 3e the front portion 2 connectively seals into the back portion 10 by an interlocking of the registration profile 9 of the sealing mount 8 and the compression profile 13 of the soft shell 12, to complete a waterproof seal. The registration profile 9 and the compression profile 13 preferably form reciprocal profiles.
(53) Referring to FIG. 3f, the soft plastic headphone-jack seal 19 and the charger-port seal 20 of the back portion 10 are connected to the frame 11 by means of compression sealing and have several annular convex profiles to create a watertight seal with the shell 12 when inserted into their corresponding apertures.
(54) Referring to FIGS. 3e and 3g, a sound isolating, acoustic membrane 18 covers the bottommost microphone aperture of the cover 1 corresponding to the electronic device's mouthpiece microphone (not shown). The sound isolating, acoustic membrane 18 includes a perforated metal screen 18a and a waterproof seal 18b having an annular flange. The screen 18a serves to reinforce the seal 18b. The membrane 18 isolates incoming sound, directing it into the electronic device's mouthpiece microphone and preventing the incoming sound from reverberating inside the cover 1. The sound isolating, acoustic membrane 18 is preferably dimensioned to fit over or into the mouthpiece-microphone aperture of the bottom region of the back portion 10.
(55) Referring to FIGS. 4a to 4c, the cover 1 comprises a fully integrated camera frame 21 for the rear-facing camera (not shown) and flash (not shown) of the electronic device (not shown). The camera frame 21 is thermally and chemically bonded to the hard, translucent frame 11 during the injection molding process. The camera-flash frame 21 can be manufactured by over-molding the camera frame 21 to the translucent frame 11. The camera-flash frame 21 encases the lenses 22, which are dimensioned to protect the rear-facing camera and the flash of the electronic device. The lenses 22 are contiguous with the translucent frame 11. The perimeter of the lens and flash apertures of the camera-flash frame 21 are angled at 45° to augment the passage of light through the camera frame 21. The camera-flash frame 21 incorporates a partition 23 between the camera lens and flash apertures to diffuse reflection and prevent glare from the flash on the rear-facing camera lens. A waterproof, sound isolating, acoustic membrane 24 is adhered over an aperture in the partition 23 of the camera-flash frame 21. The waterproof, sound isolating, acoustic membrane 24 includes a perforated metal screen 24a and a waterproof seal 24b having an annular flange. The screen 24a serves to reinforce the seal 24b. The seal 24b includes a membrane, which may be a silicone membrane, extending across the annular region of the annular flange. The sound isolating, acoustic membrane 24 is operable to permit the transmission of sound therethrough while maintaining water-tightness of the cover 1. The partition 23 aligns with the auxiliary microphone of the electronic device that is located between the rear-facing camera lens and the flash lens of the electronic device. The sound isolating, acoustic membrane 24 and the partition 23 together isolate incoming sound, directing it into the auxiliary microphone (not shown) and preventing the incoming sound from reverberating inside the cover 1.
(56) Referring to FIGS. 1a to 4c, each of the hard, translucent plastic frame 11, soft shell 12, protective membrane 3 with plastic border 4, and the camera frame 21 are form-fitted to correspond to the particular electronic device (not shown) for which it is designed, including the configurations of the electronic device's peripheral controls, apertures, sensors, forward-facing and rear-facing cameras and screen. For example, the electronic device typically has a ring/silent toggle switch, volume controls, an earpiece speaker, a microphone, a home button, a speakerphone-mode speaker, a forward-facing camera lens, a rear-facing camera lens, a flash lens, an auxiliary microphone and a power button. In order to allow proper functioning of these electronic-device features, the cover 1 has respective areas and cover 1 features corresponding to these features of the electronic device (not shown).
(57) FIGS. 5a to 8c show a cover 26 in accordance with a second embodiment of the invention.
(58) Referring to FIGS. 5a and 5b, the cover 26 has a bottom portion or “end-cap” 36 and a top portion 27. The top portion 27 has sides and an open bottom through which an electronic device can be inserted into the top portion 27 prior to connectively sealing the top portion 27 and the end-cap 36 together to create a waterproof enclosure by the cover 26.
(59) The top portion 27 comprises a protective membrane 31 attached to a hard plastic translucent frame 28 that is over-molded with a soft elastomeric shell 29. The shell 29 typically has a durometer in the range of 60 Shore A to 90 Shore A, such that the shell 29 is soft relative to the translucent frame 28. The protective membrane 31 is positioned so as to correspond to the position of the screen (not shown) of the electronic device to be placed in the cover 26. During manufacturing, the frame 28 and the soft shell 29 are thermally and chemically fused together. The translucent frame 28 contains apertures and cut-outs that provide access to the protrusions and contours of the shell 29. The protrusions and contours of the shell 29 correspond to the positions of the electronic device's apertures and peripheral controls (not shown). In the first embodiment, the shell 29 includes a power toggle switch enclosure 29a, volume switches enclosures 29b, and ring/silent toggle switch cap 30, lenses 46 covering the rear-facing camera and rear-facing flash apertures and a waterproof membrane 49 for covering the electronic device's home button (not shown).
(60) Referring to FIG. 6a, a sealing mount 33 is contiguous with and forms part of the frame 28. The inner perimeter of the plastic frame 28 that borders the protective membrane 31 is angled at 45° to maximize the contact area on the electronic device's touch-screen display (not shown). The hard plastic end-cap 36 connectively seals into the sealing mount 33 with a combination of reciprocal registration and compression profiles to complete a waterproof seal. The registration profile 37 encompasses the perimeter of the end-cap 36 and may be manufactured entirely in silicone and be fully integrated to the hard plastic outer member 36a (FIG. 7b described herein below) of the end-cap 36 during the molding process. The end-cap 36 further features a locking mechanism comprised of two male, registration latches 38. The sealing mount 33 in the second embodiment is over-molded with reciprocal, female receptacles 35 that correspond to the position of the registration latches 38 on the end-cap 36. The soft shell 29 features molded compression releases 39 that correspond to the position of the locking mechanism receptacles 35 in the sealing mount 33. When the end-cap 36 is connected to the top portion 27 at its sealing mount 33 by insertion into the open end of the top portion 27 of the cover 26, the registration latches 38 and receptacles 35 lock inter-connectedly. The registration latches 38 and receptacles 35 can be releasably unlocked by compression through the molded compression releases 39 in the soft shell 29. A seal 43 on the outer side of the end-cap 36 closes the headphone-jack aperture with a waterproof seal when the headphone jack (not shown) is not in use. The seal 43 may be similar or analogous to the seal 19 of the first embodiment. Also, the seal 44 for the electronic device's charging port (not shown) may be similar or analogous to the seal 20 of the first embodiment. The seals 43 and 44 are shown in closed positions in FIG. 6a.
(61) Referring to FIG. 6b, the protective membrane 31 features a thin, ellipsoidal convexity 32 (i.e. convex protrusion) dimensioned for being situated over the electronic device's earpiece speaker (not shown) to form an acoustic membrane for the earpiece speaker. The protective membrane 31 features an aperture dimensioned for being situated over the electronic device's home button (not shown). The home button on the electronic device is designed so that it scans, reads and recognizes fingerprints but it also relies on bio-electromagnets (electromagnetic fields produced by living cells, tissues or organisms). The cover 26 provides an ultra-thin, waterproof, tear-resistant home-button membrane 49 conducive to “fingerprint recognition” or digital authentication technology. In the second embodiment, the home-button membrane 49 allows for fingerprint recognition by the electronic device via the electronic device's home button (not shown) through the home-button membrane 49. The home-button membrane 49 is adhesively attached to the interior side of the plastic border region of the plastic frame 28 and has been embossed to form-fit to the curvature or concavity of the electronic device's home button. The home-button membrane 49 may be similar or analogous to the home-button membrane 25 of the first embodiment.
(62) FIG. 6c depicts the protective membrane 31, and the hard plastic, translucent frame 28 that is over-molded with the soft, elastomeric shell 29. The translucent frame 28 integrates lenses 46, for apertures of the shell 29 that are associated with the electronic device's rear facing camera (not shown) and flash (not shown). The frame 28 includes receptacles 35 for its compression locking mechanism.
(63) FIG. 6d depicts the protective membrane 31, and the hard plastic, translucent frame 28 that is over-molded with the soft, elastomeric shell 29.
(64) Referring to FIG. 6e, the shell 29 incorporates a hard plastic cap 30 that is contoured to fit over the electronic device's ring/silent toggle switch (not shown) allowing the switch to be actuated with mechanical advantage. The cap 30 is partially over-molded by the shell 29 so that the cap 30 partially protrudes through the shell 29. The toggle switch cap 30 is thermally and chemically incorporated to the soft shell 29 during the injection molding process. The cap 30 may be similar or analogous to the cap 15 of the first embodiment.
(65) Referring to FIG. 7a, the soft plastic seals 43 and 44 for the headphone-jack and charger-port apertures of the hard plastic outer member 36a are connected to the end-cap 36 by means of compression seals and have several annular convex profiles to create a watertight seal when inserted into end-cap 36 apertures.
(66) Referring to FIG. 7b, the end-cap 36 comprises a soft, elastomeric inner member 36b over-molded with or over-molded into the hard plastic outer member 36a. The soft inner member 36b is disposed on an interior side of the hard plastic outer member 36a. The protrusions and contours in the inner side of the soft inner member 36b correspond to the positions of various features of the electronic device (not shown). The end-cap 36 incorporates a molded annular seal 40 for the electronic device's headphone-jack aperture to create a watertight seal when a headphone jack (not shown) is inserted into the headphone-jack aperture of the end-cap 36. A sound-isolation chamber 41 for the speakerphone-mode speaker (not shown) is fully incorporated into the end-cap 36. The sound-isolation chamber 41 isolates sound emitted from the speakerphone-mode speaker and transmits it from the speakerphone-mode speaker into the acoustic chamber space of the cover 26. The sound-isolation chamber 41 may be similar or analogous to the chamber 17 of the first embodiment. When the electronic device is being encased by the cover 26, the acoustic chamber in the second embodiment extends between the rear side of the electronic device and an inward face of the rear side of the top portion 27. A sound isolating, acoustic membrane 42 covers or fills the mouthpiece-microphone aperture of the hard plastic outer member 36a and may be fully integrated into the end-cap 36 during the molding process. The membrane 42 includes a waterproof seal 42b with an annular flange and a perforated metal screen 42a. The screen 42a serves to reinforce the flanged seal 42b. The membrane 42 isolates incoming sound, directing it into the electronic device's microphone (not shown) and preventing the incoming sound from reverberating inside the cover 26. The membrane 42 may be similar or analogous to the membrane 18 of the first embodiment.
(67) Referring to FIGS. 8a to 8c, the cover 26 comprises a fully integrated camera-flash frame 45 for the rear-facing camera (not shown) and the flash (not shown) of the electronic device. The camera-flash frame 45 is thermally and chemically bonded to the hard, translucent frame 28 in the injection molding process. The camera-flash frame 45 includes a camera lens aperture and a flash lens aperture, which are covered by lenses 46 that are congruous with the translucent frame 28. The perimeter of the lens and flash apertures are angled at 45° to augment the passage of light through the lens and flash apertures. The camera-flash frame 45 incorporates a partition 47 between the camera lens aperture and the flash lens aperture to diffuse reflection and prevent glare from the flash (not shown) on the camera lens. The partition 47 includes an aperture for the electronic device's auxiliary microphone (not shown) located between the camera and flash. The camera-flash frame 45 may be similar or analogous to the camera-flash frame 21 of the first embodiment.
(68) Referring to FIG. 8c, a sound isolating, acoustic membrane 48 is adhered over or into the partition 47 aperture. The sound isolating, acoustic membrane 48 includes a perforated metal screen 48a and a waterproof seal 48b having an annular flange. The screen 48a serves to reinforce the seal 48b. The acoustic membrane 48 isolates incoming sound, directing it into the electronic device's auxiliary microphone (not shown) located between the electronic device's camera and flash lenses (not shown), and preventing the incoming sound from reverberating inside the cover 26. The membrane 48 may be similar or analogous to the membrane 24 of the first embodiment.
(69) Referring to FIGS. 5a to 8c, each of the hard, translucent plastic frame 28, soft shell 29, protective membrane 31, sealing mount 33, and the end-cap 36 are form-fitted to the electronic device (not shown) for which the cover 26 is designed, including the configurations of the electronic device's peripheral controls, apertures, sensors camera and screen. For example, the electronic device has a ring/silent toggle switch, volume controls, an earpiece speaker, a mouthpiece microphone, a home button, a speakerphone-mode speaker, a camera lens, a flash, an auxiliary microphone and a power button. In order to allow proper functioning of these electronic device features, the cover 26 has respective areas and cover 26 features correspond to these features of the electronic device (not shown).
(70) It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.
(71) Materials
(72) The soft shells 12, 29 and/or the covers 1 and/or 26 are preferably manufactured from thermoplastic polyurethane (TPU). It is also contemplated that thermoplastic elastomers (TPE) could be used. The soft shells 12 and/or 29 may also have a soft-touch coating based on polyurethane (PU) materials to create a low gloss, silky-feel surface that is resistant to abrasion and scratching.
(73) The translucent frame 11 and/or 28 are typically made from a hard, translucent polycarbonate (PC). Alternatively, an acrylic or polymethyl methacrylate (PMMA) may be used. The lenses 22 and/or 46, covering the rear facing camera and flash apertures, are preferably created by applying a high gloss polish to the translucent frame 11 and/or 28 molds.
(74) The camera-flash frame 21 and/or 45 and the end-cap outer member 36a are typically made from a hard polycarbonate (PC). Alternatively, acrylic, nylon or a PC and nylon blend may be used.
(75) The sealing mounts 8 and/or 33 may be manufactured from PC and over-molded with silicone, or alternatively may be manufactured entirely of silicone.
(76) The protective membrane 3 is preferably made of tempered glass that is treated with protective ultra-violet (UV) and oleophobic coatings with a silicone substrate applied to one surface that allows the protective membrane 3 to chemically adhere to the electronic device's screen (not shown). The glass membrane includes a transparent film 6 applied over the silicon substrate that may prevent the protective membrane 3 from adhering to the electronic device's screen if the transparent film is not removed. The profiles of the protective membranes 3 and/or 31 are cut from glass on a computer numerical control (CNC) machine. The glass profiles are then tempered. The protective membrane 3 and/or 31 may or may not include an edging or border, such as the border 4 or similar, around the outer perimeter of the protective membrane 3 and/or 31. A hard PC or silicone frame, such as the sealing mount 8 and/or 33 is then attached to the perimeter of the protective membrane 3 and/or 31.
(77) It is also contemplated that other materials may be used for the protective membrane 3 and/or 31. For example, a polycarbonate (PC) film, acrylic or polyethylene terephthalate (PET or PETE) film or polyethylene terephthalate glycol (PETG) film or a polyester sheet such as Mylar® could be used to form the protective membranes 3 and/or 31. An example of a suitable PC film is that marketed under the trademark LEXAN®. Said films may also be treated with protective ultra-violet (UV) and oleophobic coatings, and such films may or may not have a silicone substrate and transparent film 6 applied to the inner surface to optionally prevent the protective membrane 3 and/or 31 from chemically adhering to the electronic device's screen (not shown).
(78) The acoustic membrane 7, which is situated over the electronic device's earpiece speaker (not shown) when the cover 1 is enclosing the electronic device, is in some embodiments a three-layer composition of hydrophobic material (polymethylene) 7b, perforated aluminum screen 7a, and a PORON® gasket 7c. Alternatively, the hydrophobic material 7b may be replaced with a silicone membrane; the gasket 7c may be manufactured from rubber, silicone or TPU; and the aluminum screen 7a could be comprised of an alternative metal, metal alloy or a hard PC. Alternative embodiments of the acoustic membrane 7 involve a two or three-part composition, whereby either the gasket 7c or the metal screen 7a may not be included.
(79) The borders (e.g. border 4 shown in FIG. 2a) on the protective membranes 3 are typically made from PC. Alternatively, the borders 4 may be made from thin metal plating or be silkscreened onto the protective membranes 3.
(80) The transparent film (e.g. membrane 5 shown in FIG. 2b) attached to the interior of the borders is preferably made from PC.
(81) The sound isolating, acoustic membrane 18 and/or 42 for the mouthpiece-microphone aperture is typically made from silicone and perforated aluminum plating. It is contemplated that the acoustic membranes 18 and/or 42 could be comprised of a hydrophobic material and an alternative metal, metal alloy or a hard PC.
(82) Each of the sound isolating, acoustic membranes 24 and/or 48 for the auxiliary microphone aperture located in the partition 23 and/or 47 of the camera-flash frame 21 and/or 45 typically include a flanged waterproof seal made from silicone and a screen made from perforated aluminum plating. It is contemplated that the acoustic membranes 18 and/or 42 could alternatively be comprised of a hydrophobic material and an alternative metal, metal alloy or a hard PC.
(83) The home-button membrane 25 and/or 49 is made from a Teflon® coated polymethylene and is adhesively attached to the protective membrane 3 and/or 31, respectively. The membrane 25 and/or 49 may be colored and opaque or may be translucent. An example of a suitable adhesive is that manufactured by 3M®.
(84) The soft, elastomeric inner member 36b in the end-cap 36 is typically manufactured from silicone, but TPU, rubber or PORON® may alternatively be used.
(85) The seals for the headphone jack 19 and/or 43 and the charging port 20 and/or 44 are typically manufactured from TPU, but rubber or silicone may alternatively be used.
(86) It will be appreciated by those skilled in the art that various components may be made of different materials, and/or different durometers of materials.
