Mobile Device Case with Bonded Elastomeric Shell and Frame
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Solution Overview
Problem
Current mobile device cases that provide shock absorption and wear resistance often increase in thickness and weight, making them less portable and more costly, and are limited by the compatibility of materials used for overmolding.
Innovation Solution
A mobile device case design featuring a frame and an elastomeric shell with specific geometrical features such as outer projections and troughs, and inner projections, which allows for improved shock absorption without the need for overmolding, enabling the use of incompatible materials and reducing overall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more material is used to improve impact protection, then shock absorption is improved, but case thickness and weight increase
Solution Approach 1:
The case is divided into two separate components: a rigid frame and a flexible elastomeric shell. This segmentation allows each component to be optimized independently for its specific function (rigid structural support vs. flexible shock absorption) without requiring excessive material in either component, thereby providing impact protection while controlling weight.
Solution Approach 2:
The case combines two different materials with complementary properties: a rigid material (such as polycarbonate or aluminum) for the frame providing structural strength, and a flexible elastomeric material for the shell providing shock absorption. This composite approach achieves superior impact protection compared to using a single material, while avoiding the weight penalty of over-engineering with excessive material.
2Reliability
If more material is used to improve impact protection, then shock absorption is improved, but case thickness increases
Solution Approach 1:
By segmenting the case into frame and shell components, each can be designed with optimal thickness for its function. The rigid frame provides structural integrity with minimal thickness, while the elastomeric shell provides shock absorption with a thin compliant layer, achieving impact protection without excessive overall thickness.
Solution Approach 2:
The elastomeric shell acts as a thin flexible protective layer that absorbs impact energy through deformation rather than requiring thick rigid material. This flexible shell approach provides effective shock absorption while maintaining a sleek, thin profile.
3Reliability
If overmolding is used to combine rigid frame and flexible shell, then shock protection is improved, but material compatibility is limited
Solution Approach 1:
Separating the rigid frame and flexible shell into distinct components eliminates the overmolding process entirely. This allows any rigid material to be paired with any elastomeric material without compatibility constraints, as the components are attached through alternative methods such as adhesives, mechanical interlocks, or snap-fits rather than requiring compatible overmolding materials.
Solution Approach 2:
An adhesive or mechanical attachment method serves as an intermediary between the rigid frame and flexible shell, enabling the combination of materials that would be incompatible for overmolding. This intermediary connection method provides flexibility in material selection while maintaining effective shock protection.
4Reliability
If overmolding is used to combine rigid frame and flexible shell, then shock protection is improved, but case cost increases
Solution Approach 1:
By manufacturing the rigid frame and flexible shell as separate components, each can be produced using optimized, cost-effective processes for its specific material and function. This avoids the complexity and tooling costs of overmolding processes, while allowing independent sourcing and manufacturing of each component, potentially reducing overall case cost.
Solution Approach 2:
The rigid frame and flexible shell are manufactured separately in advance using independent, optimized processes, then assembled. This preliminary separation allows each component to be produced more efficiently without the constraints of overmolding, reducing manufacturing complexity and cost while maintaining effective shock protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides enhanced shock absorption and customization in rigidity/flexibility while maintaining portability and reducing costs by allowing the use of diverse materials, ensuring effective impact protection without excessive bulk.
Implementation Method 1
an adhesive that may be disposed between the first rigid layer and the second rigid layer and that bonds the first rigid layer and the second rigid layer together
Implementation Method 2
mobile device cases, such as mobile phones, tablets, and mobile computers, e.g., laptop computers, have been designed to provide at least some protection from impact events
Implementation Method 3
The elastomeric shell may be received in or may be configured for receipt in the frame recess and may be surrounded by or configured to be surrounded by the frame
Data Source
AI summary
A case for a mobile device includes a frame and an elastomeric shell. The elastomeric shell is received in the frame and has an outer surface, an inner surface opposite the outer surface and configured for receiving the mobile device, and a rim extending between the outer surface and the inner surface. The inner surface forms inner projections each having an inner extremity extending toward an inside of the elastomeric shell and each being configured for contact with the mobile device when arranged in the inner surface. The outer surface forms outer projections defining respective outer projection extremities and forms outer troughs extending between the outer projections and defining outer trough extremities. The outer projections extend toward a frame inner perimeter of the frame such that each of the outer trough extremities is spaced further from the frame than adjacent ones of the outer projection extremities.