Methods and apparatus for a rugged mobile device housing

Abstract

A rugged mobile device housing is provided for protecting a component (e.g., a liquid crystal display, a keyboard, a printed circuit board, or the like) and includes one or more first structures comprising a first material provided in a region of the housing capable of withstanding deflection, wherein the first material is an elastomer, and one or more second structures bonded to the first structure, wherein the second structure is a high-stiffness plastic. In one embodiment, the first material is a high-stiffness elastomer and the second material is a long glass fiber filled thermoplastic (“LGF” plastic). In one embodiment, the first structure is located at a corner of the housing and the second structure is located in the middle of the housing. In another embodiment, the first structure is located in the center of the housing and the second structures are located at the ends. In yet another embodiment, a projecting handle and hinge are provided, where the first structure is located at the handle and the second structure is located at the hinge.

1 . A housing for protecting a component in a mobile device, said housing comprising: 
 a first structure comprising a first material, wherein said first material is an elastomer;    a second structure comprising a second material and bonded to said first structure, wherein said second material is a high-stiffness plastic, and wherein the component is secured to said second structure.    
   
   
       2 . The housing of  claim 1 , wherein said second structure is bonded to said first structure via a chemical bond.  
   
   
       3 . The housing of  claim 1 , wherein said high-stiffness plastic comprises a long glass fiber filled thermoplastic.  
   
   
       4 . The housing of  claim 1 , wherein said first material comprises a thermoplastic elastomer.  
   
   
       5 . The housing of  claim 1 , wherein said first material has a room temperature flexural modulus that is greater than approximately 20 MPa.  
   
   
       6 . The housing of  claim 1 , wherein said second material has a room temperature flexural modulus that is greater than approximately 7 GPa.  
   
   
       7 . The housing of  claim 1 , wherein said second material has an room temperature notched Izod impact resistance that is greater than approximately 350 J/m.  
   
   
       8 . The housing of  claim 1 , wherein said first structure is located at a corner of the housing.  
   
   
       9 . The housing of  claim 8 , wherein said first structure is located at all corners of said housing.  
   
   
       10 . The housing of  claim 1 , wherein the housing has a first end, a center, and a second end; wherein said first structure is located at said first end and said second end; and wherein said second structure is located at said center.  
   
   
       11 . The housing of  claim 1 , wherein the housing has a projecting handle, a main body, and a hinge, wherein said first structure is located at said handle and said main body, and wherein said second structure is located at said hinge.  
   
   
       12 . The housing of  claim 1 , wherein said component is selected from the group consisting of a liquid crystal display, a keyboard, and a printed circuit board.  
   
   
       13 . The housing of  claim 1 , wherein said first structure is located in a region of the housing capable of tolerating deflection, and wherein said second structure is located in a region of the housing not capable of tolerating deflection.  
   
   
       14 . A method for forming a rugged mobile device housing for protecting a component, said method comprising the steps of: 
 identifying a first region of the mobile device housing capable of tolerating deflection;    identifying a second region of the mobile device housing not capable of tolerating deflection;    forming, using an elastomer, a first structure of a first material in said first region;    forming, using a high-stiffness plastic, a second structure of a second material in said second region;    securing the component to the second structure.    
   
   
       15 . The method of  claim 14 , wherein said high-stiffness plastic comprises a long glass fiber filled thermoplastic.  
   
   
       16 . The method of  claim 14 , wherein said first material comprises a thermoplastic elastomer.  
   
   
       17 . The method of  claim 14 , wherein said first material has a room temperature flexural modulus that is greater than approximately 20 MPa.  
   
   
       18 . The method of  claim 14 , wherein said second material has a room temperature flexural modulus that is greater than approximately 7 GPa.  
   
   
       19 . The method of  claim 14 , wherein said second material has a room temperature notched Izod impact resistance that is greater than approximately 350 J/m.  
   
   
       20 . A rugged mobile device comprising: 
 a housing, said housing comprising: 
 a first structure comprising a first material, wherein said first material is a high-stiffness elastomer, and wherein said first structure is located in a region of said housing capable of withstanding deflection;  
 a second structure comprising a second material and bonded to said first structure, wherein said second material is a long glass fiber filled thermoplastic, and  
   a liquid crystal display secured to said second structure.    
   
   
       21 . The mobile device of  claim 20 , wherein said housing includes a plurality of corners, wherein said first structure corresponds to said corners of said housing, and said second structure corresponds to the center of said housing.  
   
   
       22 . The mobile device of  claim 20 , wherein the first structure corresponds to the center of the housing, and the second structure corresponds to a first and second end of said housing.