Protective case for mobile device with reinforcing support member

Abstract

A protective case for a mobile device having a co-molded multi-layered construction having a first layer that generally forms the external back face surface of the case. A second layer generally forms the perimeter bumper of the case. The first layer is comprised of material that has a hardness and/or rigidity that is greater than the second layer. The layers are configured to interact with one another so that they are capable of distributing impact forces to mitigate damage to the mobile device. One or more reinforcing support members in the form of a beam or rod are provided and extend internally and longitudinally near the sides of the case and preferably near the long sides of a rectangular shaped case. The reinforcing support members are formed of even harder or more rigid materials, such as metal alloy or cured fiber reinforced composite rods or beams, relative to the first and second layer and are capable of providing additional support and rigidity to the mobile device to stop or mitigate unintentional or undesired bending of the mobile device.

What is claimed is: 
     
         1 . A method of manufacturing a multi-layered reinforced protective case for a mobile device, said protective case being configured to reversibly attach to the external housing of said mobile device; said method comprising the steps of:
 i) positioning one or more longitudinally extending reinforcing support members into a first mold compartment;   ii) forming a first molded construct by injecting the first mold compartment with a first polymer material around at least portions of the said one or more reinforcing support members positioned in the first mold compartment to form a first shell portion including therein the reinforcing support members;   iii) providing a second mold compartment containing the first molded construct, said second mold compartment being configured to define at least a portion of the external shape of the protective case;   iv) forming a second molded construct by injecting a second polymer material on top of the first molded construct; and   v) allowing said first and second molded constructs to harden,   wherein said second polymer material when hardened is less rigid than said first polymer material when hardened and wherein said reinforcing support members are formed of a material that is more rigid than said hardened first polymer material.   
     
     
         2 . A method of manufacturing a multi-layered reinforced protective case for a mobile device, said protective case being configured to reversibly attach to said mobile device; said method comprising the steps of:
 i) positioning a first and a second reinforcing support member into a first mold compartment configured to define at least a portion of the external shape of the protective case, each of said first and second reinforcing support members are in the form of a longitudinally extending beam having a length and a cross-sectional area and each is positioned within the first mold compartment so that they are spaced apart from one another and generally parallel to one another in orientation;   ii) forming a first molded construct by injecting the first mold compartment with a first polymer material around the reinforcing the first and second reinforcing support members positioned in the first mold compartment so as to form a first shell component including therein the first and second reinforcing support members;   iii) providing a second mold compartment containing the first molded construct, said second mold compartment also being configured to define at least a portion of the external shape of the protective case;   iv) forming a second molded construct by injecting a second polymer material on top of the first molded construct to form a second shell component; and   v) allowing the first and second molded constructs to harden,   wherein said second polymer material when hardened is less rigid than said first polymer material when hardened and wherein each of said first and second reinforcing support members are formed of material that is more rigid than said hardened first polymer material.   
     
     
         3 . The manufacturing method of  claim 2 , wherein the first reinforcing support member is formed of a metal beam and the second reinforcing support member is formed of a longitudinally extending polymer beam. 
     
     
         4 . The manufacturing method of  claim 3 , wherein at least one of said metal or polymer beam has a circular cross-sectional area. 
     
     
         5 . The manufacturing method of  claim 3 , wherein at least one of said metal or polymer beam has a hexagonal cross-sectional area. 
     
     
         6 . The manufacturing method of  claim 3 , wherein at least one of said metal or polymer beam has a rectangular cross-sectional area. 
     
     
         7 . The manufacturing method of  claim 3 , wherein at least one of said metal or polymer beam has a square cross-sectional area. 
     
     
         8 . The manufacturing method of  claim 3 , wherein at least one of said metal or polymer beam has an oval cross-sectional area. 
     
     
         9 . The manufacturing method of  claim 3 , wherein said metal beam has different cross-sectional areas than said polymer beam. 
     
     
         10 . The manufacturing method of  claim 2 , wherein a third reinforcing support member is molded into said first or second molded construct and wherein said third reinforcing support member is oriented diagonally relative to said first and second reinforcing members. 
     
     
         11 . The manufacturing method of  claim 10 , wherein a fourth reinforcing support member is molded into said first or second molded construct and wherein said fourth reinforcing support member is oriented perpendicularly relative to said first, second or third reinforcing members.