Polyurethane cold cast protective skins formed around and integrated onto existing hand-held computing devices

Abstract

A system and method for bonding a protective cover to a mobile device is disclosed. A cold cast protective cover is permanently bonded to the device and provides protection against damage from dropping, impact, exposure to electric or static discharge, and exposure to liquid, gas, and dusts. The cold cast protective cover takes the shape around all or some desired portion of the outer surface of the mobile device while still providing access to the device's user interface, including display, power and volume buttons, power charging port, memory port, speaker port, camera lens, and the like. The cold cast protective cover can, with additives, increase the safety of the device for Intrinsic Safety or Hazardous environments.

We claim: 
     
         1 . A process for permanently and fixedly bonding a protective cover to an external surface of a mobile device, comprising:
 providing an outer mold, the outer mold having an interior dimension that corresponds to an exterior surface of the mobile device, the mold configured to cover user interfaces and portholes of the mobile device and to define a desired size and shape for the protective cover;   forming a device cavity based on the outer mold, the device cavity conforming to the desired shape and size of the protective cover, the device cavity having an injection orifice and an exhaust orifice;   inserting the mobile device into the device cavity;   thereafter, inserting the device cavity containing the mobile device into a holding fixture, the holding fixture sealing the device cavity about the mobile device;   creating a polyurethane cold cast compound by mixing two compound components, the two compound components begin reacting chemically when combined;   injecting the polyurethane cold cast compound into the injection orifice of the device cavity until the device cavity is filled;   enabling excess air and excess polyurethane cold cast compound to escape via the exhaust orifice;   allowing the polyurethane cold cast compound within the device cavity to cure for a predetermined period of time;   after the predetermined period of time, removing the device cavity containing the mobile device from the holding fixture; and   thereafter, removing the mobile device from the device cavity, wherein the cured polyurethane cold cast compound acts as the protective cover that is permanently and fixedly bonded to the external surface of the mobile device.   
     
     
         2 . The process of  claim 1  wherein the polyurethane cold cast compound is a low temperature liquid compound that cures at ambient temperature and without addition of heat. 
     
     
         3 . The process of  claim 1  wherein the polyurethane cold cast compound fuses to the exterior surface of the mobile device as the compound cures. 
     
     
         4 . The process of  claim 3  further comprising, before inserting the mobile device into the device cavity, applying an adhesive to the exterior surface of the mobile device to improve fusion of the polyurethane cold cast compound to the exterior surface of the mobile device as the compound cures. 
     
     
         5 . The process of  claim 1  wherein the polyurethane cold cast compound is maintained at a desired pressure within the device cavity and about the exterior surface of the mobile device as the compound cures. 
     
     
         6 . The process of  claim 1  wherein, after mixing the two compound components to create the polyurethane cold cast compound, one or more additives are added to the polyurethane cold cast compound. 
     
     
         7 . The process of  claim 6  wherein the one or more additives include an accelerating compound to decrease the predetermined period of time for the compound to cure. 
     
     
         8 . The process of  claim 6  wherein the one or more additives affect resulting characteristics of the protective cover after the compound cures, including one or more of:
 mildew resistance, color, flexibility, durability, and static resistance. 
 
     
     
         9 . The process of  claim 1  further comprising, before inserting the mobile device into the device cavity, cleaning the exterior surface of the mobile device to remove dust, fingerprints, and dirt. 
     
     
         10 . The process of  claim 1  further comprising, before inserting the mobile device into the device cavity, covering portholes and interfaces of the exterior surface of the mobile device to protect the portholes and interfaces from contact with the polyurethane cold cast compound after the mobile device is inserted into the device cavity. 
     
     
         11 . The process of  claim 1  wherein the step of enabling excess air to escape via the exhaust orifice further includes using a vacuum chamber to remove air bubbles and prevent formation of air gaps within the polyurethane cold cast compound as the compound cures.