Cover for portable electronic device

Abstract

A light, durable, and user friendly cover for a laptop computer that integrates the protective qualities of hard shell cases with the aesthetics of soft cut-and-sew covers is disclosed. The cover includes top and bottom panels configured to cover the display and keyboard portions, respectively. Each panel is independent and separate from the other and each is formed as a unitary component of a molded resilient polymer material, such as polycarbonate, that is configured to reversibly and retentively snap-fit over the outer surface of the laptop computer. Each panel includes a raised lip along its perimeter edge region that defines an internally extending recessed region on the panel's outer surface. Fabric and/or leather overlays are positioned, sized and adhesively coupled atop the recessed regions and are protected from delaminating, fraying, and/or peeling by the raised perimeter lip.

What is claimed is: 
     
         1 . A method of manufacturing a protective cover formed and dimensioned to reversibly and retentively receive and protect a laptop computer having a display portion and a keyboard portion, said method comprising:
 molding a unitary first panel defined by opposing it and outer surfaces extending to a perimeter edge region and formed of a resilient polymer material and dimensioned to include a display portion compartment defined by the inner surface and reversibly and retentively snap-fit over and cover the display portion;   molding a unitary second panel defined by opposing, inner and outer surfaces extending to a perimeter edge region and formed of a resilient polymer material and dimensioned to include a keyboard compartment defined by the inner surface and reversibly and retentively snap-fit over the keyboard portion;
 wherein each of said panels are molded to include:
 (i) a plurality of retention tabs extending inwardly from the inner surface and positioned and dimensioned to retain the panel on the corresponding portion of the laptop, 
 (ii) an outwardly protruding wall structure extending longitudinally along, the perimeter edge region and projecting outwardly from the outer surface to define a raised perimeter lip and an adjacent recessed region on the outer surface that is defined by said perimeter lip; 
 
   removing each of said panels from their respective molds;   deburring each panel as needed to remove any sharp edges;   preparing fabric overlays by holding the fabric in a fixed and taut position and laser cutting to size each fabric overlay to match corresponding recessed regions in the first and second panels; and   positioning and adhesively coupling the fabric overlays separately to each of the recessed regions with heat and pressure, wherein each fabric overlay has a total thickness that is less than or equal to the height of the raised perimeter lip of the panel to which it is adhesively coupled.   
     
     
         2 . The method of  claim 1 , further comprising applying a polyurethane coating on the fabric overlays and then applying a heat activated adhesive over the polyurethane coating prior to positioning and adhesively coupling the fabric overlays. 
     
     
         3 . The method of  claim 1 , further comprising applying a polyurethane coating on the fabric overlays and then applying a heat activated adhesive over the polyurethane coating prior to cutting to size each fabric overlay. 
     
     
         4 . The method of  claim 1 , further comprising marking the fabric overlay and punching the fabric overlay with holes to assist in positioning the fabric overlay on the recessed region of the panel in the proper orientation. 
     
     
         5 . The method of  claim 1 , wherein the unitary second panel is molded to include a plurality of ventilation apertures defined by a outwardly protruding raised walls that are internally positioned within the second panel, wherein said fabric overlay is sized to extend to the raised walls but not over the ventilation apertures, and wherein the thickness of the fabric overlay is less than or equal to the height of the raised walls. 
     
     
         6 . The method of  claim 1 , wherein the unitary second panel is molded to include a plurality of outwardly protruding footing platforms and corresponding recessed regions on the inner surface of the second panel. 
     
     
         7 . The method of  claim 6 , wherein the fabric overlay is adhesively coupled on to of said plurality of outwardly protruding footing platforms. 
     
     
         8 . The method of  claim 7 , further comprising laser cutting foot attachment apertures into the fabric overlay and the underlying outwardly protruding footing platforms after the fabric overlay is adhesively coupled thereto. 
     
     
         9 . The method of  claim 8 , further comprising heat pressing the fabric overlay on the unitary second panel around the foot attachment apertures and the outer perimeter regions of the fabric overlay as necessary to insure proper adhesion. 
     
     
         10 . The method of  claim 9 , further comprising securing a support foot having an internal portion and external portion, wherein the support foot is secured by inserting the internal portion of the support foot through the foot attachment aperture and retentively supporting the internal surface by the recessed region on the inner surface of the second panel opposite the protruding footing platform, wherein once the support foot is secured, the external portion resides externally over both the protruding footing platform and the overlying fabric overlay. 
     
     
         11 . The method of  claim 10 , wherein once the support foot is secured, the external portion resides in contact with the overlying fabric overlay. 
     
     
         12 . A cover for a mobile electronic device comprising;
 a relatively rigid but flexible unitary molded shell having an inner surface dimensioned to reversibly snap-fit externally over the electronic device and an opposing outer surface partitioned therefrom by a perimeter edge region that includes an outwardly protruding lip that encircles and defines a recessed region on the outer surface of the shell; and   a fabric overlay comprising a fabric outer layer, a polyurethane intermediate layer, and an inner adhesive coating, wherein said fabric overlay is adhesively coupled by its inner adhesive coating to said recessed region;   wherein the fabric overlay is sized to match said recessed region and the inner surface of the shell defines a compartment that corresponds in shape with the external surface of the electronic device, such that when the electronic device is retentively received within the shell at least the majority of the inner surface of the shell is in contact with the electronic device.