Handheld computer casing with grooved feature formed on a decorative surface

[0002] The present invention relates to handheld computers. In particular, the present invention relates to a decorative casing for a handheld computer.

[0003] Handheld computers, typically referred to as personal digital assistants (PDAs), are mobile devices that can be carried by individuals as accessories. For this reason, users often pay attention to a style or appearance of a handheld computer.

[0004] Designs for handheld computers can be personalized in many ways. Some handheld computers, such as the PALM m 100 organizer, manufactured by PALM INC., allow users to purchase attachable faceplates for their organizers. The face plates have colorful designs and decors.

[0005] Handheld computers may also have decorative designs that are painted on a housing surface. In addition, encasement materials can be changed, or formed to have a certain style. For example, PALM V organizer, manufactured by PALM INC., can have attachable encasements made of materials such as titanium.

[0006] A process termed In Mold Design (IMD) is increasingly used to form devices having decorative surfaces. The IMD process allows for a decorative substrate to be used during a molding process. The substrate then forms an exterior surface of the device.

[0007] A housing component is provided for a handheld computer. The housing component is formed from a layer that provides an exterior surface for the housing component. The layer may have a first tone and a second tone. A groove is formed on the layer. The groove has a contoured interior.

[0008] In one embodiment, a first surface on an interior of the groove has the first tone. A second surface on the interior of the groove has the second tone. The presence of the first tone and second tone in the groove enhance a perception that the surface of the handheld computer is really made from two materials.

[0009] The first and second tone may correspond to colors, patterns or other designs. In one application, the groove forms a separation between a light color and a dark color.

[0010] In another embodiment, the groove is formed on a film during an In Mold Design process. The remainder of the housing component is formed in a molding process that incorporates the film. The groove distinguishes the color and/or design patters on the housing component for the handheld computer.

[0011] Embodiments of the invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. Like reference numerals are intended to refer to similar elements among different figures.

[0012] FIG. 1 is a frontal view of a housing component having a decorative groove, under an embodiment of the invention.

[0013] FIG. 2 is a cross-sectional view along lines J—J of FIG. 1, showing an interior of the groove.

[0014] FIG. 3 is an enlarged view of a groove for a housing component, under an embodiment of the invention.

[0015] FIG. 4 is a process for forming a housing component with a decorative groove, under an embodiment of the invention.

[0016] FIG. 5 illustrates a face plate configuration for a housing component with the decorative groove.

[0017] Embodiments of the invention provide for a handheld computer having a decorative housing component. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the present invention.

[0018] Embodiments of the invention provide a decorative housing component for a handheld computer. An exterior surface of the housing component includes a groove and two or more decorative designs. The decorative designs are unitarily formed on the same layer, so that the layer is homogeneous. Therefore, the different decorative designs are not created by use of paint or separate materials. Rather, the decorative design is formed using a molding process.

[0019] Homogenous material refers to a material that is chemically bonded. The homogenous material is inseparable unless the chemical bonds are destroyed. The homogeneous layer does not refer to a layer that has a coat of paint applied on it after it is formed.

[0020] The term design refers to a distinct visual appearance. A design may include a tone, a shade, a color, or a plurality of tones, shades and/or colors arranged into a pattern.

[0021] The housing component may be an integral part of the handheld computer. For example, the housing component may correspond to a front panel of the handheld computer, where the display and buttons of the handheld computer are provided. Alternatively, the housing component may be separable from an exterior of the handheld computer. For example, the housing component may correspond to a detachable faceplate for the handheld computer.

[0022] In another embodiment, a layer is formed to provide an exterior surface for the housing component. The layer includes a first tone and a second tone. A groove is formed on the layer. The groove has a contoured interior. A first surface on the interior of the groove has the first tone, and a second surface on the interior of the groove has the second tone.

[0023] According to another embodiment, handheld computers and housing components for handheld computers include external surfaces formed from a single homogenous material having unique decorative features. The decorative features may include two color or shade designs separated by a groove. The groove gives the perception that the exterior surface is formed from two materials, rather than a single homogenous material.

[0024] Several advantages are provided by embodiments described herein. A perception may be given to the user that the handheld computer is formed from two distinct materials or layers, when in fact one homogenous material is used to form the exterior surface. The perception that the handheld computer is formed from two materials enhances the marketing of the product. This perception can also be used to make the product look slimmer, and more expensive. However, by using a single homogenous material, costs are avoided that would otherwise be associated with tooling and assembling two materials into one exterior surface for the handheld computer. For example, labor and material costs are saved in comparison to having the exterior surface painted in a similar configuration. The homogenous material with the groove also enables a manufacturing process to be implemented that produces a consistent quality for the decorative design when repeated for numerous products in a product line.

[0025] FIG. 1 is a frontal view of a housing component for a handheld computer having a decorative groove, under an embodiment of the invention. Referring to FIG. 1, a housing component 110 is provided for a handheld computer 100. The housing component 110 may correspond to a front panel of handheld computer 100. Alternatively, as described with FIG. 5, the housing component 110 may correspond to a surface of a faceplate 150 for handheld computer 100.

[0026] A front surface 112 of housing component 110 includes a groove 120. The groove 120 is formed into an exterior surface of housing component 110. The exterior surface may correspond to a front surface 112, where several input and output features are provided.

[0027] The housing component 110 includes a display opening 114 and a plurality of button openings 116. The display opening 114 provides access to a display 122 on front surface 112. The display 114 can be mounted to an interior of handheld computer 100. Each of the button openings 116 provide access to a plurality of buttons 124 on front surface 112.

[0028] The groove 120 traces a shape on front surface 112. In one embodiment, the shape is a partial polygon. The groove 120 circumvents display 114 and the plurality of buttons 116. The partial polygon formed by the shape of groove 120 has an open end. In an embodiment shown, the open end of the partial polygon corresponds to a top surface 102 of handheld computer 100.

[0029] On an exterior side 104 of groove 120, housing component 110 has a first design. The housing component 110 has a second design on an interior side 106 of housing component 110. The first design may correspond to a color, shade, tone or pattern. The second design may be different than the first design, so as to correspond to another color, shade, tone or pattern. In one application, the exterior side 104 has a dark shade or color, and the interior side 106 has a light color or shade. For example, the exterior side 104 may be black, and the interior side 106 may be light blue. By featuring a dark color on the exterior side 104 of groove 120, and a light color on the interior side 106, a perception can be created that handheld computer 100 is smaller than it actually is.

[0030] FIG. 2 is a cross-sectional view along lines J—J of FIG. 1, showing an interior of groove 120. The housing component 110 includes a layer 130. The layer 130 is homogenous so that its material is chemically bonded. Groove 120 is formed on layer 130. Underneath groove 120, the layer 130 has a contoured concavity corresponding to the groove's location.

[0031] In an application for a front surface of housing component 110, the width of groove 120 may range between 0.6 and 1.0 millimeters. The depth may range between 0.2 and 0.6 millimeters. In one embodiment, groove 120 has a width of 0.86 millimeters, and a depth of about 0.4 millimeters. The term “about” means plus or minus 10% of the dimension. Embodiments of this invention are not intended to be limited to the specific dimensions and dimension ranges made explicit in this application.

[0032] FIG. 3 is an enlarged view of groove 120, under an embodiment of the invention. The groove 120 is shown as a feature formed into a film layer 132. Underneath film layer 132, layer 130 may have a corresponding shape to accommodate groove 120.

[0033] As will be described in FIG. 4, film layer 132 may comprise a polycarbonate material that is subjected to a subsequent molding process where the remainder of layer 130 is formed. The remainder of layer 130 may be formed from moldable material, such as plastic, that is formed onto the film layer 132. The film layer 132 is outwardly positioned on layer 130, and the moldable material is formed inward. The mold is such that the resulting layer 130 is chemically bonded into one homogenous material.

[0034] The thickness of film layer 132 may range between 0.1 and 0.6 millimeters. In one embodiment, a thickness of film layer 132 is about 0.3 millimeters. The dimensions of layer 130 may range between 1 and 3 millimeters. In one embodiment, a thickness of layer 130 is about 1.5 millimeters. Embodiments of this invention are not intended to be limited to specific dimensions for film layer 132 and layer 130.

[0035] The groove 120 includes an interior 128 formed from a first side 121 and a second side 123. The first and second side 121 and 123 join to form a trough 125. In an embodiment, trough 125 is contoured, or rounded. The contoured shape of groove 120 facilitates the film layer 132 to be subjected to an IMD process, where moldable material is formed onto the material.

[0036] In an embodiment, first side 121 and second side 123 combine to form an angle of between 55-75 degrees. In one application, the angle is about 68 degrees.

[0037] In addition, an embodiment provides that interior 128 of groove 120 includes two designs. For example, the interior 128 of groove 120 may provide for two colors formed on film layer 132 that adjoin within groove 120. The colors may adjoin at or near trough 125. One embodiment provides that first side 121 has a first design, and second side 123 has a second design. For example, first side 121 may be of a dark color, and second side 123 may be of a light color. The trough 125 is positioned approximate to where the two designs adjoin one another.

[0038] As shown, groove 120 can trace a geometric pattern on exterior surface 112 of handheld computer 100. The pattern may require groove 120 to be extended over edges of housing component 110. For example, groove 120 may be extended over a top of housing component 110. To accommodate the bend when transitioning from the top of handheld computer 100 to its side, the depth of groove 120 may be tapered. The tapering of groove 120 may reduce its depth.

[0039] FIG. 4 described a process for forming decorative housing component 110, under an embodiment of the invention. The groove may extend along a shape on an exterior surface of housing component 110, and serve to separate designs appearing on the exterior surface. Reference to elements of FIGS. 1-3 is intended for illustrative purposes, and not intended to limit the invention.

[0040] In step 410, a pattern is printed or otherwise provided on a sheet of homogenous material. The sheet is suitable for IMD. That is, the sheet can be used as the exterior surface of a structure formed during a molding process. In one embodiment, the sheet is formed from a polycarbonate material, and includes two or more distinct designs. The designs may adjoin one another on the sheet along a line. The line may form a geometric pattern on the sheet.

[0041] In step 420, the location for the center of groove 120 is approximated. The groove 120 center may correspond to the line where the two designs adjoin one another. The center of groove 120 may also correspond or approximate the location of trough 125.

[0042] In step 430, the sheet is formed into an approximate exterior surface for housing component 110. In this step, groove 120 may be formed into the sheet. The approximate shape of the exterior surface may correspond to a front panel of handheld computer 100, or to a front face of faceplate 150 (See FIG. 5). The exterior surface may only be an approximation of the final form, in that it may lack display opening 114, or button openings 116. In addition, there may be extra edge material that can be removed.

[0043] In step 440, the approximate exterior surface is trimmed out. The trimmed, exterior surface may correspond to film 132, of housing component 110. Trimming the exterior surface may include forming the display opening 114 and button openings 116, as well as removing extra edge material.

[0044] In step 450, the trimmed sheet is used to mold the remainder of layer 130. This may be done using an IMD process. In the IMD process, film 132 is placed into a mold for housing component 110. Moldable material is poured onto the mold. The moldable material forms the remainder of layer 130. The moldable material is formed underneath film 132, so that film 132 corresponds to exterior surface 112.

[0045] FIG. 5 illustrates a face plate configuration for a housing component with the decorative groove. In an embodiment, housing component 110 may be a faceplate 150 that is coupleable to handheld computer 100. One or both of faceplate 150 and handheld computer 100 may incorporate the groove 120 and design feature described in FIG. 1.

[0046] While embodiments described herein provide for a housing component of a handheld computer, other embodiments may apply to other kinds of devices. In particular, accessory devices for handheld computers may be provided similar decorative features such as described with FIGS. 1-5.

[0047] The groove 120 may incorporate numerous geometric shapes. The particular partial polygon shown may be replaced by other polygons and shapes. In addition, multiple grooves may be provided that separate more than two designs.

[0048] In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.