IP Library › Granted Patent US 12,737,006
Granted Patent B2
US 12,737,006 · App. 18/233,218 · Granted Sep 15, 2026

Dock with isolated dock connector and methods of making and using

Inventor: Jeffrey D. Carnevali (Seattle, WA)
Assignee: National Products, Inc.
G06F1/1632
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Quick Facts
Patent No.
US 12,737,006
App. No.
18/233,218
Granted
Sep 15, 2026
Kind
B2
Abstract

A dock for an electronic device includes a base configured to fit over at least a portion of a back surface of the electronic device; a tray extending from the base for receiving one side of the electronic device; and a dock connector arrangement that includes a dock connector formed of a first rigid or hard plastic material, a plurality of contacts extending out of, or disposed on, the dock connector, an elastomeric sleeve molded around at least a perimeter of the dock connector, and a contact box, wherein at least a portion of the contact box is molded around at least a perimeter of the elastomeric sleeve, wherein at least the portion of the contact box is formed of a second rigid or hard plastic material, wherein the contact box is coupled to, or part of, the base or the tray.

Claims (22)

1 . A method of making a dock for an electronic device, the method comprising:

molding an elastomeric sleeve around at least a perimeter of a dock connector, wherein the dock connector is formed of a first rigid plastic material and the elastomeric sleeve is formed of a thermoplastic material; and

molding at least a portion of a contact box around at least a perimeter of the elastomeric sleeve, wherein at least the portion of the contact box is formed of a second rigid plastic material.

2 . The method of claim 1 , wherein the second rigid plastic material of the portion of the contact box has a hardness of at least 70 on the Shore D scale or at least 100 on the Rockwell scale.

3 . The method of claim 1 , wherein the second rigid plastic material of the portion of the contact box has a hardness in a range of 70 to 80 on a Shore D scale or in a range of 100 to 120 on a Rockwell R scale.

4 . The method of claim 1 , wherein the thermoplastic material has a hardness of no more than 98 on a Shore A scale.

5 . The method of claim 1 , wherein at least one of the first rigid plastic material or the second rigid plastic material comprises acrylonitrile butadiene styrene (ABS), polycarbonate (PC), or a combination thereof.

6 . The method of claim 5 , wherein the thermoplastic material is selected from thermoplastic rubber (TPR), thermoplastic elastomer (TPE), thermoplastic urethane (TPU), or any combination thereof.

7 . The method of claim 1 , wherein the dock connector has a plurality of openings.

8 . The method of claim 7 , further comprising extending a plurality of contacts out of the openings of the dock connector.

9 . The method of claim 1 , wherein the first rigid material and the second rigid material are the same.

10 . The method of claim 1 , wherein molding at least the portion of the contact box around at least the perimeter of the elastomeric sleeve comprises insert molding of the contact box with the elastomeric sleeve comprising an insert.

11 . The method of claim 1 , wherein molding the elastomeric sleeve around at least the perimeter of the dock connector comprises insert molding of the elastomeric sleeve with the dock connector comprising an insert.

12 . The method of claim 1 , wherein the dock connector is part of, or attached to, a tray of the dock, wherein the tray is configured for receiving one side of the electronic device.

13 . The method of claim 12 , wherein the tray extends from a base configured to fit over at least a portion of a back surface of the electronic device.

14 . The method of claim 13 , wherein molding at least the portion of the contact box around at least the perimeter of the elastomeric sleeve comprises molding the base and the tray with the contact box around at least the perimeter of the elastomeric sleeve.

15 . The method of claim 12 , wherein the dock connector is part of the tray.

16 . The method of claim 12 , further comprising attaching the dock connector to the tray.

17 . The method of claim 12 , wherein molding at least the portion of the contact box around at least the perimeter of the elastomeric sleeve comprises molding the tray with the contact box around at least the perimeter of the elastomeric sleeve.

18 . The method of claim 1 , further comprising disposing at least one guide pin on the dock connector.

19 . The method of claim 1 , further comprising attaching a cover to the contact box opposite the dock connector.

20 . The method of claim 1 , wherein the elastomeric sleeve, dock connector, and contact box form a water-resistant seal.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 11, 2023
From: CARNEVALI, JEFFREY D.
To: NATIONAL PRODUCTS, INC.
Reel/Frame 064570/0240 →
Continuity (1)
Related Publication 20250053196A1 · Feb 13, 2025
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