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I made a cover out of very cheap spongy material (a bit like wet-suit material) and it has done a wonderful job of protecting the screen from scratches. I take the Kobo everywhere and life in my bag is tough!
My experience, from carting around very expensive musical instruments, is that it needs to be padded and unable to move to be safe. I have actually seen someone reverse their car over a very expensive violin. It was in a proper flight case and, apart from a few scratches on the case, the violin was fine (the owner was in deep shock!). Try to avoid twisting or putting pressure on the middle of the screen as glass just won't take this kind of tension.
Could there also be a problem with temperature drops? It seems a bit strange that some breakages occur overnight when the Kobo is just sitting there.
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