Custom fabric cases for electronic devices

A fabric case for an electronic device may include a back panel having a periphery and a side wall that extends around the periphery. The back panel may include a knit image of a user-selected digital photograph or other design. The design of the back panel may be customized according to the user's tastes. The case may be formed using computing equipment and knitting equipment. The computing equipment may receive a digital image from the user and may reduce the resolution and the number of colors in the digital image according to the specifications of the textile machine. Fabric pattern design software may convert the digital image into knitting instructions. The knitting instructions may be executed by knitting equipment to produce a custom back panel having a knit image of the digital photograph. The back panel may be attached to a peripheral side wall to form the fabric case.

FIELD

This relates generally to fabric, and, more particularly, to forming fabric for structures such as cases for electronic devices.

BACKGROUND

Electronic devices such as cellular telephones, computers, and other electronic equipment are sometimes used in conjunction with external cases. A user may, for example, place an electronic device in a removable plastic case to protect the electronic device from scratches. Removable cases may also be used to personalize electronic devices.

Plastic cases may be satisfactory in certain situations, but some users may desire a case with different aesthetics. As a result, fabric cases have been developed.

There are challenges associated with forming fabric cases for electronic devices. A user may have limited choices when it comes to selecting a fabric case for his or her device. The user may be able to select a desired color, but may otherwise be unable to customize a fabric case according to the user's preferences.

SUMMARY

A fabric case for an electronic device may include a back panel having a periphery and a side wall that extends around the periphery. The back panel and the side wall may be joined monolithically or may be joined using seams.

The back panel may include a knit image of a digital photograph or other design. The design of the back panel may be customized according to the designer's tastes. The designer may be a user of the case or electronic device, or the designer may be a manufacturer of the case or electronic device.

The case may be designed and constructed using computing equipment and knitting equipment. The computing equipment may receive a user-selected digital image from the user. The computing equipment may use image processing software to reduce the resolution and the number of colors in the digital image according to the specifications of the textile machine.

Fabric pattern design software may convert the digital image into knitting instructions. The knitting instructions may be executed by knitting equipment to produce a back panel for a fabric case. The back panel may have a knit image of the digital photograph. The back panel may include rows and columns of knitted loops of colored yarn. Each loop may form a pixel in the knit image. The knit image may be located on an exterior surface of the fabric case. The back panel may be attached to a peripheral side wall to form a recess that receives the electronic device.

DETAILED DESCRIPTION

Electronic devices may be provided with cases such as fabric cases. The fabric cases may be removable external cases. When a user desires to protect an electronic device from scratches or other damage, the user may place an electronic device within a case. When the user wishes to use a different case to change the appearance of an electronic device, the electronic device may be transferred from one case to another. If desired, fabric may be incorporated into an electronic device housing or may be used in forming other fabric-based structures. Arrangements in which fabric is used in forming removable external cases are sometimes described herein as an example.

The fabric for a removable case may be woven, knitted (e.g., weft knitted or warp knitted), or braided, or may be formed using other strand intertwining techniques. For example, fabric can be knit using a knitting machine.

An electronic device of the type that may be provided with a removable case that has been formed using intertwined strands is shown inFIG. 1. In the example ofFIG. 1, device10includes a display such as display14mounted in housing12. Housing12, which may sometimes be referred to as an enclosure or case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of any two or more of these materials. Housing12may be formed using a unibody configuration in which some or all of housing12is machined or molded as a single structure or may be formed using multiple structures (e.g., an internal frame structure, one or more structures that form exterior housing surfaces, etc.).

Display14may be a touch screen display that incorporates a layer of conductive capacitive touch sensor electrodes or other touch sensor components (e.g., resistive touch sensor components, acoustic touch sensor components, force-based touch sensor components, light-based touch sensor components, etc.) or may be a display that is not touch-sensitive. Display14may include an array of pixels formed from liquid crystal display (LCD) components, an array of electrophoretic pixels, an array of plasma pixels, an array of organic light-emitting diode pixels or other light-emitting diodes, an array of electrowetting pixels, or pixels based on other display technologies.

Display14may be protected using a display cover layer such as a layer of transparent glass or clear plastic. The display cover layer may form a planar front face for device10. The rear of housing12may have a parallel planar surface. Housing side walls may run around the periphery of housing12. Device10may have a rectangular outline (e.g., a rectangular footprint when viewing the front face of the device) or may have other suitable footprints.

Openings may be formed in the display cover layer. For example, an opening may be formed in the display cover layer to accommodate a button such as button16. An opening may also be formed in the display cover layer to accommodate ports such as speaker port18. Openings may be formed in housing12to form communications ports (e.g., an audio jack port, a digital data port, etc.), to form openings for buttons, etc.

Electronic device10may be a computing device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, a device embedded in eyeglasses or other equipment worn on a user's head, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, equipment that implements the functionality of two or more of these devices, or other electronic equipment. In the illustrative configuration ofFIG. 1, device10is a portable device such as a cellular telephone, media player, tablet computer, or other portable computing device. Other configurations may be used for device10if desired. The example ofFIG. 1is merely illustrative.

FIG. 2is a perspective view of device10ofFIG. 1in a configuration in which device10has been mounted in a removable case. As shown inFIG. 2, removable case20may have walls that run around the periphery of device10. If desired, case20may form a cover with a hinged portion, a structure with a pocket into which device10may slide, or other enclosure that receives device10. In the example ofFIG. 2, case20surrounds device10, but does not cover display14. This type of arrangement, which may be desirable for devices such as cellular telephones, watches, and tablet computers, allows display14to be viewed by a user without opening a cover flap or moving any portion of case20. If desired, however, case20may be provided with pockets, flaps, hinged portions, straps, and other structures. The configuration ofFIG. 2is merely illustrative.

FIG. 3is a perspective view of case20ofFIG. 2in a configuration in which device10is not present (i.e., a configuration in which case20has been removed from device10). As shown inFIG. 3, case20may have four straight segments each of which runs along and covers a respective one of the four straight peripheral edges of the rectangular housing of device10. Corner portions of the case join the straight segments together to form a case with a rectangular ring shape. Corners20C may be rounded when viewed from above (i.e., when case20has a footprint with rounded corners) or may have other shapes. Central opening22may have a rectangular shape (e.g., a rectangular shape with rounded corners) or other shape suitable for receiving electronic device10when electronic device10is mounted within case20.

Case20may have one or more portions formed from fabric42. Fabric42may be soft (e.g., case20may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., the surface of case20may be formed from a stiff fabric), may be coarse, may be smooth, may have ribs or other patterned textures, and/or may be formed as part of a device that has portions formed from non-fabric structures of plastic, metal, glass, crystalline materials, ceramics, or other materials.

The strands of material in fabric42may be single-filament strands (sometimes referred to as fibers or monofilaments), may be yarns or other strands that have been formed by intertwining multiple filaments (multiple monofilaments) of material together, or may be other types of strands (e.g., tubing). Monofilaments for fabric42may include polymer monofilaments and/or other insulating monofilaments and/or may include bare wires and/or insulated wires. Monofilaments formed from polymer cores with metal coatings and monofilaments formed from three or more layers (cores, intermediate layers, and one or more outer layers each of which may be insulating and/or conductive) may also be used.

Yarns in fabric42may be formed from polymer, metal, glass, graphite, ceramic, natural materials as cotton or bamboo, or other organic and/or inorganic materials and combinations of these materials. Conductive coatings such as metal coatings may be formed on non-conductive material. For example, plastic yarns and monofilaments in fabric42may be coated with metal to make them conductive. Reflective coatings such as metal coatings may be applied to make yarns and monofilaments reflective. Yarns may be formed from a bundle of bare metal wires or metal wire intertwined with insulating monofilaments (as examples). Yarns in fabric42may be any suitable color (e.g., red, orange, yellow, green, blue, indigo, violet, gray, black, white, different shades of these colors, a mix of two or more of these colors, etc.).

Strands of material may be intertwined to form fabric42using intertwining equipment such as weaving equipment, knitting equipment, or braiding equipment. Intertwined strands may, for example, form woven fabric, knit fabric, braided fabric, etc.

A cross-sectional view of case20ofFIG. 3taken along line24and viewed in direction26is shown inFIG. 4. As shown inFIG. 4, case20may have peripheral portions such as peripheral wall portions32and a rear wall portion such as back panel34. Back panel34may cover the rear side of electronic device10when device10is within case20. Peripheral walls32may include vertical side walls30that join respective upper horizontal wall portion28. Peripheral walls32may extend around the periphery of device10when device10is installed within case20. The cross-sectional shape of case20ofFIG. 4(i.e., the shape in which horizontal walls28are perpendicular to vertical walls30) is merely illustrative. If, for example, device10has edges with a curved cross-sectional shape, the profile of peripheral walls32may have a corresponding curved shape (e.g., side wall30may bow outwards). In some arrangements, horizontal portion28of walls32may be omitted. If desired, the fabric of case20may be formed from strands that are elastic to accommodate and/or conform to devices10with a variety of different edge profiles and footprints. The example ofFIGS. 3, 4, and 5is merely illustrative.

Back panel portion34may be formed from a layer of plastic or metal or may be formed from a layer of fabric. Rear portion34may cover some or all of the rear of device10and may be attached to portions32or woven or formed as an integral portion of portions32. In the example ofFIG. 4, peripheral walls32and back panel34are formed from fabrics that are joined monolithically (e.g., without joints or seams).

FIG. 5is a cross-sectional side view of an illustrative case20in which peripheral walls32and back panel34are formed from fabrics that are joined using seams such as seam38. Seam38may be a chain stitch formed using a linking strand, or may be any other suitable type of stitch, seam, or attachment member. When peripheral walls32and back panel34are formed separately and then subsequently joined, different methods and techniques may be employed in the formation of each piece, if desired. For example, peripheral walls32may be flat knit single layer structure, a warp knit fabric, a weft knit fabric, a seamless tube of fabric, one or more strips of fabric that are joined to form a rectangular outline, a spacer fabric, or other suitable fabric type. Back panel34may be a flat knit structure, a warp knit structure, a weft knit structure, a spacer fabric, one or more strips of fabric that are joined to form a panel, or other suitable fabric type.

Some or all of fabric42of case20may include a custom design. The custom design may, for example, be an image, pattern, or other design. The image may be formed using different colors of yarn. The yarn may be knit or woven in such a way as to create the desired image or pattern on case20. For example, case20may include an image of a person, a landscape, a car, or any other suitable object or scene, and/or may include patterns, shapes, or other design elements. The custom design portion may, for example, be located on rear panel34or may be located on other portions of case20. The design may face the exterior of case20so that the design is visible even when device10is located in case20. The image may comprised of “pixels,” where each pixel is formed by one or more loops or stitches of fabric42.

Knitted fabric such as knitted fabric42ofFIGS. 3, 4, and 5may be formed using any suitable knitting equipment. An illustrative knitting system for forming fabric42(e.g., fabric having a user-selected image) is shown inFIG. 6. As shown inFIG. 6, knitting equipment such as knitting system58may include a yarn source such as yarn source60. Yarn source60may include a creel with spools of yarn68. Knitting elements70may be used to knit yarn68into knitted fabric42. Knitted fabric42may be gathered on drums or other take-down equipment66.

Knitting elements70may include yarn guide structures such as feeders62that guide yarn68towards needles and other equipment64. Equipment64may include latch needles or needles of other types. In some arrangements, equipment64may include multiple beds of needles such as a front needle bed and a back needle bed. Equipment64may include yarn positioning structures that move yarn68from one bed to another bed. Equipment64may also include hooks or other cam structures and other structures for manipulating the positions of needles. The needles, feeders, and other knitting elements70may be implemented as separately adjustable components or the functionality of two or more of these tools may be combined in equipment64. Equipment such as feeders62and needles64(i.e., knitting elements70) may sometimes be referred to as knitting equipment.

The use of a knitting system such as knitting system58ofFIG. 6to knit fabric42is sometimes described herein as an illustrative example. Other techniques for forming fabric42may be used, if desired. For example, a weaving machine may be used in arrangements where some or all of fabric42is woven fabric. In general any suitable textile machine may be used to form fabric42(e.g., a knitting machine, a weaving machine, a braiding machine, a dial linking machine, etc.).

Knitting system58or other suitable strand intertwining equipment may be used to create custom fabric cases for electronic devices. Custom fabric cases may include color images, patterns, or other designs. Knitting system58may receive data from a knitting program that instructs knitting system58how to knit the fabric to achieve the desired design. If, for example, a designer (e.g., a user, the case manufacturer, or a third party) wanted a photograph of a landscape on the fabric case, fabric pattern design software may be used to convert the photograph into a textile machine file. The textile machine file may be loaded onto control circuitry that operates knitting system58(e.g., that supplies control signals to knitting system58based on the textile machine file) or the textile machine file could be provided to a technician who operates knitting system58according to the textile machine file instructions. When knitting system58knits fabric42according to the textile machine file instructions, fabric42may have an image of the user-selected photograph. In some arrangements, the image on fabric42may have a lower resolution and fewer colors than the original user-selected photograph.

Illustrative computing equipment that may be used to convert image files into a textile machine file for knitting system58is shown inFIG. 7. As shown inFIG. 7, computing equipment80may include control circuitry44. Control circuitry44may include processing circuitry such as one or more microprocessors, microcontrollers, digital signal processors, application-specific integrated circuits, and other processors and may include storage such as random access memory, flash storage (e.g., flash disk drives), hard disk drives, and other memory. Control circuitry44may run software such as fabric pattern design software46and image processing software48.

Fabric pattern design software46may be used to convert image files into a textile machine file. The textile machine file may be provided to knitting equipment58, and knitting equipment58may knit fabric42based on the textile machine file received from computing equipment80. In some arrangements, the textile machine file may be computer code that is loaded onto the control circuitry of knitting equipment58and that instructs the control circuitry how to operate the textile machine to produce the desired pattern. In other arrangements, the textile machine file may be a knitting pattern (e.g., a knitting chart) that is readable by a technician operating the textile machine, who is then able to operate the textile machine according to the knitting pattern instructions. In either case, the resulting fabric (e.g., fabric42) may have a knit version of the electronic image file. This fabric may be used in forming case20.

Image processing circuitry48may be used to process images before the images are converted into a textile machine file by fabric pattern design software46. Image processing circuitry48may be used to adjust the resolution, colors, brightness, size, content, or other characteristic of an image before it is converted into a textile machine file. For example, if an image is high resolution and has more colors than the textile machine can produce, image processing circuitry48may be used to reduce the resolution of the image and reduce the number of colors in the image to match the capabilities of knitting equipment58. If desired, some or all of the functionality of image processing software48may be implemented using fabric pattern design software46. For example, the resolution, colors, brightness, size, or content of an image may be adjusted before the image is converted into a textile machine file, or any of these characteristics may be adjusted after the image is converted into a textile machine file.

Communications circuitry50may be used to transmit information from computing equipment80to knitting equipment58and/or to external equipment and/or may be used to receive information from knitting equipment50or external equipment. For example, a textile machine file produced by fabric pattern design software46may be supplied from computing equipment80to knitting system58. Communications circuitry50may also be used to gather information from knitting system58such as machine specifications (e.g., the textile machine make and model, the gauge of the textile machine, the diameter or width of the textile machine, the number of feeders, the number of yarn colors, the number of needles etc.). If desired, machine specifications may be provided to computing equipment manually (e.g., by a technician operating computing equipment80and/or knitting equipment58). The example in which machine specifications are gathered using communications circuitry50is merely illustrative. Communications circuitry50may also be used to gather image data (e.g., user-selected photographs or other custom designs) to be converted into a textile machine file.

Communications circuitry50may include antennas and wireless local area network transceiver circuitry (e.g., WiFi® circuitry), Bluetooth® transceiver circuitry, cellular telephone transceiver circuitry, other radio-frequency transceiver circuitry (e.g., circuitry operating in bands from 700 MHz to 2700 MHz, below 700 MHz, above 2700 MHz, or other suitable wireless communications frequencies).

FIG. 8is a diagram showing how an image file may be reproduced on a fabric case. Image52may be a digital image file such as a Tagged Image File Format (TIFF) file, a bitmap (BMP) file, a Joint Photographic Experts Group (JPEG) file, a Photoshop® (PSD) file, a portable networks graphics (PNG) file, a Graphics Interchange Format (GIF) file, or other suitable digital image file. Digital image52may be a photograph (e.g., a digital photograph taken and/or selected by a user of case20and device10, by a manufacturer of case20and/or device10, or by a third party), may be a pattern with different shapes and colors, may be a combination of a photograph and other designs, or may be other suitable image.

Image52may be provided to computing equipment80(FIG. 7). Computing equipment80may use image processing software48to adjust one or more characteristics of image52(e.g., to reduce the resolution of image52, reduce the number of colors in image52, or make other suitable adjustments to image52). Fabric pattern design software46may be used to convert the image into a textile machine file. The textile machine file may be provided to knitting equipment58. Knitting equipment58may then be used to knit fabric42with image52′. Image52′ may be a knit version of the original image52. Image52′ may, if desired, be located on back panel34of case20and may face the exterior of case20.

FIG. 9is a top view of case20showing how image52′ may be created on case20by forming different regions of case20with different colors. Fabric42of case20may be made up of an array of pixels such as pixels54. Each pixel54may be a point of color. There may be one, two, four, six, twelve, more than twelve, or less than twelve colors that make up image52′ on fabric42. Each pixel54may have one of the possible colors that make up image52′. For example, pixels54-1may be a first color, pixels54-2may be a second color, and pixels54-3may be a third color. The color of each pixel may be selected to create the desired image52′. Knitting equipment58may be used to knit fabric42so that yarns68of the appropriate color are placed at each pixel54.

There may be any suitable number of pixels54in image52′ on fabric42. In one suitable arrangement, image52′ on fabric42has 120 rows and 64 columns of pixels54(e.g., 120×64 resolution). This is, however, merely illustrative. Arrangements in which the resolution of image52′ is greater or less than 120 pixels by 64 pixels may also be used.

FIG. 10shows how fabric42may be comprised of knitted yarn68. Each pixel54may be formed from one or more loops or stitches in fabric42. In the example ofFIG. 10, each pixel54is formed from one loop in fabric42. This is, however, merely illustrative. If desired, each pixel54may be formed from two or more adjacent loops in fabric42(e.g., two, four, six, or other suitable number of loops in fabric42).

The design of case20(e.g., back panel34of case20) may be customized by a designer. The designer may be a user of case20and/or device10, the designer may be a manufacturer of case20and/or device10, or the designer may be a third party.FIG. 11is a flow chart of illustrative steps involved in producing a custom case20for a designer.

At step100, computing equipment80may receive an image such as image52from the designer. Image52may be a photograph (e.g., taken with a camera), may be a computer-generated image, may be a pattern of different shapes and colors, or may have any other suitable design. If desired, the designer may request other custom-characteristics for case20. For example, the designer may specify the fabric construction (e.g., warp knit, flat knit, woven, etc.), the type of yarn or material in case20, the amount of friction on case20(e.g., whether one or more sides of case20should have more friction to enhance landscape or portrait orientation viewing), the amount and placement of drop protection features (e.g., whether corners of case20should be more drop-resistant than sides of case20), the elasticity of one or more portions of case20, the softness or feel of case20, the amount of transparency or translucency in portions of case20, any additional materials to be incorporated into case20(e.g., leather, cashmere, silk, plastic, etc.), or other suitable specifications.

At optional step102, computing equipment80may use image processing software48to make adjustments to image52according to the capabilities of knitting equipment58and according to the desired characteristics of case20(e.g., the size, shape, or other characteristic of case20). For example, a 21-gauge textile machine (e.g., having 21 needles per inch) may be able to produce a higher resolution image than an 18-gauge textile machine (e.g., having 18 needles per inch). If image52is a high-resolution image having a large number of colors, and if knitting equipment58is capable of forming fabrics with six colors and 120 pixels by 64 pixels resolution, then image processing software48may reduce the resolution of image52to 120 pixels by 64 pixels, and may reduce the number of colors in image52to six. If image52already has the appropriate resolution and number of colors, then step102may be omitted.

At step104, computing equipment80may use fabric pattern design software46to convert image52(e.g., the adjusted version of image52having the appropriate resolution and number of colors for knitting equipment58) into a textile machine file. The textile machine file may be a set of knitting instructions that indicate the order of knitting, the type of stitch, the transfer rows, and other suitable knitting information that results in fabric42having the desired image52′ when the knitting instructions are followed. The textile machine file may be a file of computer code that is loaded onto knitting equipment58and executed automatically (e.g., using computer-generated control signals to instruct knitting equipment58to follow the textile machine file instructions), or the textile machine file may be a graphical representation of the knitting instructions (e.g., a knitting chart) that allows a technician to manually operate knitting equipment58according to the textile machine file instructions.

At step106, computing equipment80may generate a rendering of the finished case20with image52′ for review by the designer. The rendering may be a two-dimensional rendering of back panel34having the desired image52′, or the rendering may be a three-dimensional rendering of case20having the desired image52′. This allows the designer to review and approve the proposed design and, if desired, make changes (e.g., changes to the colors, content, tone, material, size, and/or other characteristic).

At step108, computing equipment80may receive the updates or an approval from the designer. If the designer approves the rendering, processing may proceed without any changes to the textile machine file. If the designer makes changes, computing equipment80may make the appropriate updates to the textile machine file (e.g., using fabric pattern design software46and/or image processing software48). The review portion of the process is merely illustrative. If desired, steps106and108may be omitted.

At step110, knitting equipment58may be used to create fabric42with image52′ using the textile machine file generated by computing equipment80. This may include loading the textile machine file onto control circuitry that controls knitting equipment58so that knitting equipment58automatically knits according to the textile machine file, or this may include providing a knitting chart to a technician so that the technician can manually operate knitting equipment58according to the textile machine file. In both cases, the resulting fabric will be such that yarns68of the appropriate color are placed at each pixel54to produce the desired image52′ on fabric42. In arrangements where image52′ is formed on back panel34, back panel34may be joined (e.g., joined monolithically or joined with seams) to side walls32to form a finished case20(as shown inFIGS. 3, 4, and 5). Image52′ may, if desired, be located on the external surface of back panel34of case20(e.g., the surface that faces away from device10when device10is located in case20).