PATENT DOCUMENT

Publication Number: US-10966332-B2
Application Number: US-201815891533-A
Country: US
Kind Code: B2

Title: Structured fabrics for electronic devices

Abstract:
Electronic equipment may include structured fabric. Structured fabric may be used as a protective case or cosmetic cover for an electronic device, may be used to form a band that holds an electronic device against a user&#39;s body, or may be used to cover one or more openings in an electronic device. Structured fabrics may be soft and pliable while maintaining the ability to hold a given shape without added support. Structured fabric may be formed by laminating fabric such as warp-knit fabric with a stiffener such as polymer film. Structured fabrics may include openings through which signals such as optical or audio signals pass. To maintain the geometry and shape of the openings in the structured fabric without covering the openings, the stiffener and adhesive that are attached to the fabric may be cut to form a pattern of openings that align with the openings in the fabric.

Claims:
What is claimed is: 
     
       1. A cover for an electronic device, comprising:
 a first knit fabric layer having a first array of openings; 
 a second knit fabric layer having a second array of openings; and 
 an adhesive layer interposed between the first and second knit fabric layers, wherein the adhesive layer has a third array of openings that align with the first and second arrays of openings. 
 
     
     
       2. The cover defined in  claim 1  wherein the first, second, and third arrays of openings each comprise diamond-shaped openings. 
     
     
       3. The cover defined in  claim 1  wherein at least part of the cover has a cylindrical shape. 
     
     
       4. The cover defined in  claim 1  further comprising a stiffener interposed between the first and second knit fabric layers. 
     
     
       5. The cover defined in  claim 4  wherein the stiffener has a fourth array of openings that align with the first, second, and third arrays of openings. 
     
     
       6. The cover defined in  claim 5  wherein the stiffener comprises a polymer film. 
     
     
       7. The cover defined in  claim 6  further comprising an additional adhesive layer interposed between the first and second knit fabric layers. 
     
     
       8. The cover defined in  claim 7  wherein the stiffener is interposed between the adhesive layer and the additional adhesive layer. 
     
     
       9. The cover defined in  claim 8  wherein the additional adhesive layer has a fifth array of openings that align with the first, second, third, and fourth arrays of openings. 
     
     
       10. The cover defined in  claim 1  wherein at least one of the first and second knit fabric layers comprises warp knit fabric. 
     
     
       11. A flexible cover for a speaker, comprising:
 a first cylindrical fabric portion; 
 a second cylindrical fabric portion; 
 a layer of adhesive interposed between the first and second cylindrical fabric portions; and 
 an array of openings that pass through the first cylindrical fabric portion, the second cylindrical fabric portion, and the layer of adhesive. 
 
     
     
       12. The flexible cover defined in  claim 11  wherein at least one of the first and second cylindrical fabric portions comprises warp knit fabric. 
     
     
       13. The flexible cover defined in  claim 11  wherein the openings are less than 10 millimeters wide. 
     
     
       14. The flexible cover defined in  claim 11  wherein array of openings comprises rows of diamond-shaped openings that extend around a longitudinal axis of the flexible cover. 
     
     
       15. The flexible cover defined in  claim 11  further comprising a foam layer interposed between the first and second cylindrical fabric portions. 
     
     
       16. A removable cover for an electronic device, comprising:
 multiple layers of fabric, including at least one warp knit fabric layer; 
 adhesive that attaches the multiple layers of fabric together; and 
 openings that pass through the multiple layers of fabric and the adhesive, wherein the openings permit sound from the electronic device to pass through the removable cover. 
 
     
     
       17. The removable cover defined in  claim 16  further comprising a stiffener interposed between the warp knit fabric layer and the adhesive. 
     
     
       18. The removable cover defined in  claim 17  wherein the stiffener comprises a material selected from the group consisting of: metal and polymer. 
     
     
       19. The removable cover defined in  claim 16  wherein the openings are diamond-shaped. 
     
     
       20. The removable cover defined in  claim 16  wherein the multiple layers of fabric surround a cavity that receives the electronic device.

Description:
This application is a continuation of U.S. patent application Ser. No. 14/579,953, filed Dec. 22, 2014, which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     This relates generally to electronic devices and, more particularly, to electronic devices having structured fabric. 
     Electronic devices can be formed from fabric or can have portions that are formed from or covered with fabric. The fabric-based electronic device may be worn or held by a user. In some situations, the fabric may be used to hold an electronic device against a user&#39;s wrist, arm, or other part of the body. In other situations, a fabric can form a housing component, case, or protective cover for an electronic device. 
     Because of its softness and lack of rigidity, fabric is typically regarded as unsuitable for use as a structural component in an electronic device. Rigid structures such as meshes and protective cases are typically formed using metal or plastic. Plastic cases and metal meshes may be satisfactory in certain situations, but some users may desire a different look and feel. 
     It would be desirable to be able to address these concerns by providing improved techniques for incorporating structure and rigidity into fabric for an electronic device. 
     SUMMARY 
     Electronic equipment may include structured fabric. Structured fabric may be used as a protective case or cosmetic cover for an electronic device, may be used to form a band that holds an electronic device against a user&#39;s body, or may be used to cover one or more openings in an electronic device. 
     Structured fabrics may be soft and pliable while maintaining the ability to hold a given shape without added support. Structured fabric may be formed by laminating fabric such as warp-knit fabric with a stiffener such as polymer film. Structured fabrics may include openings through which signals such as optical or audio signals pass. To maintain the geometry and shape of the openings in the structured fabric without covering the openings, the stiffener and adhesive that are attached to the fabric may be cut to form a pattern of openings that align with the openings in the fabric. 
     The stiffener, adhesive, and fabric may be placed between upper and lower mold structures during the lamination process. The lower mold structure may include alignment posts that help align the fabric with the stiffener and adhesive. For example, the lower mold structure may include alignment posts having a shape, size, and spacing that matches the shape, size, and spacing of openings in the fabric. Each alignment post may be inserted into a respective opening in the fabric, a respective opening in the adhesive layer, and a respective opening in the polymer film. Heat and pressure may be applied while compressing the fabric, adhesive, and stiffener between the upper and lower mold structures to thereby laminate the fabric to the stiffener using the adhesive. 
     The structured fabric may be shaped into the appropriate form factor during lamination or may be shaped following lamination. The structured fabric may, for example, have a cylindrical shape to form a hollow tube that surrounds an electronic device or the structured fabric may have any other suitable shape. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of illustrative electronic equipment having one or more stiffeners incorporated into fabric in accordance with an embodiment. 
         FIG. 2  is a perspective view of illustrative electronic equipment including a structured fabric sleeve for an electronic device in accordance with an embodiment. 
         FIG. 3  is a perspective view of the electronic equipment of  FIG. 2  showing how a structured fabric sleeve can be removed from an electronic device in accordance with an embodiment. 
         FIG. 4  is a perspective view of illustrative electronic equipment including a structured fabric band attached to an electronic device in accordance with an embodiment. 
         FIG. 5  is a top view of structured fabric having diamond-shaped openings in accordance with an embodiment. 
         FIG. 6  is a top view of structured fabric having circular openings in accordance with an embodiment. 
         FIG. 7  is a top view of structured fabric having rectangular openings in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of structured fabric having a fabric layer laminated with a stiffener in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of structured fabric having a fabric layer laminated with a stiffener and with an additional layer interposed between two adhesive layers in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of structured fabric having two fabric layers laminated with a stiffener and two adhesive layers in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of structured fabric having a fabric layer laminated with a stiffener and an additional layer in accordance with an embodiment. 
         FIG. 12  is a cross-sectional side view of structured fabric having rigid portions laminated with stiffeners and flexible portions without stiffeners in accordance with an embodiment. 
         FIG. 13  is a diagram of an illustrative system being used to form a laminated stack with an adhesive layer and a stiffener having a pattern of openings in accordance with an embodiment. 
         FIG. 14  is a diagram of an illustrative system being used to form a laminated stack with an adhesive layer and a stiffener having a pattern of openings in accordance with an embodiment. 
         FIG. 15  is an exploded perspective view of an illustrative system being used to laminate a fabric layer with a stiffener in accordance with an embodiment. 
         FIG. 16  is a cross-sectional side view of an illustrative system being used to laminate a fabric layer with a stiffener in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A schematic diagram of an illustrative fabric-based system that may include one or more stiffeners incorporated into fabric is shown in  FIG. 1 . Fabric-based electronic equipment  24  of  FIG. 1  may include an electronic device such as electronic device  10  and fabric such as fabric  20 . Electronic device  10  and fabric  20  may be integral with one another, may be detachable or non-detachable from one another, and/or may be physically separate from one another while maintaining the ability to communicate with each other. 
     In one illustrative arrangement, fabric  20  in system  24  may be an accessory for electronic device  10 . For example, fabric  20  may be a removable external case for electronic equipment, may be a strap, may be a wrist band or head band, may be a removable cover for a device, may be a case or bag that has straps or that has other structures to receive and carry electronic equipment and other items, may be a necklace or arm band, may be a wallet, sleeve, pocket, or other structure into which electronic equipment or other items may be inserted, may be part of a chair, sofa, or other seating, may be part of an item of clothing, or may be any other suitable fabric-based item. If desired, fabric  20  may be used in forming part of an electronic device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a speaker, 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&#39;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 fabric-based equipment is mounted in a kiosk, in an automobile or other vehicle, equipment that implements the functionality of two or more of these devices, or other electronic equipment. 
     Fabric  20  may form all or part of electronic device  10 , may form all or part of a housing wall for electronic device  10 , may form internal structures in electronic device  10 , may cover one or more openings, recesses, or ports in electronic device  10 , or may form other fabric-based structures. Fabric-based device  24  may be soft (e.g., the device may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., the surface of the device may be formed form 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. 
     As shown in  FIG. 1 , electronic device  10  may include control circuitry  16 . Control circuitry  16  may include storage and processing circuitry for controlling the operation of device  10 . Control circuitry  16  may, for example, include storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive), volatile memory (e.g., static or dynamic random-access-memory), etc. Control circuitry  16  may include processing circuitry based on one or more microprocessors, microcontrollers, digital signal processors, baseband processors, power management units, audio codec chips, application specific integrated circuits, etc. 
     Input-output devices  12  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. Input-output devices  12  may also include input-output components with which a user can control the operation of device  10 . A user may, for example, supply commands through input-output devices  12  and may receive status information and other output from device  10  using the output resources of input-output devices  12 . 
     Input-output devices  12  may include sensors and status indicators such as an ambient light sensor, a proximity sensor, a temperature sensor, a pressure sensor, a magnetic sensor, an accelerometer, a touch sensor, a fingerprint sensor, and light-emitting diodes and other components for gathering information about the environment in which device  10  is operating and providing information to a user of device  10  about the status of device  10 . Audio components in devices  12  may include speakers and tone generators for presenting sound to a user of device  10  and microphones for gathering user audio input. Devices  12  may include one or more displays such as display  14 . Displays may be used to present images for a user such as text, video, and still images. Sensors in devices  12  may include a touch sensor array that is formed as one of the layers in display  14 . During operation, user input may be gathered using buttons and other input-output components in devices  12  such as touch pad sensors, buttons, joysticks, click wheels, scrolling wheels, touch sensors such as a touch sensor array in a touch screen display or a touch pad, key pads, keyboards, vibrators, cameras, and other input-output components. The input-output devices of device  10  may include wired and wireless communications circuitry (e.g., circuitry to support digital data communications, a radio-frequency transceiver and antennas for supporting wireless communications, etc.). 
     Fabric  20  may be formed from intertwined fibers. Fibers that form fabric  20  may be single-strand filaments or may be threads, yarns, or other fibers that have been formed by intertwining single-strand filaments. Fibers may be formed from polymer, metal, glass, graphite, ceramic, natural materials such 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 fiber cores. Fibers may also be formed from single filament metal wire or stranded wire. Fibers may be insulating or conductive. Fibers may be conductive along their entire length or may have conductive segments (e.g., metal portions that are exposed by locally removing polymer insulation from an insulated conductive fiber). Threads and other multi-strand fibers that have been formed from intertwined filaments may contain mixtures of conductive fibers and insulating fibers (e.g., metal fibers or metal coated fibers with or without exterior insulating layers may be used in combination with solid plastic fibers or natural fibers that are insulating). 
     One or more stiffening structures such as stiffeners  28  may be incorporated into fabric  20 . Stiffener  28  may be used to provide rigidity and structure to fabric  20 . For example, the shape and structure of fabric  20  and/or the shape and structure of openings in fabric  20  may be maintained using stiffener  28 . Stiffener  28  may be formed from a plastic layer (e.g., polyethylene terephthalate, polycarbonate, or other polymer film), a metal sheet (e.g., a thin stainless steel layer), a foam layer, silicone or other elastomeric material, or other rigid layers of plastic, metal, etc. 
     Stiffeners  28  may be intertwined (e.g., interwoven) with fibers of fabric  20 , may be sandwiched between two layers of fabric  20 , may be stitched into fabric  20 , may be attached to the surface of edge of fabric  20 , or may be integrated with fabric  20  using any other suitable method. There may be only one stiffener  28  in fabric  20  or fabric  20  may include multiple stiffeners  28 . Stiffeners  28  may be separated into multiple layers of fabric  20  or may be formed in a single layer of fabric  20 . Stiffeners  28  may be stacked (e.g., may overlap each other in fabric  20 ) or may be formed in different regions of fabric  20  (e.g., a first stiffener  28  may be formed in a first portion of fabric  20  and a second stiffener  28  may be formed in a second portion of fabric  20 ). 
     Path  22  may form a mechanical, electrical, and/or wireless connection between fabric  20  and electronic device  10 . For example, path  22  may be an attachment structure that physically attaches fabric  20  to electronic device  10  and/or path  22  may be or may include conductive pathways that convey electrical signals between electronic device  10  and fabric  20 . 
     Control circuitry  16  may be used to run software on device  10  such as operating system code and applications. During operation of system  24 , the software running on control circuitry  16  may display images for a user on display  14  and may use other devices within input-output devices  12 . For example, the software running on control circuitry  16  may be used to process input from a user using one or more sensors (e.g., capacitive touch sensors, mechanical sensors, thermal sensors, force sensors, switches, buttons, touch screen displays, and other components) and may be used to provide status indicator output and other visual and/or audio output. Control circuitry  16  may use devices  12  to provide vibrations, pressure, and/or other physical output (e.g., haptic output). Changes in fabric attributes such as fabric temperature, texture, size, and shape may also be produced using devices  12  and/or using output devices in fabric  20  to convey output to a user. 
     A perspective view of illustrative electronic equipment  24  in which fabric  20  forms a removable cover or sleeve for electronic device  10  is shown in  FIG. 2 . In the example of  FIG. 2 , electronic device  10  has a capsule-like cylindrical shape, and fabric  20  has a matching cylindrical (tube-like) shape to conform to the outer surface of electronic device  10  when fabric  20  is placed on electronic device  10 . Electronic device  10  may, for example, be a speaker device such as BEATS PILL® portable speakers or other suitable speaker device. This is, however, merely illustrative. In general, electronic device  10  may be any suitable type of electronic device having any suitable exterior shape (e.g., cylindrical, rectilinear, round, etc.), and fabric  20  may have a corresponding shape to form a cover or case for electronic device  10 . 
     Fabric  20  may be a warp-knit fabric having fibers that zigzag along the length of the fabric or may be formed from fibers (e.g., warp fibers and weft fibers) woven in a plain weave. In general, fabric  20  may include any intertwined fibers (woven, knitted, braided, etc.). Fabric  20  may contain conductive fibers, may contain a mixture of conductive and insulating fibers, or may be formed exclusively from insulating fibers. 
       FIG. 3  is a perspective view of the electronic equipment of  FIG. 2  showing how fabric-based cover  20  may be removed from electronic device  10 . Fabric-based cover  20  may, for example, be formed from structured fabric that holds its shape even when removed from electronic device  10 . As shown in  FIG. 3 , for example, fabric-based cover  20  maintains a cylindrical shape even when removed from the cylindrical body of electronic device  10 . 
     A perspective view of another illustrative type of fabric-based system is shown in  FIG. 4 . In the example of  FIG. 4 , fabric  20  is attached to housing  50  of electronic device  10  and may, for example, be used to attach electronic device  10  to some part of a user&#39;s body. For example, fabric  20  may form a wrist band, an arm band, a head band, a waist band, or other article that can be secured against a user&#39;s body and that can support or hold electronic device  10  in place (e.g., against a user&#39;s skin). The arrangement of  FIG. 4  is, however, merely illustrative. In general, electronic device  10  and fabric  20  may be integrated with or attached to one another in any suitable fashion. 
     It can be difficult to maintain structure and shape in warp-knit fabrics. Without structure and rigidity, warp-knit fabric may be unable to maintain a shape on its own. Patterns in the fabric such as patterned openings may become deformed if not properly supported. To ensure that fabric  20  is able to maintain a desired structure and shape, fabric  20  may include one or more stiffeners. Incorporating stiffeners into fabric  20  may allow fabric  20  to maintain a curved shape as shown in the example of  FIGS. 2, 3, and 4 . Portions of fabric  20  that include patterns or openings may be provided with rigidity to ensure that the geometry of a pattern or opening is accurately maintained. 
     A top view of an illustrative fabric  20  that may be used in equipment  24  is shown in  FIG. 5 . As shown in  FIG. 5 , fabric  20  may be attached to housing  50 . Fabric  20  may, for example, be attached to opposing edges of an electronic device housing that encloses electronic components (e.g., as in the example of  FIG. 4 ). In other arrangements, fabric  20  may be mounted in or over an opening or recess in housing  50  of an electronic device. For example, fabric  20  may be mounted over an electrical component in housing  50  such as light-emitting diodes, lamps, displays, lasers, or other light-emitting components, vibrators, buzzers, speakers, tone-generators, microphones, or other acoustic components, sensors such as touch sensors, temperature sensors, accelerometers, compasses, gyroscopes, position sensors, proximity sensors, or other suitable electronic components. 
     As shown in  FIG. 5 , fabric  20  may include one or more openings such as openings  18 A. Openings  18 A may provide fabric  20  with a desired aesthetic, may provide fabric  20  with breathability, and/or may provide fabric  20  with pathways through which signals such as optical signals, audio signals, or other signals may pass (e.g., from the interior of housing  50  to the exterior of housing  50  and/or from the exterior of housing  50  to the interior of housing  50 ). For example, components such as light-emitting components, speakers, or other components may transmit signals through openings  18 A in fabric  20 . 
     Openings  18 A may be relatively large openings (e.g., each spanning a distance of 10 mm, 50 mm, or more than 50 mm) or openings  18 A may be relatively small openings (e.g., each spanning a distance of less than 10 mm). For example, in fabric  20  of  FIG. 5  with diamond shaped openings  18 A, the horizontal distance A spanned by each opening may be between 2 mm and 3 mm, the horizontal distance between adjacent openings  18 A may be between 1.5 mm and 2.5 mm, the vertical distance C spanned by each opening may be between 4 mm and 5 mm, and the vertical distance D between adjacent openings  18 A may be between 3 mm and 4 mm. These are merely illustrative examples, however. In general, openings  18 A may have any suitable size, shape, and spacing. If desired, openings  18 A may be circular as shown in  FIG. 6 , may be rectangular as shown in  FIG. 7 , or may have any other suitable shape (e.g., an oval shape, a spiral shape, a triangular shape, an annular shape, etc.). 
     It may be desirable to maintain the geometry and shape of openings  18 A in fabric  20 . For example, if signals such as optical signals or audio signals are passing through openings  18 A in fabric  20 , care must be taken to ensure that the flexibility of fabric  20  does not cause fabric  20  to become limp and openings  18 A to become blocked or deformed. 
     To provide fabric  20  with a desired rigidity, fabric  20  may be laminated with a stiffener as shown in  FIG. 8 . A shown in  FIG. 8 , adhesive  26  may adhere a stiffener such as stiffener  28  to fabric layer  20  to form structured fabric  44 . In arrangements where fabric  20  does not include openings  18 A, adhesive  26  and stiffener  28  may each form a solid contiguous layer on fabric  20 . In arrangements where fabric  20  includes visible openings such as openings  18 A, adhesive  26  and stiffener  28  may also include openings that align with openings  18 A of fabric  20 . Aligning openings in adhesive  26  and stiffener  28  with openings  18 A of fabric  20  may ensure that signals such as optical signals and/or audio signals can pass through openings  18 A in fabric  20 . This is, however, merely illustrative. If desired, fabric  20  may include openings  18 A that are covered by an adhesive layer and stiffener layer. 
     Adhesive  26  may be an adhesive tape that includes a flexible layer, sometimes referred to as a carrier or substrate. Pressure sensitive adhesive can be used to coat a single carrier surface or double-sided tape can be formed by coating opposing carrier surfaces with pressure sensitive adhesive. This is, however, merely illustrative. If desired, adhesive  26  may be a chemically activated adhesive (e.g., a two-part adhesive having a hardener and a resin), a thermally activated adhesive that is cured by raising the temperature of the adhesive above room temperature, a light-cured adhesive (e.g., an adhesive cured by application of ultraviolet (UV) light) such as UV epoxy, or other suitable adhesive. 
     Adhesive  26  may be provided with flexible carriers such as one or more flexible polymer layers. Examples of polymers that may be used as tape carriers include polyester film (i.e., polyethylene terephthalate) and polyimide. Other polymer layers that may be used as pressure sensitive adhesive tape carriers may be used if desired. Tape may be dispensed in the form of elongated strips, in ring shapes (e.g., die cut circular or rectangular rings with open centers), L-shaped and C-shaped patterns, circles, squares, other solid shapes, or other suitable shapes. If desired, stiffener  28  may be used as a tape carrier for adhesive  26  or adhesive  26  may have a carrier that is separate from stiffener  28 . If desired, non-stick release liners may be coupled to the exposed surfaces of adhesive  26  during manufacturing to facilitate tape handling. 
     Stiffener  28  may be formed from a plastic layer (e.g., polyethylene terephthalate, polycarbonate, or other polymer film), a metal sheet (e.g., a thin stainless steel layer), metal wires (e.g., a grid or web of thin metal wires that align with fabric  20  and do not overlap openings  18 A), a foam layer, silicone or other elastomeric material, or other rigid layers of plastic, metal, etc. If desired, stiffener  28  may include multiple layers of stiffening structures, such as a foam layer interposed between opposing polymer film layers. 
       FIG. 9  is a cross-sectional side view of another illustrative configuration for structured fabric  44 . In the arrangement of  FIG. 9 , structured fabric  44  includes a first adhesive layer  26 A and a second adhesive layer  26 B interposed between fabric layer  20  and stiffener  28 . An additional layer such as layer  40  may be interposed between adhesive layers  26 A and  26 B. Layer  40  may be an ink layer (e.g., a conductive ink layer, a non-conductive ink layer, a black ink layer, or other suitable ink layer), a polymer film layer, a metal layer, a thermally conductive layer, or other suitable layer. If desired, layer  40  may be formed selectively (e.g., may be patterned) between fabric  20  and stiffener  28  or may be formed as a single contiguous layer between fabric  20  and stiffener  28 . Layer  40  may, for example, form a carrier substrate for adhesive layer  26 A and  26 B to form a double-sided tape. 
       FIG. 10  is a cross-sectional side view of another illustrative configuration for structured fabric  44 . In the arrangement of  FIG. 10 , structured fabric  44  includes multiple layers of fabric such as fabric layer  20 A and fabric layer  20 B laminated with stiffener  28  and adhesive layers  26 A and  26 B. Stiffener  28  is interposed between first adhesive layer  26 A and second adhesive layer  26 B, and the adhesive layers  26 A and  26 B are interposed between outer layers of fabric  20 A and  20 B. The use of fabric  20  to form the outermost layers of structured fabric  44  can provide a soft surface on both sides of the structured fabric. 
       FIG. 11  is a cross-sectional side view of another illustrative configuration for structured fabric  44 . In the example of  FIG. 11 , structured fabric  44  includes only one adhesive layer interposed between fabric  20  and stiffener  28 . Layer  40  may be formed between adhesive layer  26  and stiffener  28  (as shown in the example of  FIG. 11 ) and/or layer  40  may be formed between adhesive layer  26  and fabric  20 . 
       FIG. 12  is a cross-sectional side view of structured fabric  40  showing how some portions such as portions  46  of fabric layer  20  may be laminated with a stiffener while other portions such as portions  42  of fabric layer  20  may not include any stiffeners and may therefore remain flexible and bendable. For example, the absence of stiffener  28  in portion  42  of fabric layer  20  may allow portion  42  of fabric layer  20  to bend about bend axis B while portions  46  remain stiff and flat. This is, however, merely illustrative. If desired, all of fabric  20  may be stiff and rigid or fabric  20  may include one or more rigid portions  46  and one or more flexible portions  42 . 
     If desired, adhesive  26  and stiffener  28  may be laminated together prior to being attached to fabric layer  20 .  FIG. 13  is a system diagram showing how adhesive  26  and stiffener  28  may be attached together and provided with a pattern of openings that matches the pattern of openings  18 A of fabric  20 . As shown in  FIG. 13 , lamination equipment  30  may be used to laminate adhesive  26  to stiffener  28 . Lamination equipment  30  may include a roller laminator, vacuum lamination equipment, or other equipment for attaching adhesive  26  to stiffener  28 . 
     In arrangements where fabric  20  does not include a pattern of openings, stiffener  28  and adhesive  26  may be kept as solid contiguous layers (without openings) and may be laminated with fabric  20  (e.g., using lamination equipment  30 ). In arrangements where fabric  20  includes a pattern of openings and has a web-like configuration, it may be desirable to cut adhesive  26  and stiffener  28  to have a corresponding pattern of openings and a corresponding web-like configuration. 
     Cutting equipment such as cutting tool  32  (e.g., die cutting equipment, laser cutting equipment, a cutting blade, or other suitable cutting equipment) may be used to cut or trim adhesive  26  and stiffener  28  into the desired shape. This may include, for example, cutting adhesive  26  and stiffener  28  to form holes  18 B in adhesive  26  and stiffener  28 . Openings  18 B may have a shape, size, and spacing that corresponds to the shape, size, and spacing of openings  18 A in fabric  20 . Providing adhesive  26  and stiffener  28  with a pattern of openings that matches the pattern of openings in fabric  20  may allow stiffener  28  to provide structure to the portions of fabric  20  that surround openings  18 A while ensuring that adhesive material  26  and stiffener material  28  do not overlap with openings  18 A in fabric  20 . 
     The example of  FIG. 13  in which adhesive  26  and stiffener  28  are laminated together prior to cutting openings  18 B using cutting tool  32  is merely illustrative. If desired, adhesive  26  and stiffener  28  may each be cut separately prior to being laminated together. This type of arrangement is shown in  FIG. 14 . As shown in  FIG. 14 , cutting tool  32  may be used to cut openings  18 B in adhesive  26  and in stiffener  28  before adhesive  26  and stiffener  28  are laminated together. Following formation of openings  18 B in adhesive  26  and stiffener  28 , adhesive  26  and stiffener  28  may aligned such that openings  18 B in adhesive  26  align with openings  18 B in stiffener  28 . Adhesive  26  and stiffener  28  may then be laminated together using lamination equipment  30 . 
     Following lamination of adhesive  26  and stiffener  28 , adhesive  26  and stiffener  28  may be laminated with fabric  20 .  FIG. 15  is an exploded perspective view of illustrative equipment that may be used to laminate fabric  20  to stiffener  28 . As shown in  FIG. 15 , fabric  20 , adhesive  26  and stiffener  28  may be placed onto a mold structure such as lower mold  34 A. Lower mold  34 A may serve as a support structure for layers  28 ,  26 , and  20  during the lamination process. In the example of  FIG. 15 , stiffener  28  is placed directly on lower mold  34 A and is interposed between lower mold  34 A and fabric  20 . This is, however, merely illustrative. If desired, fabric  20  may be placed directly on lower mold  34 A and may be interposed between lower mold  34 A and stiffener  28 . 
     If desired, lower mold  34 A may be provided with alignment features such as alignment posts  36 . Alignment posts  36  may protrude upwards from the surface of lower mold  34 A and may have a shape, size, and spacing that matches the shape, size, and spacing of holes  18 A and  18 B. For example, in arrangements where openings  18 A and  18 B have a diamond shape, alignment posts  26  may have a corresponding diamond shape that fits within openings  18 A and  18 B. In this way, alignment posts  36  may pass through openings  18 A and  18 B when layers  26 ,  28 , and  20  are placed on lower mold  34 A. This helps to ensure that the alignment of holes  18 A in fabric  20  and holes  18 B in stiffener  28  and adhesive  26  is maintained throughout the lamination process. 
     The example of  FIG. 15  in which alignment posts  36  are formed in a pattern that precisely matches the pattern of openings  18 A and  18 B is merely illustrative. If desired, alignment post  36  may be formed with a different pattern. For example, there may be only one alignment post  36  that aligns with an opening in fabric  20 , there may be one alignment post  36  at each corner of mold  34 A that aligns with openings in fabric  20 , or there may be any other suitable number of alignment posts  36  to assist in aligning fabric  20  with stiffener  28 . If desired, alignment posts  36  may have a different shape, size, or spacing than openings  18 A and  18 B. 
       FIG. 16  is a system diagram showing how fabric  20  may be laminated to stiffener  28 . As shown in  FIG. 16 , adhesive  26  may be interposed between fabric  20  and stiffener  28 , and these layers may be interposed between lower mold  34 A and upper mold  34 B (sometimes referred to as upper and lower support structures). Lower mold  34 A and upper mold  34 B may, for example, be formed from thermally conductive materials such as metal. 
     Tool  56  may include hot pressing equipment (e.g., heated dies or other equipment for applying heat and pressure). Hot pressing equipment  56  may be used to heat and compress fabric  20 , adhesive  26 , and stiffener  28  between lower mold  34 A and upper mold  34 B. The heat and pressure from hot pressing equipment  56  may in turn activate adhesive  26  to thereby permanently attach fabric  20  to stiffener  28 . If desired, the lamination process may also include a cooling step following application of heat by equipment  56 . After laminating fabric  20  to stiffener  28 , fabric  20  and stiffener  28  may together form a structured fabric having a desired rigidity. 
     If desired, hot pressing equipment  56  may be used to compress fabric  20 , adhesive  26 , and stiffener  28  into a desired shape. Hot pressing tools  56  may, for example, form structured fabrics with angled bends, shapes with curves, shapes with compound curves, shapes with openings (e.g., circular or rectangular holes or holes having a combination of straight and curved edges), shapes that form open pockets (e.g., open-topped boxes), shapes that form planar covering structures (e.g., shapes with portions that are configured to cover openings), etc. Molds  34 A and  34 B may be formed with a desired shape to produce a corresponding shape in fabric  20 . This is, however, merely illustrative. If desired, fabric  20  and stiffener  28  may be laminated together as planar or substantially planar sheets and may be shaped into the appropriate form factor after lamination. Following lamination and shaping, the structured fabric may be mounted or attached to an electronic device (e.g., as shown in  FIGS. 2, 3, and 4 ).

Metadata:
Filing Date: 20180208
Publication Date: 20210330
Grant Date: 20210330
Priority Date: 20141222
Inventors: HAMADA, Yohji
BAKER, JOHN J.
COXETER, PETER F.
RAPPOPORT, BENJAMIN M.
WALKER, JOSEPH B.
Assignee: APPLE INC
CPC Classifications: [{"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24273", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B37/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/03", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B38/0008", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B37/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B38/0004", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24322", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2305/182", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24306", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24322", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B38/0008", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2305/182", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24273", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24306", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B37/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/03", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B38/0004", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B37/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B7/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B27/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 61148130