PATENT DOCUMENT

Publication Number: US-10336031-B2
Application Number: US-201615006446-A
Country: US
Kind Code: B2

Title: In-process polyurethane edge coating of laser cut polyurethane laminated fabric

Abstract:
Processes for forming cosmetically appealing edges on laminated fabric structures are described. The methods involve a laser cutting process that includes in-process melting of polymer material within the laminated fabric so as to coat fibers of the laminated fabric. The resultant cut laminated fabric has a cosmetic edge that has no exposed fibers. The laser cutting and melting can be performed in a single laser cutting operation, making it well suited for integration into manufacturing product lines.

Claims:
What is claimed is: 
     
       1. A method of forming a cosmetic edge on a laminated fabric, the laminated fabric including a polymer layer and an attached fabric layer, the fabric layer including fibers, the method comprising:
 cutting an edge of the laminated fabric by directing a laser beam at the polymer layer and the attached fabric layer, wherein during the cutting: 
 the laser beam melts a portion of the polymer layer forming a pool of melted polymer material, wherein the pool of melted polymer material coats the fibers along the edge so as to prevent exposure of the fibers along the edge. 
 
     
     
       2. The method of  claim 1 , wherein cutting the edge comprises using a pulsed laser beam that impinges the laminated fabric a plurality of times. 
     
     
       3. The method of  claim 1 , wherein cutting the edge comprises scanning the laser beam over the laminated fabric a plurality of times. 
     
     
       4. The method of  claim 1 , wherein cutting the edge and melting the portion of the polymer layer occurs using a single laser operation. 
     
     
       5. The method of  claim 1 , wherein the laminated fabric includes a plurality of polymer layers and wherein the fabric layer is positioned between at least two of the plurality of polymer layers. 
     
     
       6. The method of  claim 1 , wherein the polymer layer includes at least one of polyurethane, epoxy, acrylic, polyester and a polyimide. 
     
     
       7. The method of  claim 1 , wherein the fibers include at least one of polymer-based fibers, carbon fibers and glass fibers. 
     
     
       8. The method of  claim 1 , wherein the cut edge is a beveled edge. 
     
     
       9. A method of cutting a laminated fabric, the laminated fabric including a polymer layer and a fabric layer, the fabric layer having fibers, the method comprising:
 impinging a laser beam on the laminated fabric such that the laser beam cuts the laminated fabric, wherein the laser beam locally heats the polymer layer forming a pool of melted material that completely coats a cut edge of the fabric layer; and 
 repeating the impinging until the laser beam cuts through a width of the laminated fabric such that a final cut edge of the laminated fabric has a coating that completely covers the fabric layer and the fibers along the final cut edge. 
 
     
     
       10. The method of  claim 9 , wherein repeating the impinging comprises using a pulsed laser beam that impinges the laminated fabric a plurality of times. 
     
     
       11. The method of  claim 9 , wherein repeating the impinging comprises scanning the laser beam over the laminated fabric a plurality of times. 
     
     
       12. The method of  claim 9 , wherein repeating the impinging comprises stepwise cutting the laminated fabric and melting the polymer layer in a single laser operation. 
     
     
       13. The method of  claim 9 , wherein the pool of melted material cools and at least partially hardens prior to repeating the impinging.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C § 119(e) to U.S. Provisional Application No. 62/233,525, entitled “IN-PROCESS POLYURETHANE EDGE COATING OF LASER CUT POLYURETHANE LAMINATED FABRIC,” filed on Sep. 28, 2015, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate generally to laminated polymer fabrics. More particularly, the present embodiments relate to cutting laminated polymer fabrics using laser techniques. 
     BACKGROUND 
     Polyurethane laminated fabrics are laminated fabrics generally characterized as being flexible and water resistant, and are thus used in a wide range of applications including garments and medical equipment and accessories. The polyurethane laminated fabrics generally include woven fibers or threads of material that give them a flexible and cloth-like feel and movement. One of the manufacturing challenges associated with using polyurethane laminated fabrics as a raw material is that when the laminated fabric is cut, the cut woven fibers or threads can protrude from edges of the laminated fabric, leaving a ragged and cosmetically unappealing edge. In addition, the fibers or threads may be a different color than the polyurethane, exacerbating the cosmetic problem. What are needed therefore are methods for efficiently cutting polyurethane laminated fabrics such that the cut laminated fabric has clean and cosmetically appealing edges. 
     SUMMARY 
     This paper describes various embodiments that relate to laser techniques for cutting laminated fabric materials. In particular embodiments, efficient laser cutting techniques for forming cosmetically appealing cut edges on laminated fabrics in a manufacturing setting are described. 
     According to one embodiment, a method of forming a cosmetic edge on a laminated fabric is described. The laminated fabric includes a polymer layer and a fabric layer. The fabric layer includes fibers. The method includes cutting an edge of the laminated fabric by directing a laser beam at the laminated fabric. During the cutting, the laser beam melts a portion of the polymer layer forming a pool of melted polymer material, wherein the pool of melted polymer material coats the fibers along the edge so as to prevent exposure of the fibers along the edge. 
     According to another embodiment, a laminated fabric that includes a polymer layer and a fabric layer is described. The fabric layer has fibers. The laminated fabric includes an edge having a coating comprised of a material of the polymer layer. The coating covers a portion of the fibers proximate to the edge so as to prevent exposure of the fibers at the edge. 
     According to a further embodiment, a method of cutting a laminated fabric is described. The laminated fabric includes a polymer layer and a fabric layer. The method includes impinging a laser beam on the laminated fabric such that the laser beam cuts the laminated fabric. The laser beam locally heats the polymer layer forming a pool of melted material that at least partially coats a cut edge of the fabric layer. The method also includes repeating the impinging until the laser beam cuts through a width of the laminated fabric such that a final cut edge of the laminated fabric has a coating that covers the fabric layer and prevents exposure of the fibers along the final cut edge. 
     These and other embodiments will be described in detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements. 
         FIG. 1  shows a plan view and a partial cross-section view of laminated fabric. 
         FIGS. 2A-2D  shows cross section views of a laminated fabric undergoing a laser cutting process in accordance with some embodiments. 
         FIG. 3  shows a cross section view of a laminated fabric with a beveled edge after undergoing a laser cutting process in accordance with some embodiments. 
         FIG. 4  shows a flowchart indicating a process for cutting a laminated fabric in accordance with some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure relates to laminated fabrics, such as polyurethane laminated fabrics. The laminated fabrics can include a polymer layer and a fabric layer that includes a woven network of fibers. The techniques described herein involve the use of lasers so as to cut a laminated fabric while creating a cosmetically appealing cut edge within one laser cutting operation. The methods involve using a laser beam having a high enough energy to cut the laminated fabric but not so high as to pierce through the laminated fabric without melting polymer material of the polymer layer. By cutting the laminated fabric in the same laser operation as melting a polymer material, the melted polymer can coat an edge of the laminated fabric as it is being cut. The laser operation can be tuned such that the melted polymer material flows over and coats edges of the fibers, resulting in a fully coated cosmetic edge that is free from exposed fibers. 
     In some embodiments, the laser cutting process involves a stepwise process where the laser beam impinges upon the laminated fabric a number of times, gradually cutting and coating the edge with each impingement. This can be accomplished using a pulsed laser beam or by scanning a continuous laser beam over the laminated fabric a number of times. Between each laser interaction, the melted polymer material can partially cool and harden, preventing splatter of the polymer material. The stepwise process can continue until an entire width of the laminated fabric is cut. The laminated fabrics and cutting processes described herein are well suited for implementation in the manufacture of consumer products, such as those manufactured by Apple Inc., based in Cupertino, Calif. 
     These and other embodiments are discussed below with reference to  FIGS. 1-4 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  shows plan view  100  and partial cross-section view  101  of laminated fabric  102 . Laminated fabric  102  can be used to make any of a number of products such as garments, bags, cases, etc. In some embodiments, laminated fabric  102  is designed to be flexible, durable, and at least partially water resistant. In some cases, laminated fabric  102  is used as a material for a cable cover as part of an electronic device, such as described in U.S. provisional Patent Application 62/167,848, which is incorporated herein in its entirety. 
     Laminated fabric  102  includes fabric layer  103 , which has fibers  104  that can be arranged in a woven network. Fibers  104  are optionally embedded within matrix material  105 . In some embodiments, fibers  104  are synthetic fibers, such as polymer-based fibers, carbon fibers, or glass fibers. In other embodiments, fibers  104  include natural fibers such as cotton, wool or flax. In some embodiments, fibers  104  include a combination of different types of synthetic fibers and/or natural fibers. The material for fibers  104  can be chosen based on high strength modulus, chemical and thermal stability and other factors. Suitable synthetic polymer fibers  104  can include Vectran® (registered trademark of Kuraray America, Inc.) and Kevlar® (registered trademark of E. I. du Pont de Nemours and Company (a.k.a., DuPont)). 
     In some embodiments, fibers  104  are embedded within matrix material  105 , which can be a thermosetting polymer material. Matrix material  105  can provide structural support for fabric layer  103  within laminated fabric  102 . In addition, matrix material  105  can be used to bond fabric layer  103  with surrounding layers. Suitable materials for matrix material  105  can include one or more of polyurethane, epoxy, acrylic, polyester, a polyimide, etc. In some preferred embodiments, matrix material  105  includes polyurethane. 
     Fabric layer  103  is sandwiched between first polymer layer  106  and second polymer layer  108 , which can act as physical and moisture barriers to fabric layer  103 . In some cases first polymer layer  106  and second polymer layer  108  are directly bonded to fabric layer  103 , while in other cases an adhesive is used to adhere first polymer layer  106  and second polymer layer  108  to fabric layer  103 . The materials of first polymer layer  106  and second polymer layer  108  can be chosen based on flexibility and water repelling capability. In some embodiments, one or both of first polymer layer  106  and second polymer layer  108  include one or more thermosetting polymer materials, such as polyurethane, epoxy, acrylic, polyester, a polyimide, etc. In some preferred embodiments, first polymer layer  106  and second polymer layer  108  both include polyurethane. 
     In some embodiments, laminated fabric  102  includes cosmetic layer  110  that covers first polymer layer  106 . Laminated fabric  102  can correspond to an exterior layer that is visible to and/or in direct contact with a consumer. Cosmetic layer  110  can be made of any suitable material and be chosen for qualities such as a desired color, texture, durability, fade resistance, etc. In a particular embodiment, cosmetic layer  110  includes a faux suede material. In some cases more than one cosmetic layer is used. For example a second cosmetic layer (not shown) can cover second polymer layer  108 . 
     One of the problems associated with cutting laminated fabric  102  is that the cutting process can expose fibers  104  such that they can partially unravel and protrude from edges  112 , leaving edges  112  with an inconsistent and cosmetically unappealing appearance. In addition, fibers  104  may have a different color than first polymer layer  106 , second polymer layer  108  and/or cosmetic layer  110 , making exposed fibers  104  even more visibly apparent and exacerbating the cosmetic problem. 
     The techniques described herein can be used to create cosmetically clean and appealing edges  112 . The techniques can be done quickly and efficiently, and are therefore well suited for use in manufacturing product lines. It should be noted that the laminated fabrics that can be used in accordance with the laser cutting techniques described here are not limited to those presented in  FIG. 1 . For example, a laminated fabric can include multiple fabric layers, polymer layers and/or cosmetic layers. Alternatively, a laminated fabric with only one polymer layer and one fabric layer may be used. 
     The techniques involve the use of a laser cutting operation.  FIGS. 2A-2D  shows cross section views of laminated fabric  102  undergoing a laser cutting process in accordance with some embodiments.  FIG. 2A  shows laser  200  positioned such that laser beam  202  impinges on laminated fabric  102 . Laser  200  is configured to generate laser beam  202  having high enough energy to cut through cosmetic layer  110 , first polymer layer  106 , fabric layer  103  and second polymer layer  108 . However, laser beam  202  should have a low enough energy to cause first polymer layer  106  to melt. That is, laser beam  202  should not have such a high energy so as to cleanly sever through first polymer layer  106  without also melting it. Additionally, laser beam  202  should not have such a high energy so as to cause first polymer layer  106  to splatter. Instead, laser beam  202  is of sufficiently low energy to cause pool  204  of melted polymer material from first polymer layer  106  to form at the site of laser beam  202  impingement. 
     The cutting operation can be continued in a stepwise fashion in which laser beam  202  periodically impinges upon an is averted from laminated fabric  102 . In some embodiments, this is accomplished using laser beam  202  that is pulsed, with each pulse cutting into and laminated fabric  102  and forming a pool  204  of melted polymer material. Alternatively, laser beam  202  can be scanned over laminated fabric  102  a number of times with progressive cutting and melting each time laser beam  202  is scanned over and impinges upon laminated fabric  102 . In some embodiments, a laser beam  202  is both pulsed and scanned over laminated fabric  102 . 
       FIG. 2B  shows laminated fabric  102  after laser beam  202  has completed several impingements within laminated fabric  102  such that subsequent pool  206  of melted polymer material from first polymer layer  106  is formed. The gradual stepwise cutting and melting action allows for periods of time between impingements of laser beam  202  to allow slight cooling and hardening of previously melted pools of material of first polymer layer  106 . In this way, laser beam  202  gradually nibbles away at laminated fabric  102  with each passes of laser beam  202 . This also can prevent splattering of melted polymer material. 
       FIG. 2C  shows laminated fabric  102  after laser beam  202  has passed through first polymer layer  106  and fabric layer  103  such that a series of previously melted pools of first polymer layer  106  cover fibers  104  within fabric layer  103 . That is, coating  208  made of the material of first polymer layer  106  is formed over a region of fabric layer  103 . Coating  208  covers the edge of laminated fabric  102  that is being cut. Laser beam  202  can progress through second polymer layer  108  with each interaction with laser beam  202  until an entire with of laminated fabric  102  is cut, thereby completing the cutting process. 
     Note that when laser beam  202  cuts through second polymer layer  108 , laser beam  202  can either continue the stepwise melting/cutting action. Alternatively, laser beam  202  can be switched to a continuous cutting operation or be switched to higher power in order cleanly and more quickly cut through second polymer layer  108 . The latter may be chosen if it is determined to significantly save overall process time in a manufacturing situation. However, the former may be chosen if it is determined that using the stepwise melting/cutting provides a more consistent appearing coating  208  along the full edge of laminated fabric  102 . 
       FIG. 2D  shows laminated fabric  102  after completion of the laser cutting operation. Edge  210  has coating  208  that covers fabric layer  103  and prevents fibers  104  from being exposed. In this way, edge  210  appears consistent and cosmetically appealing. In a particular embodiment, first polymer layer  106  and second polymer layer  108  have a black color such that coating  208  appears as a consistent black colored polymer coating along edge  210 . Thickness  211  of coating  208  can vary depending on a number of factors such as the material of first polymer layer  106 , the power of laser beam  202 , and the scan and/or pulse rate of laser beam  202 . In some embodiments, thickness  211  of coating  208  is nominally very thin—on the order of micrometers. In some embodiments, thickness  211  is less than a millimeter, in some cases less than 50 micrometers, in some cases less than 10 micrometers. 
     It should be noted that the laser cutting/melting operations described herein could be performed in a single manufacturing operation. That is the stepwise laser scanning and/or pulsing can be performed at a single station with a measurable and repeatable overall time for the laser cutting/melting operation. That is, the coating process can be performed in situ or in-process with the cutting process. This is different than processes that involve a first process for cutting and a second process for coating the cut edge. This in-process cutting and coating technique can save in overall time compared to a multiple process operation. 
     One factor to consider when determining process parameters for implementing a particular laser cutting/melting operation includes the relationship between the effectiveness of the laser cutting/melting and the ratio of thickness  212  of first polymer layer  106  and thickness  214  of fiber layer  103 . For example, if thickness  214  of fiber layer  103  is much greater than that of first polymer layer  106 , it may be difficult to melt enough polymer material of first polymer layer  106  with each scan or pulse of laser beam  202  to adequately coat fiber layer  103 . Thus, the thickness  212 -to-thickness  214  ratio should be sufficiently high to provide adequate coverage of fiber layer  103  along edge  210 . 
     There are some ways of compensating when the thickness  212 -to-thickness  214  ratio is too low to form adequate coverage. One way is to stretch laminated fabric  102  during the laser cutting/melting operation so as to locally and temporarily reduce thickness  214  of fiber layer  103 . Since fiber layer  103  is a woven material that can be more deformable than polymer layer  106 , the stretching force may reduce thickness  214  of fiber layer  103  more than reducing thickness  212  of first polymer layer  106 . Once coating  208  is adequately formed and allowed to cool and harden, the stretching force can be removed. 
     An alternative or additional way of compensating for a low thickness  212 -to-thickness  214  ratio is by increasing the spot size of laser beam  202 . This can be done by adjusting laser parameters such that a diameter or beam width of laser beam  202  is increased such that a greater volume of the material of first polymer layer  106  is melted with each impingement of laser beam  202 . Thus, the spot size of laser beam  202  can be adjusted based on the thickness  212 -to-thickness  214  ratio. 
     The laser cutting/melting process shown in  FIGS. 2A-2D  involves laser beam  202  cutting in a direction substantially perpendicular to external surface  215  of laminated fabric  102 . It should be noted, however, that laser beam  202  can alternatively be oriented at a non-perpendicular angle with respect to external surface  215  so as to form a beveled edge. This is depicted at  FIG. 3  showing a cross section view of laminated fabric  302 , which includes fabric layer  303  sandwiched between first polymer layer  306  and second polymer layer  308 . Fabric layer  303  includes fibers  304 , which is optionally embedded within matrix material  305 . In some embodiments, laminated fabric  302  includes cosmetic layer  310  that covers first polymer layer  306 . 
     Laminated fabric  302  has beveled edge  312  that is coated with coating  314 . Beveled edge  312  can be formed by directing a laser beam at a non-perpendicular angle with respect to exterior surface  315  of laminated fabric  302  in a stepwise fashion similar to as described above with respect to  FIGS. 2A-2D . The angle of beveled edge  312  with respect to exterior surface  315  corresponds to the angle at with the laser beam was directed to laminated fabric  302  with respect to exterior surface  315 . Alternatively, beveled edge  312  can be formed using a laser beam directed in a perpendicular orientation with respect to exterior surface  315 . For example, the position of the perpendicularly oriented laser beam could be shifted with each scan so as to create an overall angled cut, corresponding to beveled edge  312 . 
     In a manufacturing setting where process cycle times can be crucial for good production through put, it may be beneficial to implement time saving measures such as cutting only certain edges of a laminated fabric using the cutting/melting techniques described above since these techniques can take more time than high powered or non-stepwise laser cutting. For example, returning to  FIG. 1 , only one, two or three of the four cut edges of laminated fabric  102  may be visible to a consumer. Thus, only these visible edges can be cut using the cutting/melting techniques described above, whereas remaining non-visible edges are cut using traditional cutting techniques that are faster, thereby increasing the through put of the overall laser cutting process. 
       FIG. 4  shows flowchart  400  indicating a process for cutting a laminated fabric. The laminated fabric includes a polymer layer and a fabric layer. The fabric layer has fibers that are optionally embedded within a matrix material. The laminated fabric optionally includes at least one more polymer layers and/or one or more cosmetic layers. At  402 , the laminated fabric is cut using a laser beam that melts a portion of the polymer layer. The laser beam has a high enough power to cut into a portion of the laminated fabric, in some cases ablating away portions of the laminated fabric. However, the laser power is not so high as to splatter the material of the polymer layer or cleanly pierce through the polymer layer without melting it. That is, the laser beam melts a portion of the polymer layer such that a pool of molten polymer material at least partially coats the fabric layer along the cut edge. 
     At  404 , the laser cutting is repeated until the laser beam cuts through a width of the laminated fabric. In addition, a melted portion of the polymer material coats a final cut edge of the fabric layer, thereby preventing exposure of the fibers along the final cut edge. The repeating can involve using a stepwise process where the laser beam is impinged upon the laminated fabric a number of times. For example, a pulsed laser beam can be used to provide separated pulsed of the laser beam with short intervals of time between the pulses for the melted polymer material to cool and partially harden. Alternatively or additionally, the laser beam can be scanned over the laminated fabric a number of times such that the laminated fabric is cut and melted with each scan. The melted polymer material can cool and partially harden in periods between each pulse or scan. 
     After the laser cutting/melting process is complete, the cut edge has a polymer coating that covers the fibers and provides a consistent and continuous appearance. In some embodiments, the laser cutting process is used to form a straight (i.e., perpendicular edge), while in other embodiments the laser cutting process is used to form a beveled edge. The laser cutting process can cut all or some of the edges of a final laminated fabric piece. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20160126
Publication Date: 20190702
Grant Date: 20190702
Priority Date: 20150928
Inventors: LANCASTER-LAROCQUE, SIMON REGIS LOUIS
NIELSON, BRADLEY J.
KONONIUK, Jacob S.
Assignee: APPLE INC
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Family ID: 58406110