PATENT DOCUMENT

Publication Number: US-10286636-B1
Application Number: US-201615054400-A
Country: US
Kind Code: B1

Title: Fabric-based items with three-dimensional shapes

Abstract:
A fabric-based item may be vacuum-formed into a three-dimensional shape. The fabric-based item may include one or more layers of fabric and one more polymer layers that can be molded when heated. To vacuum-form the fabric-based item into a three-dimensional shape, the fabric based item may be heated until the polymer layer reaches a forming temperature and becomes soft and pliable. When heated, a vacuum tool is used to pull the fabric-based item onto a mold so that the fabric-based item conforms to the shape of the mold. As the fabric-based item cools on the mold, the polymer material hardens into the shape imparted by the mold. The polymer material is able to hold the fabric layers in this shape after the layers are removed from the mold.

Claims:
What is claimed is: 
     
       1. A method for forming a fabric-based item into a three-dimensional shape, wherein the fabric-based item comprises a polymer layer interposed between first and second fabric layers, comprising:
 with a heat source, applying heat to the fabric-based item while the fabric-based item is held by a frame, wherein the polymer layer has first and second portions held within the frame and wherein applying heat to the fabric-based item comprises heating the first portion of the polymer layer while cooling the second portion of the polymer layer; 
 with a vacuum tool, pulling the fabric-based item onto a mold; and 
 removing the fabric-based item from the mold. 
 
     
     
       2. The method defined in  claim 1  wherein the mold has a shape and wherein pulling the fabric-based item onto the mold with the vacuum tool comprises pulling the fabric-based item onto the mold with the vacuum tool so that the fabric-based item conforms to the shape of the mold. 
     
     
       3. The method defined in  claim 1  further comprising allowing the fabric-based item to cool while the fabric-based item is on the mold. 
     
     
       4. The method defined in  claim 1  wherein applying heat to the fabric-based item comprises applying heat to the fabric-based item while pulling the fabric-based item onto the mold with the vacuum tool. 
     
     
       5. The method defined in  claim 1  wherein applying heat to the fabric-based item comprises applying heat to the fabric-based item prior to pulling the fabric-based item onto the mold with the vacuum tool. 
     
     
       6. The method defined in  claim 1  wherein pulling the fabric-based item onto the mold comprises pulling air through a grid of openings under the mold, the method further comprising:
 blocking some of the openings while pulling the fabric-based item onto the mold. 
 
     
     
       7. The method defined in  claim 1  wherein the mold comprises opposing upper and lower surfaces and wherein pulling the fabric-based item onto the mold comprises pulling the fabric-based item onto the upper and lower surfaces of the mold. 
     
     
       8. A method for forming a fabric-based item into a three-dimensional shape, wherein the fabric-based item comprises a layer of fabric and a thermoplastic polymer, the method comprising:
 heating the fabric-based item until a temperature of the thermoplastic polymer reaches a forming temperature, wherein the thermoplastic polymer comprises a reduced-thickness region that is thinner than other regions of the thermoplastic polymer; 
 vacuuming air from under the fabric-based item to bring the fabric-based item in contact with upper and lower opposing surfaces of a mold; and 
 cooling the fabric-based item while the fabric-based item is in contact with the upper and lower opposing surfaces of the mold. 
 
     
     
       9. The method defined in  claim 8  wherein cooling the fabric-based item comprises hardening the thermoplastic polymer into a shape imparted by the mold. 
     
     
       10. The method defined in  claim 9  further comprising removing the fabric-based item from the mold while the thermoplastic polymer holds its shape, wherein the three-dimensional shape of the fabric-based item corresponds to the shape of the thermoplastic polymer imparted by the mold. 
     
     
       11. The method defined in  claim 8  wherein heating the fabric-based item comprises selectively heating only a portion of the fabric-based item. 
     
     
       12. The method defined in  claim 8  wherein the fabric-based item comprises an additional layer of fabric, wherein the thermoplastic polymer is interposed between the layer of fabric and the additional layer of fabric. 
     
     
       13. The method defined in  claim 12  wherein the layer of fabric and the additional layer of fabric have a curved shape and wherein the thermoplastic polymer holds the layer of fabric and the additional layer of fabric in the curved shape after the fabric-based item is cooled. 
     
     
       14. The method defined in  claim 12  wherein the thermoplastic polymer comprises thermoplastic polyurethane. 
     
     
       15. The method defined in  claim 12  wherein at least one of the layer of fabric and the additional layer of fabric comprises a fabric selected from the group consisting of: a woven fabric and a knit fabric. 
     
     
       16. The method defined in  claim 12  wherein the fabric-based item comprises an additional thermoplastic polymer and a stiffener, wherein the stiffener is interposed between the thermoplastic polymer and the additional thermoplastic polymer. 
     
     
       17. The method defined in  claim 16  wherein the stiffener comprises an opening.

Description:
BACKGROUND 
     This relates generally to fabric-based items and, more particularly, to fabric-based items having three-dimensional shapes. 
     It may be desirable to form bags, furniture, clothing, and other items from materials such as fabric. To form a three-dimensional object, fabric is typically cut and joined at the edges to form the desired shape. Forming objects by joining separate pieces of fabric together in this way results in seams along the edges of the object. Seams can be visually unappealing and can create weak points in the structure of the object. 
     To reduce the number of seams in an object, some fabrics are compression molded into the desired three-dimensional shape. Compression molding involves applying heat and pressure to a laminated fabric to form the desired shape. While this method reduces the number of seams, the compression molding process can impart undesirable characteristics onto the fabric. For example, compression of the fabric can cause the texture of the mold to be transferred onto the fabric or it can lead to surface deformations that compromise the original look and feel of the fabric. 
     SUMMARY 
     A fabric-based item may be vacuum-formed into a three-dimensional shape. The three-dimensional shape may be that of a case or cover for an electronic device, a bag, a backpack, a wristband, or other suitable object. 
     The fabric-based item may include one or more layers of fabric and one more polymer layers that can be molded when heated. The polymer layer may, for example, be a thermoplastic or thermosetting polymer. 
     To vacuum-form the fabric-based item into a three-dimensional shape, the fabric based item may be heated until the polymer layer reaches a forming temperature and becomes soft and pliable. When heated, a vacuum tool is used to pull the fabric-based item onto a mold so that the fabric-based item conforms to the shape of the mold. As the fabric-based item cools on the mold, the polymer material hardens into the shape imparted by the mold. The polymer material is able to hold the fabric layers in this shape after the layers are removed from the mold. 
     The texture, amount of rigidity, and appearance of the fabric-based item can be varied across different regions of the fabric-based item by selectively applying heat to only some portions of the fabric-based item during the forming process, by selectively cooling some portions of the fabric-based item during the forming process, and/or by selectively blocking one or more openings through which air is vacuumed during the forming process. 
     The construction of the fabric-based item itself may also be altered to obtain regions with varying flexibility, appearance, or structure. For example, a stiffener may be incorporated into one or more regions of the fabric-based item, a release liner may be used during the forming process and subsequently removed to expose the hardened polymer layer, layers in the fabric-based item may have openings or regions of reduced thickness to increase flexibility in certain regions, and/or other fabric constructions may be used. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an illustrative fabric-based item in accordance with an embodiment. 
         FIG. 2  is a cross-sectional side view of illustrative fabric in accordance with an embodiment. 
         FIG. 3  is a cross-sectional side view of layers of material that may be incorporated into a fabric-based item in accordance with an embodiment. 
         FIGS. 4, 5, 6, 7, and 8  are perspective views of illustrative three-dimensional shapes that may be formed using fabric in accordance with an embodiment. 
         FIGS. 9A, 9B, and 9C  show illustrative steps and equipment involved in one suitable method of vacuum forming fabric into a three-dimensional shape in accordance with an embodiment. 
         FIGS. 10A, 10B, and 10C  show illustrative steps and equipment involved in another suitable method of vacuum forming fabric into a three-dimensional shape in accordance with an embodiment. 
         FIG. 11  shows how fabric can be manipulated during the vacuum forming process to achieve varying effects across the fabric in accordance with an embodiment. 
         FIG. 12  is a cross-sectional side view of a portion of an illustrative fabric-based item having a polymer layer between fabric layers in accordance with an embodiment. 
         FIG. 13  is a cross-sectional side view of a portion of an illustrative fabric-based item having a stiffener between fabric layers in accordance with an embodiment. 
         FIG. 14  is a cross-sectional side view of a portion of an illustrative fabric-based item having a release liner that can be removed after vacuum forming in accordance with an embodiment. 
         FIG. 15  is a cross-sectional side view of an illustrative strand having a core with a polymer coating in accordance with an embodiment. 
         FIG. 16  is a cross-sectional side view of an illustrative strand having a polymer core in accordance with an embodiment. 
         FIG. 17  is a cross-sectional side view of a portion of an illustrative fabric-based item having one or more layers with openings to increase flexibility of the fabric-based item in accordance with an embodiment. 
         FIG. 18  is a cross-sectional side view of a portion of an illustrative fabric-based item having one or more layers with reduced thickness to increase flexibility of the fabric-based item in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Strands of material may be incorporated into strand-based items such as strand-based item  10  of  FIG. 1 . Item  10  may be an electronic device or an accessory for an electronic 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&#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 item  10  is mounted in a kiosk, in an automobile, airplane, or other vehicle, other electronic equipment, or equipment that implements the functionality of two or more of these devices. If desired, item  10  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 (e.g., cushions or other seating structures), may be part of an item of clothing or other wearable item (e.g., a hat, belt, wrist band, headband, etc.), or may be any other suitable strand-based item. 
     Strands in strand-based item  10  may form all or part of a housing wall for an electronic device, may form internal structures in an electronic device, or may form other strand-based structures. Strand-based item  10  may be soft (e.g., item  10  may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., the surface of item  10  may 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. 
     Item  10  may include intertwined strands  12 . The strands may be intertwined using strand intertwining equipment such as weaving equipment, knitting equipment, braiding equipment, or equipment that intertwines strands by entangling the strands with each other in other ways (e.g., to form felt). Intertwined strands  12  may, for example, form woven or knitted fabric or other fabric (i.e., item  10  may be a fabric-based item), a braided cord, etc. 
     Strands  12  may be single-filament strands or may be threads, yarns, or other strands that have been formed by intertwining multiple filaments of material together. Strands  12  may be formed from polymer, metal, glass, graphite, ceramic, natural fibers such as cotton, bamboo, wool, or other organic and/or inorganic materials and combinations of these materials. Strands  12  may be insulating or conductive. 
     Conductive coatings such as metal coatings may be formed on non-conductive strands (e.g., plastic cores) to make them conductive and strands such as these may be coated with insulation or left bare. Reflective coatings such as metal coatings may be applied to strands  12  to make them reflective. Strands  12  may also be formed from single-filament metal wire, multifilament wire, or combinations of different materials. 
     Strands  12  may be conductive along their entire length or may have conductive segments (e.g., metal portions that are exposed by locally removing insulation or that are formed by adding a conductive layer to a portion of a non-conductive strand.). Threads and other multifilament yarns that have been formed from intertwined filaments may contain mixtures of conductive fibers and insulating fibers (e.g., metal strands or metal coated strands with or without exterior insulating layers may be used in combination with solid plastic fibers or natural fibers that are insulating). 
     Item  10  may include additional mechanical structures  14  such as polymer binder to hold strands  12  together, support structures such as frame members, housing structures (e.g., an electronic device housing), and other mechanical structures. 
     Circuitry  16  may be included in item  10 . Circuitry  16  may include components that are coupled to strands  12 , components that are housed within an enclosure formed by strands  12 , components that are attached to strands  12  using welds, solder joints, adhesive bonds (e.g., conductive adhesive bonds), crimped connections, or other electrical and/or mechanical bonds. Circuitry  16  may include metal structures for carrying current, integrated circuits, discrete electrical components such as resistors, capacitors, and inductors, switches, connectors, light-emitting components such as light-emitting diodes, audio components such as microphones and speakers, vibrators, solenoids, piezoelectric devices, and other electromechanical devices, connectors, microelectromechanical systems (MEMs) devices, pressure sensors, light detectors, proximity sensors, force sensors, moisture sensors, temperature sensors, accelerometers, gyroscopes, compasses, magnetic sensors, touch sensors, and other sensors, components that form displays, touch sensors arrays (e.g., arrays of capacitive touch sensor electrodes to form a touch sensor that detects touch events in two dimensions), and other input-output devices. Circuitry  16  may also include control circuitry such as non-volatile and volatile memory, microprocessors, application-specific integrated circuits, system-on-chip devices, baseband processors, wired and wireless communications circuitry, and other integrated circuits. 
     Item  10  may interact with electronic equipment or other additional items  18 . Items  18  may be attached to item  10  or item  10  and item  18  may be separate items that are configured to operate with each other (e.g., when one item is a case and the other is a device that fits within the case, etc.). Circuitry  16  may include antennas and other structures for supporting wireless communications with item  18 . Item  18  may also interact with strand-based item  10  using a wired communications link or other connection that allows information to be exchanged. 
     In some situations, item  18  may be an electronic device such as a cellular telephone, computer, or other portable electronic device and strand-based item  10  may form a case or other structure that receives the electronic device in a pocket, an interior cavity, or other portion of item  10 . In other situations, item  18  may be a wrist-watch device or other electronic device and item  10  may be a strap or other strand-based item that is attached to item  18 . In still other situations, item  10  may be an electronic device, strands  12  may be used in forming the electronic device, and additional items  18  may include accessories or other devices that interact with item  10 . 
     If desired, magnets and other structures in items  10  and/or  18  may allow items  10  and  18  to interact wirelessly. One item may, for example, include a magnet that produces a magnetic field and the other item may include a magnetic switch or magnetic sensor that responds in the presence of the magnetic field. Items  10  and  18  may also interact with themselves or each other using pressure-sensitive switches, pressure sensors, force sensors, proximity sensors, light-based sensors, interlocking electrical connectors, etc. 
     The strands that make up item  10  may be intertwined using any suitable strand intertwining equipment. For example, strands  12  may be woven or knitted together to form a fabric. The fabric may have a plain weave, a satin weave, a twill weave, or variations of these weaves, may be a three-dimensional woven or knitted fabric, may be a warp knit fabric, or may be other suitable fabric. If desired, the strands that make up item  10  may be intertwined using knitting equipment, braiding equipment, or other strand intertwining equipment. Item  10  may also incorporate more than one type of fabric or intertwined strand-based material (e.g., item  10  may include both woven and knitted portions). 
     A cross-sectional side view of illustrative woven fabric  12  is shown in  FIG. 2 . As shown in  FIG. 2 , fabric  12  may include yarns or other strands of material such as warp strands  20  and weft strands  22 . In the illustrative configuration of  FIG. 2 , fabric  12  has a single layer of woven strands. Multi-layer fabric constructions may be used for fabric  12  if desired. 
     Fabric-based item  10  may include non-fabric materials (e.g., structures formed from plastic, metal, glass, ceramic, crystalline materials such as sapphire, etc.). These materials may be formed using molding operations, extrusion, machining, laser processing, and other fabrication techniques. In some configurations, some or all of fabric-based item  10  may include one or more layers of material such as layers  26  of  FIG. 3 . Layers  26  may include layers of fabric  12  and layers of structural material  48 . Structural material  48  may be formed from materials such as polymer, metal, glass, fabric, adhesive, crystalline materials, ceramic, patterned layers of material, and/or other layers. Structural material  48  may be used to hold fabric  12  in a desired three-dimensional shape. In the absence of structural material  48 , fabric  12  may be very pliable and soft, making it difficult to maintain a three-dimensional shape. Structural material  48  may be used to increase the rigidity and structure in fabric  12  so that fabric  12  can maintain a desired three-dimensional shape. The amount of rigidity provided by structural material  48  may be adjusted to achieve the desired structure in fabric  12 . For example, structural material  48  may be configured to create very hard and rigid portions of fabric  12  or it may be configured to only slightly increase the rigidity of fabric  12  so that fabric  12  remains pliable and soft while still maintaining some shape and structure. 
     Structural material  48  may, for example, include one or more layers of polymer that are sandwiched between layers of fabric  12 . The polymer material may be a thermoplastic polymer material, a thermoset polymer material, or other adhesive material that becomes soft when heated to an appropriate temperature. To form fabric  12  into a three-dimensional shape, the polymer layers between fabric layers  12  (e.g., structural layers  48 ) may be heated until they become soft enough to mold into the desired three-dimensional form (e.g., using a mold). As the adhesive cools, the adhesive becomes more rigid and holds its shape within fabric  12 . Because structural material  48  is sometimes formed from a polymer adhesive, material  48  may sometimes be referred to as adhesive material  48  or polymer material  48 . 
     The example of  FIG. 3  in which structural material  48  is formed as a separate layer between layers of fabric  12  is merely illustrative. If desired, structural material  48  may be embedded in, integral with, intertwined with, or otherwise incorporated into fabric layers  12 . 
     If desired, layers  26  of fabric  12  and structural material  48  may be formed into a desired shape using vacuum-forming techniques. Using this method, layers  26  are heated until material  48  becomes soft. While material  48  is soft and pliable, layers  26  are placed over a mold while a vacuum tool pulls air through holes under the mold. This forces layers  26  onto the mold and causes layers  26  to conform to the shape of the mold. Adhesive material  48  is then allowed to cool and harden while layers  26  remain on the mold. Once cooled, layers  26  are removed from the mold. The hardened adhesive material  48  in layers  26  is sufficiently stiff to hold fabric  12  in the shape imparted by the mold. Vacuum forming fabric into a three-dimensional shape may reduce or eliminate seams in the fabric-based item while preserving the texture and appearance of the fabric (e.g., texture and appearance characteristics which would be compromised if the fabric were formed using compression molding techniques). 
     Illustrative three-dimensional objects that may be formed using vacuum-forming techniques are shown in  FIGS. 4, 5, 6, 7, and 8 . In the example of  FIG. 4 , layers  26  have been formed into a book-like shape having a first planar portion  52 A, a middle portion  52 B, and a second planar portion  52 C. The shape of  FIG. 4  illustrates how it may be desirable to have different portions of fabric-based item  10  with different levels of rigidity. In some arrangements, it may be desirable to have first and second planar portions  52 A and  52 C be more rigid than middle portion  52 B. Middle portion  52 B may be configured to flex back and forth (e.g., middle portion  52 B may transition between a C-shape, a flat shape, and a backwards C-shape, whereas planar portions  52 A and  52 C may remain substantially flat). This allows middle portion  52 B to be bent back and forth, thereby rotating first planar portion  52 A relative to second planar portion  52 C. This type of configuration may be used in forming foldable fabric-based displays or other foldable items. 
     In other configurations, it may be desirable to have middle portion  52 B more rigid than planar portions  52 A and  52 C. For example, in configurations where fabric-based item  10  forms a bag, middle portion  52 B may form a portion of the bag that rests on the ground, while portions  52 A and  52 C may form the sides of the bag. It may be desirable to have a certain amount of slouch in the sides of the bag (e.g., portions  52 A and  52 C), while portion  52 B that rests on the ground remains flat and rigid or semi-rigid. 
     In the example of  FIG. 5 , layers  26  have been formed into an annular shape (e.g., for a wrist band, a watch, a belt, a head band, an ankle strap, etc.). In the example of  FIG. 6 , layers  26  have been formed into a backpack shape having a structured and substantially flat lower portion  56 A and a curved upper portion  56 B.  FIG. 7  shows an example in which layers  26  have been formed into a tote bag shape with four structured side portions  58 .  FIG. 8  shows an example in which layers  26  have been formed into a bottle shape with a circular cross-section and contoured sides. 
     The examples of  FIGS. 4-8  are merely illustrative, however. If desired, layers  26  may be vacuum-formed into a rectangular shape, an oval shape, a spherical shape, a tubular shape, a shape for forming a case for an electronic device, a more complex shape such as a shape that combines flat surfaces, curved surfaces, and/or compound curves, or other suitable shape. 
     Vacuum forming techniques may be used to form layers  26  into any of the shapes of  FIGS. 4-8  or any other suitable shape. With vacuum forming, these three-dimensional shapes may, if desired, be formed from a single piece of fabric (or a single piece of multi-layer fabric such as the multi-layer construction of  FIG. 3 ) instead of requiring multiple separate pieces of fabric to be stitched together. Vacuum forming provides a method of manipulating the fabric without damaging or comprising the functional or cosmetic qualities of the fabric. 
       FIGS. 9A, 9B, and 9C  show illustrative equipment and steps involved in vacuum-forming layers  26  into a desired three-dimensional shape (e.g., a shape as shown in  FIGS. 4-8  or other suitable shape). As shown in  FIG. 9A , vacuum-forming equipment  42  may include a chamber  32  surrounding cavity  40  over which plate  38  is located. Plate  38  may be a metal mesh have openings  36  through which air is pulled into chamber  32 . Chamber  32  may have one or more openings  34  through which air is pulled out of chamber  32 . 
     A mold such as mold  30  may be placed on plate  38 . Mold  30  may be selected based on the desired shape that is to be imparted on layers  26 . In the example of  FIGS. 9A-9C , mold  30  has a mushroom-like shape with an upper horizontal surface  30 - 1 , an opposing lower horizontal surface  30 - 2 , and a vertical side surface  30 - 3  extending below the upper and lower surfaces. It should be understood, however, that mold  30  may have any desired shape and may be significantly different from the shape shown in  FIG. 9A  depending on the desired three-dimensional shape that fabric  12  is to be formed in. Mold  30  may be interchangeable and easily replaced with a mold of a different shape. 
     Vacuum forming equipment  42  may also include a frame  28  that holds layers  26  during the vacuum forming process. Frame  28  may be operated manually or may be operated using computer-controlled positioners that move frame  28  (and layers  26 ) into the desired position over chamber  32 . 
     Initially, frame  28  may hold layers  26  over mold  30  in an unheated state as shown in  FIG. 9A . Layers  26  may include one or more fabric layers  12  and one or more uncured adhesive layers  48  ( FIG. 3 ). Prior to being heated, layers  26  may be relatively flat. 
     When layers  26  are in place over mold  30  and chamber  32 , heat source  46  may be used to apply heat to layers  26 , as shown in  FIG. 9B . Heat source  46  may be a heated chamber (e.g., an oven) or may be any other suitable heat source (e.g., a hot element, heated air, etc.). Arrangements when mold  30  itself is heated may also be used. 
     The application of heat by heat source  46  raises the temperature of the adhesive material in layers  26 , causing the adhesive material to become soft and pliable. The adhesive material in layers  26  may, for example, be raised to a temperature between 60° C. and 90° C., between 80° C. and 100° C., between 100° C. and 150° C., between 150° C. and 200° C., between 200° C. and 250° C., etc. The temperature at which the adhesive material becomes moldable is sometimes referred to the forming temperature of the adhesive material. 
     While layers  26  are heated, a vacuum tool such as vacuum tool  60  may be used to vacuum air  44  out of chamber  32  through opening  34 . This causes the air above plate  38  to be pulled into chamber  32  via openings  36 . The force of air being pulled into chamber  32  pulls layers  26  down towards plate  38  and mold  30 . As layers  26  are pulled downward, layers  26  come into contact with mold  30  and begin to conform to its shape. 
     After layers  26  have conformed to the shape of mold  30 , as shown in  FIG. 9C , layers  26  may be cooled while in contact with mold  30 . As the adhesive material in layers  26  cools, it becomes more rigid. However, rather than returning to the flat shape of  FIG. 9A , the adhesive material hardens into the shape imparted by mold  30 . As shown in  FIG. 9C , layers  26  have been vacuum-formed into a three-dimensional shape having a portion conforming to upper surface  30 - 1  of mold  30 , a portion conforming to lower surface  30 - 2  of mold  30 , and a portion conforming to vertical side surface  30 - 3  of mold  30 . This example is merely illustrative, however. If desired, mold  30  may impart onto layers  26  one of the three-dimensional shapes of  FIGS. 4-8  or may impart any other suitable shape onto layers  26 . 
     Vacuum forming layers  26  into a three-dimensional shape minimizes any damage to layers  26  that may otherwise occur during the forming process. Rather than compressing layers  26  between two structures and potentially altering the texture and appearance of the fabric, one side of layers  26  is pulled against a mold using air and the opposing side of layers  26  is untouched by the mold. This preserves the integrity and texture of the fabric, with the untouched side of layers  26  keeping its original form throughout the forming process. Being able to preserve the original texture and appearance of the fabric may be useful when forming objects of the type shown in  FIGS. 4-8 . The fabric that is used in forming a bag, for example, may maintain its original look and feel even after being vacuum-formed (as opposed to looking and feeling like the fabric has been compressed or damaged). If desired, the fabric that does not contact mold  30  during the forming process may be used as an outer surface of a three-dimensional object (e.g., the outer surface of a bag or other object). 
     The example of  FIGS. 9A-9C  in which layers  26  are heated during the vacuum forming process (e.g., while vacuum tool  60  is vacuuming air  44  out of chamber  32 ) is merely illustrative. If desired, layers  26  may be heated prior to vacuum forming. This type of arrangement is illustrated in  FIGS. 10A, 10B, and 10C . 
     Initially, layers  26  may include adhesive material in an uncured state and may be relatively flat. As shown in  FIG. 10A , layers  26  may be heated using a heat source  46  to thereby raise the temperature of the adhesive material until it becomes soft and pliable. Heat source  46  may be a heated chamber (e.g., an oven) or may be any other suitable heat source (e.g., a hot element, heated air, etc.). 
     When the adhesive material in layers  26  is heated to the appropriate temperature, layers  26  may be transferred to vacuum forming equipment  42 , as shown in  FIG. 10B . Vacuum tool  60  may be used to vacuum air  44  out of chamber  32  through opening  34 . This causes the air above plate  38  to be pulled into chamber  32  via openings  36 . The force of air being pulled into chamber  32  pulls layers  26  down towards plate  38  and mold  30 . As layers  26  are pulled downward, layers  26  come into contact with mold  30  and begin to conform to its shape. 
     After layers  26  have conformed to the shape of mold  30 , as shown in  FIG. 10C , layers  26  may be allowed to cool while in contact with mold  30 . As the adhesive material in layers  26  cools, it becomes more rigid. However, rather than returning to the flat shape of  FIG. 10A , the adhesive material hardens into the shape imparted by mold  30 . As shown in  FIG. 10C , layers  26  have been vacuum-formed into a three-dimensional shape having a portion conforming to upper surface  30 - 1  of mold  30 , a portion conforming to lower surface  30 - 2  of mold  30 , and a portion conforming to vertical side surface  30 - 3  of mold  30 . This example is merely illustrative, however. If desired, mold  30  may impart onto layers  26  one of the three-dimensional shapes of  FIGS. 4-8  or may impart any other suitable shape onto layers  26 . 
     To obtain complex shapes and/or to achieve a desired look and feel of fabric-based item  10 , it may be desirable to control how certain regions of layers  26  are affected during the vacuum forming process. For example, it may be desirable to heat some regions of layers  26  while keeping other regions cool. It may be desirable to pull some regions of layers  26  towards mold  30  with greater force than other regions of layers  26 . The ability to control and adjust the temperature and vacuum force across layers  26  may help form areas with different textural and/or structural properties. Cosmetic surfaces may be preserved in original form, certain areas may stretch more than others, portions of the fabric may move differently during the vacuum forming process, etc. 
       FIG. 11  illustrates an example of how layers  26  may be manipulated during vacuum forming to achieve a desired effect. As shown in  FIG. 11 , some of holes  36  in plate  38  are covered with air blocking material  88 , while other holes  36  remain uncovered. In this example, holes  36  underneath mold  30  are uncovered, whereas holes  36  around the perimeter of mold  30  are covered. This causes the outer portions  90  of layers  26  to be pulled inwards and under mold  30  in direction  92 . 
       FIG. 11  also shows how heating and cooling may be selectively applied to layers  26 . For example, one or more heat sources such as heat sources  46 - 1  and  46 - 2  may apply heat to outer portions  90  of layers  26  while a cooling source such as cooling source  86  keeps central portion  94  of layers  26  cool. This causes outer portions  90  to become more stretchy and flexible than central portion  94 . Thus, even after vacuum forming, central portion  94  may remain in substantially the same condition that it was in prior to vacuum forming, whereas outer portions  90  have changed shape and have become slightly stretched. 
     The example of  FIG. 11  is merely illustrative, however. If desired other methods may be used to adjust the shape and structure of layers  26  during vacuum forming. For example, in addition to or instead of using vacuum tool  60  to pull air from under layers  26 , a tool that pushes air towards layers  26  (e.g., a fan or other suitable equipment) may be used to blow air onto layers  26  to further manipulate layers  26  during the forming process. 
       FIG. 12  shows a cross-sectional side view of illustrative layers that may be included in a fabric-based item having a three-dimensional shape. In the example of  FIG. 12 , layers  26  include a polymer layer such as polymer layer  62  sandwiched between first and second fabric layers  12 - 1  and  12 - 2 . Polymer layer  62  may be a structural layer (e.g., one of structural layers  48  of  FIG. 3 ) that helps provide structure and shape to item  10 . For example, polymer layer  62  may be a thermoset polymer material (e.g., polyurethane or other thermosetting resin), thermoplastic material (e.g., thermoplastic polyurethane, etc.), or other adhesive material that becomes soft when heated to an appropriate temperature so that layers  26  can be vacuum formed into the desired shape using vacuum forming equipment of the type shown in  FIGS. 9A, 9B, 9C, 10A, 10B, and 10C . As polymer layer  62  is heated during the vacuum forming process, it forms mechanical bonds with fabric layers  12 - 1  and  12 - 2 . 
     If desired, polymer  62  and fabric layers  12 - 1  and  12 - 2  may be laminated together using roll-to-roll lamination equipment. Arrangements where polymer  62  is impregnated in, spray coated onto, or otherwise formed on fabric layers  12  may also be used. 
     If desired, polymer layer  62  may be located throughout layers  26  or may be located only in select portions of layers  26 . For example, polymer layer  62  may be located in regions where it is desired to provide fabric-based item  10  with a structured shape, while other portions of fabric-based item  10  may be free of polymer material  62  so that those portions of fabric-based item  10  remain more slouchy. 
     If desired, additional layers may be incorporated into layers  26  to achieve a desired look and feel of fabric-based item  10 . In the example of  FIG. 13 , a stiffening layer such as stiffener  64  is located between first and second polymer layers  62 - 1  and  62 - 2 , which are sandwiched between first and second fabric layers  12 - 1  and  12 - 2 . Stiffener  64  may be a layer of polycarbonate, acrylonitrile butadiene styrene (ABS) plastic, an additional fabric layer (e.g., a tightly woven or knitted fabric with some stiffness and rigidity), a layer of metal, ceramic, or other material, or other suitable stiffening layer. 
     If desired, stiffener  64  may be located throughout layers  26  or may be located only in select portions of layers  26 . For example, stiffener  64  may be located in regions where it is desired to provide fabric-based item  10  with additional rigidity and structure, while other portions of fabric-based item  10  may be free of stiffener  64  so that those portions of fabric-based item  10  remain more flexible. 
     If desired, polymer layer  62  may be sandwiched between two different layers, such as a fabric layer and a non-fabric layer. As shown in  FIG. 14 , for example, polymer layer  62  may be interposed between fabric  12  and release liner  66 . Release liner  66  may be a silicone film or other release liner that allows layers  26  to be handled during manufacturing without polymer layer  62  attaching itself to other materials. For example, layers  26  of  FIG. 14  may be vacuum formed into the desired shape and cooled. Once cool, polymer layer  62  will be solidified in the desired shape and release liner  66  may be removed. This allows polymer layer  62  to form an outer surface of layers  26  rather than being sandwiched between two layers of fabric. 
     In some arrangements, polymer material  62  may be incorporated into fabric  12 , as shown in  FIGS. 15 and 16 . In the example of  FIG. 15 , one or more strands  24  of fabric  12  are formed from a core  68  (e.g., a dielectric or conductive core) that has been coated with polymer material  62 . In the example of  FIG. 16 , one or more strands  24  of fabric  12  are formed from a core of polymer material  62  that has been coated with outer layer  74  (e.g., an insulating outer layer, a conductive outer layer, or other suitable outer layer). 
     As discussed in connection with  FIG. 4 , it may be desirable to have regions of varying stiffness in fabric-based item  10 .  FIGS. 17 and 18  show illustrative ways in which varying degrees of rigidity and flexibility may be imparted on fabric-based item  10 . 
     In the example of  FIG. 17 , layers  26  include polymer layer  62  interposed between fabric layer  12  and an additional layer  80 . Additional layer  80  may be a release liner (e.g., a release liner of the type shown in  FIG. 14 ), a stiffener (e.g., a stiffener of the type shown in  FIG. 13 ), an additional fabric layer, other suitable layer, or a combination of any two or more of these layers. Additional layer  80  may include an opening such as opening  76 . Opening  76  creates a flexible region  78 B in layers  26  that is more flexible than adjacent portions  78 A and  78 C. 
     Opening  76  may be formed from removed portions of layer  80  or opening  76  may be formed from a gap between two separate sections of layer  80 . There may be one, two, three, four, or more than four openings  76  in layers  26  for creating flexible regions such as region  78 B. If desired, other layers in layers  26  such as polymer layer  62  may have openings to enhance flexibility. Region  78 B may, for example, form a flexible spine between two rigid regions as in the example of  FIG. 4 , thus allowing fabric-based item  10  to be folded like a book. 
     If desired, flexible regions such as region  52 B of  FIG. 4  may be formed by reducing the thickness of one or more layers in item  10 . As shown in  FIG. 18 , for example, polymer layer  62  may have a first thickness T 1  in regions  84 A and  84 C and a second thickness T 2  that is less than thickness T 1  in region  84 B. The reduced thickness of polymer layer  62  in region  84 B increases the flexibility of layers  26  in region  84 B relative to adjacent portions  84 A and  84 C. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20160226
Publication Date: 20190514
Grant Date: 20190514
Priority Date: 20160226
Inventors: ELLIS, SHANE
Assignee: APPLE INC
CPC Classifications: [{"code": "B32B2250/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/28", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B27/12", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2101/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2101/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C51/004", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B27/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C51/004", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B2262/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/42", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/103", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/062", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B9/047", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B9/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2479/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2437/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/106", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2255/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B27/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2250/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2255/205", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B27/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2250/40", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2262/101", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B5/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2260/046", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2260/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/7129", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/48", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2313/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/428", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/422", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2791/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2101/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2250/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B27/12", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2101/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B27/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C51/004", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B5/024", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B3/28", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C51/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/428", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/48", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/7129", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C51/422", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2791/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2313/00", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 66439387