PATENT DOCUMENT

Publication Number: US-10427374-B2
Application Number: US-201815920340-A
Country: US
Kind Code: B2

Title: Seamless spacer fabrics for electronic devices

Abstract:
Electronic equipment may include seamless spacer fabric. Seamless spacer fabric may be used as a protective case or cosmetic cover for an electronic device such as a speaker. A seamless spacer fabric may include a seamless fabric outer layer, a spacer fabric inner layer, and an adhesive layer that bonds the seamless outer layer to the spacer fabric inner layer. The spacer fabric layer may have a seam region where one portion of the spacer fabric layer is joined with another portion of the fabric layer. The seamless fabric outer layer may cover the seam region to hide it from view. One or more additional seam hiding layers or strips may be formed on opposing sides of the spacer fabric layer to cover the seam. The seamless spacer fabric may have an array of openings that extends uniformly around the perimeter of the seamless spacer fabric.

Claims:
What is claimed is: 
     
       1. A cover for an electronic device, comprising:
 a seamless fabric tube having opposing interior and exterior surfaces that surround a longitudinal axis; 
 a spacer fabric that lines the interior surface of the seamless fabric tube; and 
 an adhesive material interposed between the seamless fabric tube and the spacer fabric. 
 
     
     
       2. The cover defined in  claim 1  wherein the spacer fabric has a first array of openings, the adhesive material has a second array of openings, the seamless fabric tube has a third array of openings, and wherein the first, second, and third arrays of openings are aligned with one another. 
     
     
       3. The cover defined in  claim 2  wherein the openings in the first, second, and third arrays of openings comprise diamond-shaped openings. 
     
     
       4. The cover defined in  claim 2  wherein the spacer fabric comprises first and second fabric layers joined by a spacer layer. 
     
     
       5. The cover defined in  claim 2  wherein the spacer fabric has a fused region where a first portion of the spacer fabric has been fused to a second portion of the spacer fabric. 
     
     
       6. The cover defined in  claim 5  further comprising:
 an elongated strip of fabric interposed between the seamless fabric tube and the spacer fabric, wherein the elongated strip of fabric overlaps the fused region. 
 
     
     
       7. The cover defined in  claim 6  further comprising a fourth array of openings in the elongated strip of fabric, wherein the fourth array of openings aligns with the first, second, and third arrays of openings. 
     
     
       8. The cover defined in  claim 7  wherein the first, second, and third arrays of openings extend around the cover in a uniform pattern. 
     
     
       9. The cover defined in  claim 1  wherein the seamless fabric tube, the spacer fabric, and the adhesive material surround a central opening having a length that extends parallel to the longitudinal axis, wherein the central opening has a first diameter at a first location along the length and a second diameter that is less than the first diameter at a second location along the length. 
     
     
       10. The cover defined in  claim 9  wherein the cover has first and second opposing ends, wherein the length of the opening extends between the first and second ends, wherein the second location with the second diameter is at one of the first and second ends, and wherein the first location with the first diameter is between the first and second ends. 
     
     
       11. A fabric item, comprising:
 a multi-layer spacer fabric that forms a loop around a longitudinal axis, wherein the multi-layer spacer fabric has a seam region where first and second portions of the multi-layer spacer fabric have been joined, and wherein the multi-layer spacer fabric comprises first openings; 
 a single-layer fabric that forms a seamless loop around the longitudinal axis, wherein the single-layer fabric comprises second openings that align with the first openings; and 
 an adhesive layer interposed between the multi-layer spacer fabric and the single-layer fabric, wherein the adhesive layer has third openings that align with the first and second openings. 
 
     
     
       12. The fabric item defined in  claim 11  wherein the first, second, and third openings have a matching shape, size, and spacing. 
     
     
       13. The fabric item defined in  claim 11  wherein the multi-layer spacer fabric comprises first and second fabric layers joined by a spacer layer. 
     
     
       14. The fabric item defined in  claim 11  wherein the single-layer fabric surrounds the multi-layer spacer fabric. 
     
     
       15. The fabric item defined in  claim 11  wherein the multi-layer spacer fabric comprises fusible material. 
     
     
       16. A removable fabric cover for an electronic device, comprising:
 a first fabric layer that forms a seamless loop; and 
 a second fabric layer that forms a loop having a seam, wherein the second fabric layer lines an interior surface of the first fabric layer such that the first fabric layer covers the seam in the second fabric layer, wherein the second fabric layer has a pattern of openings that extends uniformly across the seam, and wherein the first fabric layer is bonded to the second fabric layer. 
 
     
     
       17. The removable fabric cover defined in  claim 16 , further comprising a thermoplastic material that bonds the first fabric layer to the second fabric layer. 
     
     
       18. The removable fabric cover defined in  claim 17  wherein the thermoplastic material has a pattern of openings that aligns with the pattern of openings in the second fabric layer. 
     
     
       19. The removable fabric cover defined in  claim 18  wherein the first fabric layer comprises a tube of single-layer knit fabric and the second fabric layer comprises a spacer fabric having first and second outer layers joined by a spacer layer. 
     
     
       20. The removable fabric cover defined in  claim 19  wherein the first fabric layer has a pattern of openings that aligns with the pattern of openings in the second fabric layer.

Description:
This application claims the benefit of provisional patent application No. 62/474,320, filed Mar. 21, 2017, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD 
     This relates generally to fabric-based items, and, more particularly, to fabric-based items with seamless spacer fabrics. 
     BACKGROUND 
     Items are sometimes formed using fabric. For example, an electronic device may have portions formed from fabric or may be covered with a fabric case. 
     It can be challenging to form fabric items with the desired look, feel, and functionality. Spacer fabrics are sometimes used for their softness, durability, and breathability, but spacer fabrics are often joined with an unsightly seam that users may find aesthetically unappealing. Seamless fabrics provide a uniform appearance, but generally do not offer the same protection or cushiony feel of spacer fabrics. 
     It would therefore be desirable to be able to provide improved fabric items. 
     SUMMARY 
     Electronic equipment may include seamless spacer fabric. Seamless spacer fabric may be used as a protective case or cosmetic cover for an electronic device such as a speaker, may be used to form a band that holds an electronic device against a user&#39;s body, or may be used for other types of electronic equipment. 
     A fabric cover formed with seamless spacer fabric may include a seamless outer layer, a spacer fabric interior layer, and an adhesive layer that bonds the seamless outer layer to the spacer fabric interior layer. The seamless outer layer may be a single-layer tube of fabric. The spacer fabric interior layer may include first and second fabric layers joined by a spacer layer. The seamless outer layer may provide the fabric cover with a uniform appearance, whereas the spacer fabric may provide the fabric cover with a soft, cushiony feel that also helps protect the electronic device from damage by absorbing mechanical stress. 
     The fabric cover may have an array of openings that extend uniformly around the perimeter of the fabric cover. The openings may extend through the seamless outer layer, the adhesive layer, and the spacer fabric interior layer. The openings may have a diamond shape or other suitable shape. 
     The spacer fabric layer may have a seam region where one portion of the spacer fabric is fused or otherwise joined with another portion of the spacer fabric. The outer seamless layer may cover the seam region of the spacer fabric layer to hide the seam region from view. 
     One or more seam hiding strips of fabric may be placed on opposing sides of the seam region to help obscure the seam region from view. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of illustrative electronic equipment with fabric in accordance with an embodiment. 
         FIG. 2  is a perspective view of illustrative electronic equipment including an electronic device and a fabric cover for the electronic device in accordance with an embodiment. 
         FIG. 3  is a perspective view of the electronic equipment of  FIG. 2  showing how a fabric cover may be removed from an electronic device in accordance with an embodiment. 
         FIG. 4  is a top view of illustrative fabric having rectangular openings in accordance with an embodiment. 
         FIG. 5  is a top view of illustrative fabric having round openings in accordance with an embodiment. 
         FIG. 6  is a top view of illustrative fabric having diamond-shaped openings in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of the fabric of  FIG. 6  showing how a fabric cover may be a multi-layer fabric with openings in accordance with an embodiment. 
         FIG. 8  is an exploded perspective view of the fabric of  FIG. 7  showing how each layer in the fabric may have an array of openings that aligns with the arrays of openings in the other layers of the fabric in accordance with an embodiment. 
         FIG. 9  is a perspective view of a seamless fabric tube that may be used in a fabric cover for an electronic device in accordance with an embodiment. 
         FIG. 10  is a perspective view of an illustrative spacer fabric that may be used in a fabric cover for an electronic device in accordance with an embodiment. 
         FIGS. 11, 12, and 13  show illustrative steps involved in forming a loop of spacer fabric with a uniform, uninterrupted pattern of openings in accordance with an embodiment. 
         FIG. 14  is a perspective view of illustrative equipment that may be used to form a fabric cover for an electronic device in accordance with an embodiment. 
         FIG. 15  is a top view of an illustrative system being used to form a fabric cover for an electronic device in accordance with an embodiment. 
         FIG. 16  is a perspective view of an illustrative fabric cover for an electronic device after being processed using the system of  FIG. 15  in accordance with an embodiment. 
         FIG. 17  is a top view of the fabric cover of  FIG. 16  after being inverted to produce a seamless outer layer in accordance with an embodiment. 
         FIG. 18  is a top view of an illustrative fabric cover formed from seamless spacer fabric in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A schematic diagram of illustrative electronic equipment that may include one or more seamless fabric layers is shown in  FIG. 1 . 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 equipment  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. Electronic equipment  24  may be soft (e.g., may have a fabric surface that yields to a light touch), may have a rigid feel (e.g., 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. 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 a display. 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.). 
     Control circuitry  16  may be used to run software on device  10  such as operating system code and applications. During operation of equipment  24 , the software running on control circuitry  16  may display images for a user on a display and/or 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. 
     Fabric  20  may be formed from intertwined strands of material. Fabric  20  may include one or more layers of woven fabric, knit fabric, warp knit fabric, flat knit fabric, circular knit fabric, and/or fabric that has been formed using other intertwining techniques. Fabric  20  may be a multi-layer fabric in which multiple fabric layers are joined (e.g., using an adhesive layer, using a fusible fabric layer, using strands of material that are intertwined to hold the multiple fabric layers together, and/or using other techniques). Fabric  20  may, for example, include a spacer fabric inner layer (e.g., a fabric having two or more layers separated by a soft and cushiony spacer layer), a seamless fabric outer layer, and an adhesive layer joining the spacer fabric inner layer and the seamless fabric outer layer. The seamless outer layer may provide the fabric with a uniform appearance, whereas the spacer fabric may provide a soft, cushiony feel that also helps protect device  10  from damage by absorbing mechanical stress. This is merely illustrative, however. In general, any suitable combination of fabrics and other materials may be used to form fabric  20 . 
     The strands of material that form fabric  20  may be monofilaments, may be multifilament strands (sometimes referred to herein as yarns or threads), may be formed from metal (e.g., metal monofilaments and/or yarns formed from multiple monofilament wires), may be formed from dielectric (e.g., polymer monofilaments and yarns formed from multiple polymer monofilaments), may be formed from fusible material such as thermosetting polymer material (e.g., thermosetting polyester, polyurethane, polyimide, or other thermosetting resin), thermoplastic material (e.g., thermoplastic polyester, nylon or other suitable polyamide, thermoplastic polyurethane, etc.), or other fusible material that becomes soft when heated to an appropriate temperature (e.g., between 60° C. and 140° C., between 60° C. and 160° C., 80° C. and 100° C., less than 180° C., etc.), may include dielectric cores covered with conductive coatings such as metal (e.g., metal coated dielectric monofilaments and yarns of metal coated polymer-core monofilaments may be used to form conductive monofilaments and conductive yarns, respectively), may include outer insulating coatings (e.g., coatings of polymers or other dielectrics may surround each metal-clad polymer monofilament or each collection of metal-clad polymer monofilaments in a yarn, polymer insulation may enclose a multifilament metal wire, etc.), or may be other suitable strands of material for forming fabric. 
     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 cylindrical housing, and fabric  20  has a matching tube-like shape that conforms 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 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., conical shapes, pyramidal shapes with curved and/or planar sidewall surfaces, spherical housing shapes, other shapes, a combination of these shapes, etc.), and fabric  20  may have a corresponding shape to form a cover or case for electronic device  10 . 
       FIG. 3  is a perspective view of the electronic equipment of  FIG. 2  showing how fabric cover  20  may be removed from electronic device  10  (e.g., by pulling cover  20  in direction  62 ). Fabric 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 cover  20  maintains a cylindrical shape even when removed from the cylindrical body of electronic device  10 . 
       FIG. 3  shows how fabric cover  20  may have a central opening  64  that receives device  10 . Opening  64  may have a uniform diameter along the length L of cover  20 , or opening  64  may have different diameters at different locations along length L. As shown  FIG. 3 , for example, opening  64  of cover  20  may have a first diameter D 1  at a first end (end  20 A) of cover  20  and a second diameter D 2  at a second opposing end (end  20 B) of cover  20 . Diameter D 2  may, if desired, be smaller than D 1 . In other arrangements, opening  64  in cover  20  may have diameter D 2  (e.g., a smaller diameter than D 1 ) at both ends of cover  20  and may have diameter D 1  along a middle portion of length L between ends  20 A and  20 B. These examples are merely illustrative, however. In general, opening  64  in cover  20  may have any suitable diameter or combination of diameters along length L of cover  20 . 
     If desired, fabric cover  20  may be pliable and stretchable such that D 1  and/or D 2  can expand or shrink. For example, cover  20  may have one set of diameters when cover  20  is in a relaxed state (e.g., neither stretched nor compressed) and a different set of diameters when cover  20  is stretched or compressed. In one illustrative arrangement, the diameter D 2  at end portion  20 B of cover  20  may be smaller than the diameter D 3  of device  10  when cover  20  is in a relaxed state. As device  10  is inserted into opening  64 , D 2  may expand (e.g., may expand to be equal to or greater than D 3 ) to accommodate device  10  in opening  64 . Once fully inserted, end portion  20 B of cover  20  may extend beyond device  10  and may therefore return to a relaxed state in which diameter D 2  is smaller than D 3  (e.g., so that cover  20  hooks over surface  66  of device  10 ), or end portion  20 B of cover  20  may meet flush with surface  66  of device  10  and may therefore remain in a stretched state in which the diameter D 2  of opening  64  is equal to or greater than diameter D 3  of device  10 . 
     In an illustrative arrangement, which is sometimes described herein as an example, device  10  may be a speaker (e.g., a portable speaker) and fabric  20  may be a removable fabric case or cover for the speaker. With this type of arrangement, device  10  may include one or more speaker grills such as speaker grill  68 . Speaker grill  68  may cover all or some of the exterior surfaces of device  10 . Speaker grill  68  may cover one or more speaker drivers (e.g., speaker drivers that each drive an associated diaphragm) in device  10 . 
     As shown in  FIG. 3 , fabric  20  may include one or more openings such as openings  14 . Openings  14  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 audio signals, optical signals, and/or other signals may pass (e.g., to or from device  10 ). For example, components such as speakers, light-emitting components, or other components in device  10  may transmit signals through openings  14  in fabric  20 . 
     Openings  14  may be relatively large openings (e.g., each spanning a distance of 10 mm, 50 mm, or more than 50 mm) or openings  14  may be relatively small openings (e.g., each spanning a distance of less than 10 mm). If desired, openings  14  may be rectangular as shown in  FIG. 4 , may be circular as shown in  FIG. 5 , may have a diamond shape as shown in  FIG. 6 , or may have any other suitable shape (e.g., an oval shape, a spiral shape, a triangular shape, an annular shape, etc.). In general, openings  14  may have any suitable size, shape, and spacing. 
     If desired, fabric cover  20  may be formed from multiple layers to achieve a desired look, feel, and functionality.  FIG. 7  is a cross-sectional side view of fabric cover  20  taken along line  60  of  FIG. 6 . As shown in  FIG. 7 , fabric  20  may have multiple layers such as layer  26 , layer  28 , and layer  30 . In one illustrative arrangement, which is sometimes described herein as an example, layer  26  may be a spacer fabric (e.g., having two or more fabric layers joined by a cushiony spacer layer), layer  30  may be a seamless tube fabric (e.g., a continuous loop of fabric), and layer  28  may be an adhesive layer that holds spacer fabric  26  and seamless fabric  30  together. The compressibility and permeability of spacer fabric  26  may provide cover  20  with a soft, cushiony feel while also protecting device  10  from damage (e.g., by absorbing mechanical stress during a drop event). Seamless fabric  30  may provide cover  20  with a seamless outer layer having a uniform appearance from any viewing angle. If desired, fabric  20  may include additional layers or may be formed without some of the layers in  FIG. 7 . The example of  FIG. 7  is merely illustrative. 
     Adhesive  28  may be a stand-alone adhesive layer or may be an adhesive tape having one or more adhesive layers on a carrier substrate. For example, adhesive  28  may be a pressure sensitive adhesive (e.g., coated on one or both sides of a carrier substrate), 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. In one illustrative arrangement, which is sometimes described herein as an example, adhesive  28  may be a fusible layer (e.g., a sheet of fusible material or a fabric formed from intertwined strands of fusible material) formed from thermosetting polymer material (e.g., thermosetting polyester, polyurethane, polyimide, or other thermosetting resin), thermoplastic material (e.g., thermoplastic polyester, nylon or other suitable polyamide, thermoplastic polyurethane, etc.), or other fusible material that becomes soft when heated to an appropriate temperature (e.g., between 60° C. and 140° C., between 60° C. and 160° C., 80° C. and 100° C., less than 180° C., etc.). 
     As shown in  FIG. 7 , cover  20  may have openings  14  that pass through all of the layers in cover  20  (e.g., layers  26 ,  28 , and  30 ). It may be desirable to ensure that the openings in layers  26 ,  28 , and  30  are not only aligned with one another but that they all have the same cross-sectional dimensions (e.g., dimensions along the x and y axes of  FIG. 7 ). This may ensure that signals (e.g., audio signals) passing from device  10  through openings  14  in cover  20  (e.g., in direction  70 ) are uninhibited by any one of layers  26 ,  28 , and  30 . It may also ensure that a user such as viewer  36  viewing cover  20  in direction  72  does not see any protruding portions of layers  26 ,  28 , or  30  in openings  14 . This is, however, merely illustrative. If desired, openings  14  may have different dimensions among layers  26 ,  28 , and  30 . Arrangements in which openings  14  have uniform cross-sectional dimensions in layers  26 ,  28 , and  30  are sometimes described herein as an example. 
     Openings such as openings  14  of  FIG. 7  may be formed by stamping (punching), cutting, machining, plasma cutting, waterjet cutting, heating, ablation, chemical removal (e.g., polymer dissolving techniques, metal etching techniques, etc.), laser-based techniques (sometimes referred to as laser hole formation or laser drilling), and/or other suitable material removal techniques. Openings  14  may also be formed during the process of fabricating some or all of layers  26 ,  28 , and  30  (e.g., by molding openings  14  into layer  28  as layer  28  is formed during a plastic molding process, by printing layer  28  in a pattern that includes openings  14 , by extruding layer  28  with openings  14 , by intertwining strands of material so that openings  14  are formed as fabric layers  26  and  30  are constructed, or by using other fabrication techniques in which openings such as openings  14  are formed during fabrication of layers  26 ,  28 , and  30 , rather than by removing material from layers  26 ,  28 , and  30  after the layers have been fabricated). 
     Openings  14  in fabric  20  may be formed after layers  26 ,  28 , and  30  have been attached to one another, or openings  14  may be formed in layers  26 ,  28 , and  30  before the layers are attached to one another. As shown in  FIG. 8 , for example, layer  26  may have openings  14 - 1 , layer  28  may have openings  14 - 2 , and layer  30  may have openings  14 - 3 . Openings  14 - 1  and  14 - 3  in fabric layers  26  and  30  may, for example, be formed as part of the fabric construction process or may be formed using a material removal technique described above. Openings  14 - 2  in adhesive  28  may be formed by printing, depositing, or molding layer  28  in a pattern that includes openings  14 - 2  or may be formed using a material removal technique described above. When attached, the edges of openings  14 - 1 ,  14 - 2 , and  14 - 3  may align with one another to form openings  14  of  FIG. 7 . 
     To provide cover  20  with a seamless outer layer having a uniform appearance from all viewing angles, seamless fabric  30  may form an outer layer of cover  20 . A perspective view of an illustrative seamless fabric tube that may be used as an outer layer of cover  20  is shown in  FIG. 9 . Rather than being constructed as a flat layer with two edges that are later joined, fabric  30  may be constructed (e.g., knitted) in the form of a tube, in which strands  76  that make up fabric  30  extend continuously around longitudinal axis  78 , with no edges or seams observable by a viewer such as viewer  36  viewing fabric  30  in direction  74 . 
     While seamless tube fabrics such as fabric  30  of  FIG. 9  may provide fabric cover  20  with a uniform outer appearance, it may be desirable to incorporate a spacer fabric in cover  20  to provide cover  20  with a soft, cushiony feel while also protecting device  10  from damage (e.g., by absorbing mechanical stress during a drop event). An illustrative spacer fabric of the type that may be used in cover  20  is shown in  FIG. 10 . 
     As shown in  FIG. 10 , spacer fabric  26  includes outer fabric layers  26 - 1  and  26 - 2  joined by spacer layer  26 - 3 . Layers  26 - 1  and  26 - 2  may be warp knit or weft knit fabrics, each formed with its own set of intertwined strands  40 . Layers  26 - 1  and  26 - 2  may have the same construction and material or may have different constructions and materials. Spacer layer  26 - 3  includes strands  42  that intertwine with strands  40  of layers  26 - 1  and  26 - 2  to join the two layers together. The width W between layers  26 - 1  and  26 - 2  may be between 1 mm and 15 mm, between 5 mm and 10 mm, between 20 mm and 30 mm, less than 1 mm, greater than 30 mm, or other suitable width. The air-filled space  80  between layers  26 - 1  and  26 - 2  gives fabric  26  a cushiony feel and allows fabric  20  to absorb mechanical stresses (and still be able to return to its original shape). 
     As shown in  FIG. 10 , spacer fabric  26  may be constructed with openings  14 - 1  (e.g., diamond shaped openings of the type shown in  FIG. 6 , or openings of any other suitable shape). This is, however, merely illustrative. If desired, openings  14 - 1  may be formed in fabric  26  by removing material from fabric  26  after fabric  26  has been constructed. 
     Spacer fabric  26  may have opposing edges  48 A and  48 B that are joined to produce a continuous loop of spacer fabric (e.g., for forming a cover having a cylindrical shape as shown in the example of  FIG. 3 ). It may be desirable to ensure that the pattern of openings  14 - 1  in spacer fabric  26  are uninterrupted by the interface where edge  48 A joints edge  48 B.  FIGS. 11, 12, and 13  show illustrative steps involved in forming edges  48 A and  48 B of spacer fabric  26  to ensure that the pattern of openings  14 - 1  at edge  48 A matches up with the pattern of openings  14 - 1  at edge  48 B. 
     As shown in  FIG. 11 , spacer fabric  26  may initially be longer than the required length L 1  for forming cover  20  of  FIG. 3 . Regions  46  correspond to the regions of spacer fabric  26  that will eventually be used in forming cover  20 . Regions  44  correspond to the regions of fabric  26  that will be removed to produce edges  48 A and  48 B of  FIG. 10 . In regions  44 , the strands in some or all of the layers of fabric  26  (e.g., strands  40  in layers  26 - 1  and  26 - 2  and/or strands  42  in spacer layer  42  of  FIG. 10 ) may be formed from a soluble material such as polyvinyl alcohol, other soluble polymers, or other materials that are soluble or dissolvable in water or other solvent. In regions  46 , the strands of fabric  26  may be formed from a different material that does not dissolve in the solvent that dissolves the strands in regions  44 . Fabric  26  of  FIG. 11  may be soaked in the solvent (e.g., water or other solvent, depending on the material that forms the strands in regions  44 ) to dissolve the strands in regions  44 , thereby producing fabric  26  of  FIG. 12 , in which portions  44  have been removed and portions  46  of fabric  26  remain intact. 
     As shown in  FIG. 12 , fabric  26  may be left with opposing edges  48 A and  48 B after the strands in region  44  are dissolved. Because edges  48 A and  48 B were not produced by cutting or otherwise severing fabric  26 , edges  48 A and  48 B may be clean edges that do not disrupt the pattern of openings  14 - 1  in fabric  26 . Following removal of the soluble strands in region  44 , edge  48 A- 1  may be joined with edge  48 B- 1  of layer  26 - 1  and edge  48 A- 2  may be joined with edge  48 B- 2  of layer  26 - 2  to produce a continuous loop of spacer fabric  26  as shown in  FIG. 13 . 
     As shown in  FIG. 13 , edge  48 A of fabric  26  meets and is joined with edge  48 B of fabric  26  at interface  34  (sometimes referred to as a seam, joint, fused region, seam region, etc.). The array of openings  14 - 1  in fabric  26  may span across interface  34 , without any disruption or non-uniformity in the size, shape, spacing, or appearance of openings  14 - 1 . In other words, the pattern of openings along edge  48 A of fabric  26  aligns with the pattern of openings along edge  48 B of fabric  26  so that the resulting pattern of openings  14  across interface  34  appears as if there were no interface  34  (e.g., interface  34  may be unperceivable after edge  48 A is joined with edge  48 B). Edges  48 A and  48 B may be joined by fusing (e.g., heating fusible material in spacer fabric  26  to its melting/softening temperature), stitching, gluing with adhesive, ultrasonic welding, or other suitable attachment methods. 
     The example of  FIGS. 11-13  in which edges  48 A and  48 B are formed by dissolving strands adjacent to edges  48 A and  48 B is merely illustrative. If desired, edges  48 A and  48 B may be formed by stamping (punching), cutting, machining, plasma cutting, waterjet cutting, heating, ablation, chemical removal (e.g., polymer dissolving techniques, metal etching techniques, etc.), laser-based techniques, and/or other suitable material removal techniques. In other arrangements, edges  48 A and  48 B may be produced as part of the process of forming fabric  26 . 
     Illustrative equipment that may be used to bond spacer fabric  26 , adhesive  28 , and seamless fabric  30  together is shown in  FIG. 14 . Equipment  82  of  FIG. 14  may include a heated core  54  (e.g., a core having an adjustable temperature) with an array of protrusions  56 . Protrusions  56  may have a size, shape, and spacing that matches the size, shape, and spacing of openings  14  in fabric  20  (e.g., protrusions  56  may be an array of diamond-shaped protrusions that match the size, shape, and spacing of openings  14 - 1  in layer  26 , openings  14 - 2  in layer  28 , and openings  14 - 3  in layer  30 ). 
       FIG. 15  shows how layers  26 ,  28 , and  30  may be placed on equipment  82 . In the example of  FIG. 15 , the layers of fabric cover  20  are placed on equipment  82  in the opposite order that the layers have in the final fabric cover  20  (e.g., cover  20  of  FIGS. 17 and 18 ). Once bonded together using equipment  82 , the layers may be removed from equipment  82  and inverted. This is, however, merely illustrative. If desired, the layers of fabric cover  20  may be placed on equipment  82  in the order that the layers have in the final fabric cover  20 , or the layers of fabric  20  may be left in the order shown in  FIG. 15  without being inverted. 
     Seamless fabric layer  30  (e.g., seamless fabric tube  30  of  FIG. 9 ) may be placed on heated core  54  (e.g., by threading protrusions  56  through openings  14 - 3  in seamless fabric layer  30 ). Adhesive layer  28  may be placed on heated core  54  over seamless fabric layer  30  (e.g., by threading protrusions  56  through openings  14 - 2  in adhesive layer  28 ). Spacer fabric  26  may be placed on heated core  54  over adhesive layer  28  (e.g., by threading protrusions  56  through openings  14 - 1  in spacer fabric  26 ). 
     If desired, one or more seam hiding layers such as seam hiding strips  32  may be placed on opposing sides of spacer fabric  26  over interface  34  (where edges  48 A and  48 B of spacer fabric  26  meet as shown in  FIG. 13 ) to help obscure interface  34  from view by a user. For example, a first seam hiding strip  32  may be placed between adhesive  28  and spacer fabric  26 , and a second seam hiding strip  32  may be placed on the opposing side of spacer fabric  26  (e.g., so that interface  34  is sandwiched between seam hiding layers  32 ). Seam hiding strips  32  may only cover interface  34  rather than extending all the way around the perimeter of fabric cover  20 , as shown in the example of  FIG. 15 , or layer  32  may form a continuous loop that extends around the perimeter of fabric cover  20 . Each seam hiding strip  32  may have an array of openings (e.g., openings  14 - 4  of  FIG. 16 ) that aligns with the array of openings  14 - 1 ,  14 - 2 , and  14 - 3  in layers  26 ,  28 , and  30 , respectively. Openings  14 - 4  in seam hiding strip  32  may be formed using any of the hole formation techniques described in connection with openings  14  of  FIG. 7 . 
     Seam hiding strips  32  may each include one or more layers of material. For example, seam hiding strips  32  may include one or more fabric layers (e.g., intertwined strands of material) and one or more adhesive layers. The adhesive layer may, if desired, be pre-laminated to the fabric layer before being bonded to the remaining layers in fabric  20  on equipment  82 . 
     This is, however, merely illustrative. If desired, there may be greater or fewer than two seam hiding layers  32  in fabric cover  20 , or seam hiding layers  32  may not be included in fabric cover  20 . 
     Equipment  82  may be used to raise the temperature of fabric  20  and thereby bond the layers together. For example, core  54  may be heated to raise the temperature of adhesive layer  28  and thereby bond seamless fabric  30  to spacer fabric  26 . Heat from core  54  may also be used to fuse edges  48 A and  48 B of spacer fabric  26  together at interface  32  and to bond seam hiding layers  32  to opposing sides of spacer fabric  26 . If desired, heat may be applied after all of the layers shown in  FIG. 15  have been placed on core  54 , or heat may be applied in multiple steps to heat individual layers before all of the layers of fabric  20  have been placed on core  54 . 
       FIG. 16  is a perspective view of fabric  20  after being processed using equipment  82  of  FIG. 15 . When fabric cover  20  is initially removed from core  54 , seamless fabric  30  is located on the interior of cover  20  and spacer fabric  26  is located on the exterior of cover  20 , with seam hiding layers  32  overlapping interface  34  where edges  48 A and  48 B of spacer fabric  26  have been joined. The openings in each individual layer of fabric cover  20  (e.g., openings  14 - 1  in spacer fabric  26 , openings  14 - 2  in adhesive  28 , openings  14 - 3  in seamless fabric  30 , and openings  14 - 4  in seam hiding layers  32 ) all align with one another, producing a pattern of openings  14  in fabric cover  20  that wraps uniformly around the perimeter of cover  20 . After the layers of fabric cover  20  have been bonded together, fabric cover  20  may be inverted to produce the fabric cover  20  of  FIG. 17 . 
     As shown in  FIG. 17 , seamless fabric layer  30  forms an exterior layer of fabric cover  20 , whereas spacer fabric  26  forms an interior layer of fabric cover  20 . Interface  34  where edges of spacer fabric  26  have been joined is hidden from viewer  36  viewing cover  20  in direction  38  by outer seamless layer  30  and by seam hiding layers  32 . The combination of spacer fabric  26  and seamless layer  30  provides fabric cover  20  with the cushion and protection of a spacer fabric and the seamless, uniform appearance of a seamless fabric. The pattern of openings  14  in fabric cover  20  may wrap continuously and uniformly around longitudinal axis  90  without any disruptions or non-uniformities in size, spacing, or shape of openings  14 . 
       FIG. 18  shows an example in which fabric cover  20  does not include seam hiding layers  32 . Interface  34  where edges of spacer fabric  26  have been joined is hidden from viewer  36  viewing cover  20  in direction  38  by outer seamless layer  30 . The combination of spacer fabric  26  and seamless layer  30  provides fabric cover  20  with the cushion and protection of a spacer fabric and the seamless, uniform appearance of a seamless fabric. The pattern of openings  14  in fabric cover  20  may wrap continuously and uniformly around longitudinal axis  90  without any disruptions or non-uniformities in size, spacing, or shape of openings  14 . 
     Following lamination of fabric cover  20 , additional processing equipment may be used to form fabric cover  20  into the desired shape. The additional processing equipment may include a shaping tool that applies heat and/or pressure to shape cover  20  into the desired shape of the final product. As shown in  FIG. 3 , for example, one or both ends such as end  20 A of cover  20  may have a smaller diameter D 2  than the diameter D 1  along the middle of cover  20 . This may be achieved by placing cover  20  onto a shaping tool having a first portion with a first diameter (e.g., a diameter equal to D 1 ) and a second portion with a second diameter (e.g., a diameter equal to D 2 ). The part of fabric cover  20  that sits on the second portion of the shaping tool may be cinched inwards until it has the smaller diameter D 2 . Cutting equipment (e.g., a die cutting tool or other suitable equipment) may be used to remove portions of cover  20  that are not desired in the final product. 
     Care should be taken to ensure that the cinching process at the ends of cover  20  does not compromise the uniformity of openings  14 . If some openings  14  at the top end of cover  20  are cinched in more than others, the top row of openings  14  would not appear uniform. For example, a non-uniform cinch might cut off some openings (e.g., leaving only a half-diamond opening at the top row of openings) whereas other openings might not be cut off (e.g., leaving a full diamond opening at the top row of openings). 
     If desired, one or more sacrificial drawstrings may be incorporated into cover  20  to achieve a uniformly cinched end. For example, prior to laminating spacer layer  26  to seamless layer  30 , a drawstring (e.g., a strand or group of strands) may be inserted into spacer layer  26  at one or both ends of spacer layer  26 . The drawstring may pass through a single row of openings  14 - 1  in layer  26 . Following lamination of cover  20  (e.g., after layers  26  and  30  have been laminated with equipment  54 ), the drawstring may extend around the diameter of cover  20 . If both ends of cover  20  are to be cinched inwards, two drawstrings may be incorporated into cover  20 , with one at each end. 
     Following lamination of cover  20 , cover  20  may be placed on a shaping tool having the desired shape of the final product. In arrangements where opposing ends cover  20  are to be cinched inwards, a drawstring may be located at each end of cover  20 . The shaping tool may have opposing ends with a smaller diameter than a central portion of the shaping tool. The two drawstrings may be located on the portions of the shaping tool with the smaller diameter. As heat and pressure is applied to press cover  20  against the tool, the ends of cover  20  will collapse inwards. Because a drawstring passes through a row of openings  14  at each end of cover  20 , the openings  14  in that row and the rows adjacent to it will be prevented from non-uniformly cinching inwards. This ensures that all of openings  14  in cover  20 , even openings  14  at the cinched ends, extend uniformly around cover  20 , without a change in shape, size, or location relative to the edge of cover  20 . If desired, cover  20  may be trimmed or cut after being shaped to remove the portion of cover  20  with the sacrificial drawstring. 
     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: 20180313
Publication Date: 20191001
Grant Date: 20191001
Priority Date: 20170321
Inventors: HAMADA, Yohji
HEGDE, SIDDHARTHA
MASSE, ZEBINAH P.
BHATIA, RIMPLE
COXETER, PETER F.
BARVE, AMIT S.
OLMSTEAD, DONALD L.
MENDEZ, JAVIER
Assignee: APPLE INC
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