Laser processing of fabric for electronic devices

Patent metadata

Field	Value
Publication number	US-9997305-B2
Application number	US-201514844257-A
Country	US
Kind code	B2
Filing date	Sep 3, 2015
Priority date	Sep 3, 2015
Publication date	Jun 12, 2018
Grant date	Jun 12, 2018

Abstract

An electronic device such as a cover for a portable device or other electronic equipment may have circuitry mounted in a housing. The housing may be formed from layers of material such as fabric and polymer layers. The circuitry of the electronic device may include components mounted on a printed circuit. The components may include movable components such as keys in a keyboard. A fabric layer may overlap the keys. Border regions of the fabric layer that surround each key may be characterized by a stiffness. To ensure that the keys or other movable components in the device exhibit satisfactory stiffness levels, the keys can be tested and selected border regions or other fabric layer portions may be laser ablated or otherwise processed to locally reduce fabric layer stiffness.

First claim

What is claimed is:

1. An electronic device, comprising:
first and second keys; and
a layer of fabric that overlaps the first and second keys, wherein the layer of fabric has an opening that extends at least partway through the fabric, wherein the opening is located between a first region of the fabric that overlaps the first key and a second region of the fabric that overlaps the second key, wherein the opening has a perimeter, and wherein the fabric extends around the entire perimeter of the opening.

2. The electronic device defined in claim 1 wherein the first and second keys each comprise a movable member.

3. The electronic device defined in claim 2 wherein the layer of fabric comprises intertwined strands of material.

4. The electronic device defined in claim 3 wherein the layer of fabric comprises a laser ablated region from which a portion of the layer of fabric has been removed by laser ablation, and wherein the laser ablated region is located between the first and second regions.

5. The electronic device defined in claim 4 wherein the intertwined strands of material comprise intertwined polymer strands.

6. The electronic device defined in claim 5 wherein each strand is a yarn containing multiple polymer filaments.

7. The electronic device defined in claim 6 wherein the intertwined strands of material comprise woven fabric.

8. The electronic device defined in claim 7 further comprising a polymer coating on the woven fabric, wherein the polymer coating is located on the first and second regions of the layer of fabric, and wherein some portions of the laser ablated region are free of the polymer coating.

9. The electronic device defined in claim 7 wherein the opening comprises a laser-ablated opening that passes only partway through the woven fabric.

10. The electronic device defined in claim 7 wherein the opening comprises a laser-ablated opening that passes completely through the woven fabric.

11. The electronic device defined in claim 10 wherein the opening is part of an array of openings that surround the first key.

12. A keyboard, comprising:
a plurality of keys mounted to a printed circuit, wherein each of the keys has a key cap with a first perimeter; and
a fabric that covers the keys, wherein each of the keys is surrounded by a respective border region in the fabric, wherein the border region has four sides that form a second perimeter that is larger than the first perimeter, and wherein each of the four sides comprises an array of openings distributed along the second perimeter, wherein the openings extend at least partway through the fabric to reduce the stiffness of that border region and the key surrounded by that border region.

13. The keyboard defined in claim 12 wherein the fabric has stiff regions that overlap the keys, and wherein each array of openings is located between the stiff regions of the fabric.

14. The keyboard defined in claim 13 wherein the openings extend only partway through the fabric.

15. The keyboard defined in claim 13 wherein the openings pass completely through the fabric.

16. The keyboard defined in claim 13 wherein the border region of the fabric includes laser ablated yarn.

17. An electronic device cover, comprising:
keys having key caps; and
a fabric layer having stiff regions that overlap the keys and flexible border regions that surround the stiff regions, wherein the flexible border regions of the fabric include laser processed portions with openings that extend at least partway through the fabric, wherein the openings do not overlap the key caps.

18. The electronic device cover defined in claim 17 wherein the fabric layer comprises woven fabric.

19. The electronic device defined in claim 18 wherein the woven fabric comprises polymer strands and wherein the laser processed portions comprise laser ablated portions of the polymer strands from which polymer has been removed.

20. The electronic device defined in claim 18 wherein each stiff region has four sides, and wherein the openings comprise laser ablated recesses in the woven fabric that surround each stiff region on all four sides.

21. The electronic device defined in claim 17 wherein the stiff regions of the fabric are coated with a polymer coating that does not extend into the flexible border regions.

Assignees

• Apple Inc

Inventors

• Wang Paul X
• Ruscher Joel N
• Lebedeff Christopher T
• Murphy Sean
• Kuna Melody

Classifications

• H01H13/70

  having a plurality of operating members associated with different sets of contacts, e.g. keyboard (mounting together a plurality of independent switches H02B) · CPC title

• D06M10/005

  Laser beam treatment · CPC title

• G06F3/0202

  Constructional details or processes of manufacture of the input device · CPC title

• H01H13/704

  characterised by the layers, e.g. by their material or structure (H01H13/703 takes precedence) · CPC title

• H01H13/88

  Processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards · CPC title