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

Abstract

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

What is claimed is: 
     
         1 . A laminated fabric comprising:
 a polymer layer;   a fabric layer formed from fibers, wherein the fabric layer has an edge; and   a coating comprising a melted portion of the polymer layer that completely covers fibers at the edge.   
     
     
         2 . The laminated fabric defined in  claim 1  wherein the fibers are in a woven arrangement and embedded within a matrix material. 
     
     
         3 . The laminated fabric defined in  claim 1  wherein the polymer layer is formed from a material selected from the group consisting of: polyurethane, epoxy, acrylic, polyester, and polyimide. 
     
     
         4 . The laminated fabric defined in  claim 1  wherein the fibers comprise fibers selected from the group consisting of: polymer-based fibers, carbon fibers, cotton, wool, flax, and glass fibers. 
     
     
         5 . The laminated fabric defined in  claim 1  wherein a thickness of the coating is less than one millimeter. 
     
     
         6 . The laminated fabric defined in  claim 1  further comprising an additional polymer layer, wherein the fabric layer is interposed between the polymer layer and the additional polymer layer. 
     
     
         7 . The laminated fabric defined in  claim 1  wherein the fabric layer is configured to cover a cable in an electronic device. 
     
     
         8 . A fabric comprising:
 a fabric layer having first and second opposing surfaces and an edge that joins the first and second opposing surfaces; and   a polymer layer bonded to the first surface of the fabric layer, wherein a portion of the polymer layer forms a coating that covers the edge.   
     
     
         9 . The fabric defined in  claim 8  wherein the fabric layer comprises fibers and wherein the coating covers the fibers to prevent exposure of the fibers at the edge. 
     
     
         10 . The fabric defined in  claim 8  further comprising a matrix material, wherein the fabric layer is embedded in the matrix material and wherein the matrix material bonds the polymer layer to the first surface of the fabric layer. 
     
     
         11 . The fabric defined in  claim 8  wherein the polymer layer is bonded to the first surface of the fabric layer with an adhesive. 
     
     
         12 . The fabric defined in  claim 8  wherein the coating covers an entire width of the edge. 
     
     
         13 . The fabric defined in  claim 8  further comprising an additional polymer layer bonded to the second surface of the fabric layer. 
     
     
         14 . The fabric defined in  claim 13  wherein the coating extends from the polymer layer to the additional polymer layer. 
     
     
         15 . The fabric defined in  claim 8  wherein the fabric layer is one of a plurality of fabric layers. 
     
     
         16 . The fabric defined in  claim 8  wherein the edge is beveled. 
     
     
         17 . The fabric defined in  claim 16  wherein the coating completely covers the beveled edge. 
     
     
         18 . A fabric configured to be used in an electronic device, the fabric comprising:
 a fabric layer having fibers and an edge;   a polymer layer; and   a coating that covers the fibers along the edge, wherein the coating is formed from a portion of the polymer layer.   
     
     
         19 . The fabric defined in  claim 18 , further comprising:
 an additional polymer layer, wherein the fabric layer is interposed between the polymer layer and the additional polymer layer.   
     
     
         20 . The fabric defined in  claim 18  further comprising a matrix material, wherein the fibers in the fabric layer are woven and embedded in the matrix material, and wherein the matrix material bonds the fabric layer to the polymer layer.