Method for manufacturing a multilayer textile structure for protecting an acoustic device, method for manufacturing a component for protecting an acoustic device using a multilayer textile

Abstract

The present application relates to a method of manufacturing a multilayer textile structure for protecting an acoustic device, a method of manufacturing a component for protecting an acoustic device with a multilayer textile structure, and an acoustic device protection component obtained. A method for laminating or coupling a first precision fabric layer and a second precision fabric layer, each precision fabric layer being formed by weaving a plurality of synthetic monofilaments to achieve a double-layer textile structure for application to speakers and microphones of general electronic devices that provide at least audio functionality, such as sound, sound, sound, and sound. The invention relates to an electronic device having a double-layer textile structure for protecting the electronic device from water and solid particles and maintaining the designed sound emission and reception features, and having a sound emission (voice or music) or reception function. The method includes joining the first layer and the second layer by spraying a cementing material on synthetic monofilaments of at least one of the first precision fabric layer and the second precision fabric layer.

Description

[0001] This application is a divisional application of an application with an application date of October 4, 2016, application number 201680053182.6, and invention name “Method for manufacturing a multilayer textile structure for protecting acoustic equipment, method for manufacturing components for protecting acoustic equipment using a multilayer textile structure, and obtained acoustic equipment protection components”. Background of the Invention

[0002] According to a first aspect of the invention, the invention relates to a method of manufacturing a multilayer textile structure.

[0003] The term "multi-layer" will hereinafter be understood to mean a textile structure consisting of two layers, which has been specifically designed to protect electro-acoustic components, such as microphones, speakers, etc., built into devices of different sizes, and which consists of two overlapping synthetic monofilament precision fabric layers glued to each other, thereby providing diffuse joining thereof, optimal uniformity of the distribution of the glue material and optimal bonding of the two layers.

[0004] Furthermore, the expression "synthetic monofilament precision fabric" is intended to mean a fabric made by any known weaving method, the weaving parameters of which are precisely controlled, for example to provide a very uniform mesh of a web arrangement made of synthetic monofilaments, the dimensional parameters and the physical properties of which are precisely controlled to provide such a fabric which, through all its area portions, has such an impedance for transmitting and receiving sound waves that does not attenuate said waves, i.e., making the fabric "transparent" to said sound waves while preventing possible penetration of polluting particles, which is necessary for the proper functioning of the electroacoustic components.

[0005] In a second aspect of the invention, the invention also relates to a method for manufacturing a protective member or component starting from the above-mentioned "multi-layer" fabric, which is appropriately predetermined in size and assembled for use in electronic devices, such as audio openings, speakers, microphones or similar devices.

[0006] In other words, the field of application of the invention is the broad area of ​​all electronic devices which can be manufactured in small or large quantities and which comprise at least an audio function, i.e. sound (voice or music) emission, such as a loudspeaker or similar device, or sound reception, such as a conventional microphone.

[0007] Several component families and subfamilies fall within the broad equipment groups described above, such as the following: Telephone Field: •cell phone • Products for fixed-line telephony (e.g., phones, hands-free kits, and related accessories) • Skype / SAT phone calls Communications: • Wireless intercom • Audio equipment built into helmets, etc. • Professional radio, e.g. for military, security, civil protection, outdoor work applications, etc. entertainment: • Portable Hi-Fi equipment (MP3 players, earphones, headphones, portable speakers) • Professional audio equipment (microphones, headphones, speaker components) • Televisions (LCD, monitors, portable DVD players) transportation • Satellite navigation system including voice signalling • Automotive applications (car Hi-Fi, hands-free, voice warning applications) •Indoor communication equipment (trains, airplanes, ships).

[0008] Other applications: • Computer (monitor speakers, external speakers, additional microphone, webcam) • Home application equipment (intercom, indoor audio communication equipment) •Acoustic devices and other medical equipment for the hearing impaired In particular, the preferred field of application of the invention is indoor acoustic components, such as loudspeakers and microphones. These components are very fragile and, as mentioned above, must be protected from the ingress of water and solid particles (dust, waste, hazardous debris) while preventing the protection system from having a negative impact on the designed sound emission and reception characteristics.

[0009] The above involves a very complex pattern of functional requirements for the mentioned acoustic components, which must combine good sound transmission characteristics (achieved by using large openings through the device casing) with effective protection of the components themselves (which, conversely, requires that the acoustic components be isolated from the external environment as much as possible).

[0010] The main solution to the above problems in standard cases is to apply multi-hole protection devices on the external openings, such as in mobile phones, which are usually three and arranged at the main speaker (or "earpiece"), the microphone and the hands-free / voice speaker (or "speaker").

[0011] To protect acoustic components, the prior art provides several solutions depending on the desired application requirements, the type and degree of protection to be ensured and whether magnetic field shielding is required.

[0012] The above general solutions can form the basis for the study or design of specific derivative methods, which are appropriately synthesized and arranged in increasing order based on the level of protection to be achieved, namely: 2.1. No protection, i.e., the acoustic components are exposed to the external environment (this is a rare solution) 2.2. Plastic molded protective strips or grids, only for impact protection 2.3. Wide mesh protective net, which is made of metal material (such as spherical protective equipment for microphones), or molded from plastic material and has anti-intrusion function to prevent the intrusion of small objects (such as pencils, etc.) 2.4. A nonwoven material shield, with optional hydrophobic treatment, is arranged in front of the acoustic component to be protected 2.5. Synthetic monofilament technical fabric shield, optionally with hydrophobic treatment 2.6. Hydrophobic membrane The first three solutions above do not provide protection against liquids, but have only limited efficacy against solid medium-to-large sized items (2.2 and 2.3 above).

[0013] In contrast, solutions 2.4 to 2.6 provide good protection even against possible intrusion of liquids and powders into the acoustic components.

[0014] Of course, overlapping or stacking of several layers of protection / shielding material will tend to deteriorate the acoustic performance of the component, as the overlapping layers create additional obstacles to normal airflow. The best approach is to provide a protection / shielding medium with low acoustic impedance, or, if possible, find a compromise between the required protection level and acoustic impedance.

[0015] In the most common case, such as in a cell phone, the protective shield is assembled to a synthetic foam gasket and double-sided adhesive tape template to provide complete bonding of the shield to the external body of the device. Obviously, where multiple layers are designed to protect / shield the acoustic component, the accessories (e.g., gaskets / adhesive tapes) required to assemble the shield, as well as the assembly steps and overall thickness will increase significantly, depending on the number of protective / shielding layers used.

[0016] As mentioned above, from an acoustic point of view, the optional protective shielding does not negatively impact the input and output sound flows compared to what would have been provided when the component was designed.

[0017] Generally, for most widely consumed acoustic products, it is necessary to minimize the attenuation of sound pressure levels. Therefore, the protective shield must be "acoustically transparent" to provide its protective function while interfering as little as possible with the incoming or outgoing sound waves of the acoustic component.

[0018] The above is very common for mobile phones, where the protective shielding does not excessively attenuate speaker sound or microphone sensitivity, allowing the use of small, light and economical acoustic components.

[0019] In other cases, particularly in average / high range acoustic products, it is instead desirable for the protective shield to provide an appropriate acoustic function in order to flatten possible emission peaks or distorted sounds, thereby properly balancing the acoustic component frequency response.

[0020] In all the above cases, the textile material component (woven, nonwoven or membrane) should have the exact acoustic properties of the designed project, which vary according to the requirements from maximum "acoustic transparency" characteristics to a damping effect at a set sound level.

[0021] In order to quantify the above acoustic features appropriately, different quantization methods can be used: • "Specific airflow resistance" (ASTM C522-87), which relates the load to the loss rate in the case of a stationary airflow through a textile product. The results are given in Rayleigh MKS, and lower values ​​of this parameter correspond to "acoustically transparent" materials.

[0022] • An “Acoustic Impedance” value, based on the same parameters as above, but measured for an alternating airflow regime, i.e. under conditions more in line with the actual conditions of an acoustic application.

[0023] •Finally, if it is not possible to directly test the acoustic shield in its final configuration (shape and dimensions identical to those of the commercial product), a direct measurement of the sound pressure should be performed, with or without the textile shield arranged between the sound source and the measuring microphone. The results of this test are usually expressed in decibels dB (SPL), based on different standardized methods (ISO / FDIS 7235:2003, etc.).

[0024] The international standard IEC 60529 defines the so-called “Ingress Protection” index with reference to somewhat stricter test conditions in which an electronic component housing or casing is subjected to the intrusion of solid objects - articles or water.

[0025] • The first digit of the IP index relates to the resistance to ingress of solid materials. The levels from IP1X to IP4X are usually not important for acoustic components, which, on the contrary, almost always require an IP5X level, thereby ensuring partial protection against ingress of powders. The requirement of an IP6X level is not common per se, providing a completely sealed component.

[0026] • The second digit of the IP index relates to water resistance. The IPX3, IPX4 and IPX5 ratings indicate resistance to water sprays of several intensities. Usually, for the most common products, such as mobile phones, an IPX3 rating is sufficient. In contrast, "heavy-duty" acoustic products may need to achieve a protection rating of IPX8, corresponding to resistance to water immersion at a depth of up to 10 meters for a period of up to 24 hours. These are obviously very stringent conditions for specific applications.

[0027] As mentioned above, several technical solutions are currently used based on different textile products (nonwovens, synthetic monofilament technical woven fabrics, hydrophobic membranes) to provide the acoustic and protective properties provided by today's acoustic products (including multilayer synthetic materials taught in patent No. MI2010A000685 of the same applicant).

[0028] With regard to acoustic properties, mechanical strength, processability and geometrical consistency, in terms of protection range against particles >7 μm and hydrophobic properties of IPX4 rating, the Applicant surprisingly discovered that synthetic monofilament technical fabrics would (to be disclosed in more detail below) present the best solution to the above mentioned protection and minimal acoustic attenuation problems.

[0029] Furthermore, for aesthetic reasons alone, it is often necessary to use very large mesh fabric materials, whether metallized or not, to properly protect acoustic components. Furthermore, for mechanical reasons, it is sometimes preferred to have a fabric that is suitable for providing a good hard protective layer and also suitable for providing good intrusion resistance.

[0030] However, if on the one hand such a fabric only negatively influences the acoustic properties of the component to be protected to a minimal extent, on the other hand the level of protection against the ingress of liquids or particles would be too low.

[0031] It is therefore self-evident from the above that there is a need, the satisfaction of which constitutes the main object of the present invention, to increase in an optimal manner the level of protection against the intrusion of liquids and particles while maintaining the desired minimum attenuation of sound waves in the above-mentioned applications of the above-mentioned acoustic components.

[0032] The applicant has achieved the above objectives by using a further layer or layer of monofilament precision fabric which is characterized by a very small mesh and which is suitably coupled or laminated to an arrangement of larger meshes.

[0033] In this regard, it should be pointed out that the use of such an additional fabric layer in front of the acoustic component to be protected makes it very difficult to achieve proper overlapping or stacking assembly, since suitable adhesives and gasket materials need to be applied between each of the two involved layers, the component and the shell; it is therefore necessary to simplify this assembly as much as possible.

[0034] According to the present invention, this further object has been achieved by joining or laminating the above-mentioned two synthetic monofilament precision fabric layers by a novel method that constitutes the core of the invention, which method provides diffusion bonding between the two fabric layers, thereby transforming the two laminated or joined layers into an integral single unit that is easily and quickly assembled to its shell or shell.

[0035] Furthermore, the novel and inventive joining method described above is highly advantageous for proper post-processing of the fabric and assembly of the fabric in the target electronic device to meet all of its desired acoustic and protective property requirements.

[0036] In other words, the novel and inventive lamination or joining methods for joining the fabric materials of the present invention have been specifically designed to: • Provides diffusion bonding of two fabric layers • Even when low surface energy coatings are deposited on fabrics, a good level of adhesion between the layers is ensured, thereby increasing the desired protection against liquid intrusion • Ensures absolute equality of bonding strength and airflow resistance The lamination method according to the invention overcomes the great disadvantages of existing lamination methods, such as the HOT MELT method, which uses different types of reactive polyurethane or thermoplastic polymer materials, or other methods that deposit glue materials using a coating system by spreading the glue material on one of the layers and laminating through a continuous calender, and wherein, in order to prevent the applied glue material from completely or almost completely closing the fabric mesh, metering of the appropriate glue amount is achieved by glue spreading cylinders engraved with different engraving patterns, which means the following disadvantages: • Diffusion bonding only at the macroscopic level. If, specifically for the intended application, small components with dimensions comparable to the distance between two glue dots need to be produced, these components will partially or completely delaminate

[0037] • Inconsistent bonding levels between the two layers, as large changes in measured load will correspond to changes in position on the fabric •Another disadvantage that should be added to the above is that, since the typical dimensions of the protective components are generally in the order of several hundred microns, which is comparable to the dimensions of the dot pattern of the coated glue material, the operating characteristics between different components made from the same protective fabric roll and glued into contact will be inconsistent, because a large airflow resistance will occur at the glue points / lines, and a considerable increase in acoustic impedance will follow, and vice versa, in the area between two glue points, the airflow resistance is low.

[0038] In contrast, the lamination method according to the invention is a true jetting method, in which there is no contact, and therefore it has more operating flexibility, independent of the pattern and depth of the glue dots / lines engraved on the laminating cylinder.

[0039] In practice, the method according to the invention provides that the two fabric layers to be laminated are passed at a set speed under a plurality of spray nozzles, whereby by adjusting the fabric feed speed and the spraying or atomization of the glue material (its openings and pressure), the amount of glue deposited can be precisely determined.

[0040] If the glue is sprayed or atomized very finely, very small glue droplets can be deposited which are distributed in an almost continuous distribution across the fabric threads and thus have only a small negative impact on the air flow resistance.

[0041] In a preferred embodiment of the method according to the invention, an aqueous polyurethane glue material is used which is sprayed onto the two layers to be laminated.

[0042] After the spraying step, according to the invention, the fabric is passed through a tunnel oven at a set speed in order to evaporate the water present in the glue material.

[0043] Advantageously, as described above, the method is carried out starting from a reel, whereby an unwinding system and a winding system are arranged upstream of the spraying station and downstream of the drying tunnel, respectively.

[0044] In a preferred embodiment of the invention, the glue material used comprises a locking catalyst, for example of the polyurethane type, in order to lock the crosslinking of the sprayed glue material according to the invention.

[0045] Thus, after drying, the fabric roll can be easily stored as the fabric will be free of any remaining adhesive.

[0046] To reactivate the glue material, it is sufficient to apply a set temperature for a set period of time to properly start the cross-linking process.

[0047] In order to properly heat the two fabric layers and apply the pressure required to achieve a glued joint, a heated calender is preferably used, which heats the two fabric layers and reactivates the glue material, and connects the two layers by the pressure applied by the calender.

[0048] As described above, the method of the present invention by spray coating and lamination provides a double-layer fabric structure particularly suitable for the above disclosed acoustic applications, the fabric structure having: • Diffusion bonding • Good bonding levels between its two fabric layers, even when the two fabric layers have a low surface energy coating deposited thereon, thereby enhancing protection against liquid intrusion • Very even or consistent bonding levels • Very even or consistent air flow resistance due to truly even distribution of sprayed adhesive material.

[0049] The aforementioned steps of the method according to the invention are shown and further described in the attached schematic diagrams, which form an integral part of the present disclosure and which refer here to use in a mobile phone, but which can be used in any other electronic device of the type described above having similar acoustic functions. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 A schematic diagram showing a plurality of substantially circular die cut portions made from a double layer fabric structure according to the method of the present invention as disclosed above; Figure 2 Another schematic diagram showing two fabric layers with threads of different diameters, where the glue layer is sprayed only on the bottom fabric layer threads; Figure 3 Another schematic diagram of the method according to the invention is shown, in which glue is sprayed on two fabric layers, namely on the threads of the top layer with the smaller diameter and on the threads of the bottom layer with the larger diameter; it should be pointed out at this point that although Figure 2 and Figure 3 , the wires of the two layers are shown as wires of different diameters, but they may also have the same diameter; and Figure 4 Another schematic diagram of a die cut part made from the laminated double layer fabric of the present invention and the method of the present invention is shown. DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0051] It can be seen from the above disclosure that in the first aspect, the present invention provides a synthetic monofilament double-layer textile fabric structure, which has specially designed or targeted geometric properties, aesthetic properties, mechanical properties and acoustic properties, and comprises two overlapping layers connected or laminated by a glue spraying method and an additional lamination method for use in electronic consumer products as a protective element for protecting electroacoustic components built into devices of different sizes.

[0052] The double-layer textile structure described above provides the desired level of protection against particle and fluid intrusion while providing a level of sound attenuation that corresponds precisely to the designed sound attenuation level.

[0053] The structure has very uniform mechanical, geometrical and functional properties, also in relation to the typical dimensions of the components used in these applications. Furthermore, due to its very good adhesive properties, it can be further processed according to standard processing methods in order to produce the final or finished component and to facilitate assembly in the device.

[0054] The above-mentioned double-layer or multi-layer textile structure is made by a novel deposition method, which sprays the glue material and then laminates it into a synthetic monofilament precision fabric, which can be made of PET, PA, PP, PEEK, PPS wires with a wire diameter of 19 to 500 μm, a wire / cm density of 260 to 4, and a wire thickness of 35 μm to 1 mm.

[0055] In addition, the fabric can have a mesh size of 5 μm to 1 mm, and if desired, the fabric can be further coated by a coating process such as dip coating, plasma coating, spray coating, foam coating, doctor blade coating, sol gel and ink jet coating to provide the fabric with targeted surface properties such as hydrophobicity, antistatic, hydrophilicity, dirt release and antimicrobial properties.

[0056] The fabric of the invention may also be coated with a thin layer of material, for example made of silver, copper, aluminum, steel, titanium, titanium nitride, chromium, chromium carbide, etc., by a physical or chemical deposition process.

[0057] Preferably, in a preferred embodiment of the present invention, the double-layer textile structure of the present invention has a thickness of 170 μm, a weight of 114 g / m 2 The weight and correspondingly about 10g / m 2 Glue, 1330 lm 2 / s air permeability (measured at a pressure drop of 200 Pa), an acoustic impedance of 140 Rayles, and a very uniform delamination resistance of about 3.4 n / 5a along the entire fabric member.

[0058] On the other hand, the present invention also relates to a method for manufacturing a protective component or member, which starts with a textile structure manufactured by the method of the present invention and is assembled and packaged with suitable adhesive materials on both sides for further integration or integration into the final electronic device for protecting the desired electrical / acoustic components.

[0059] For such applications, in the final “stack-up” a double layer of fabric is placed between the component and its casing and, if necessary, gasket elements are applied to properly control geometric tolerances.

[0060] In order to properly integrate the fabric in the stacking arrangement, the fabric is laminated on both sides by a suitable adhesive material to ensure proper bonding to other operating surfaces (gasket and / or component and / or housing) and to ensure air flow through the active part of the fabric arranged in front of the acoustic component.

[0061] For example, for a circular fabric member arranged in front of a microphone, the adhesive or glue material will have a circular crown shape with an inner diameter greater than the diameter of the active portion and an outer diameter equal to the outer diameter of the fabric portion. Thus, through the circular crown of the adhesive material, the fabric can be glued to other surfaces while precisely maintaining the characteristics or properties of the fabric at its active portion.

[0062] To produce the final component, the fabric according to the invention is then cut into strips preferably having a width of 10 to 50 mm, which strips are suitable for subsequent processing operations.

[0063] According to a preferred embodiment of the invention, the adhesive tape or strip to be used (in roll form) supported by a suitable carrier or support element is unwound and fed to a machine in which the adhesive and the carrier are pre-drilled according to the effective area of ​​the component and the corresponding effective area of ​​the fabric by means of a flat or cylindrical die. Likewise, another adhesive and carrier roll is prepared, and then the fabric / multilayer strip is laminated with one of the pre-prepared adhesive strips, while the other fabric surface is further laminated with another adhesive or glue layer prepared appropriately, by an operating step suitable for providing perforated portions of two adhesive materials in a completely aligned state.

[0064] Then, one of the two carriers of adhesive or glue material is removed and the assembly is laminated with an inner liner (usually polyester film).

[0065] The stack thus formed is then cut according to the desired size, in particular the size of the outer diameter of the circular crown of adhesive or glue and the size of the construction requiring lining.

[0066] It is apparent from the above disclosure that the present invention has provided: 1. According to a first aspect of the present invention, a multilayer textile product, in which at least one of the two layers has been treated by spraying deposited glue material on one or both sides thereof and by subsequent lamination, the multilayer textile product being used as a subcomponent in general acoustic and electronic products to protect electronic acoustic components built into devices of different sizes, such as microphones, speakers, the textile product comprising a laminate of two synthetic monofilament precision fabrics obtained by a method according to the present invention, the method being deposition or coating by spraying and lamination, thereby providing diffusion bonding of the two layers, optimal uniformity of material distribution, and optimal adhesion between the layers, wherein the initial properties of the monofilament fabrics used and their specific joining method are intended to ensure the protection and acoustic properties required for proper operation of the components.

[0067] 2. A multilayer textile product according to aspect 1, for use in an application according to aspect 1, wherein the multilayer textile product is laminated together with two polymer double-sided adhesive tapes, wherein the polymer double-sided adhesive tapes are appropriately contoured to maintain the perspiring of the fabric at its effective parts while allowing bonding / assembly with a gasket element, an acoustic component to be protected and a housing of an electronic device, such as a mobile phone, a tablet computer, or a computer.

[0068] 3. A complete or finished functional subassembly comprising components according to aspects 1-2, joined to further optional subcomponents such as supports, acoustic channels or cavities, the subcomponents typically being moulded from a plastic material or made in any other suitable manner, optionally including the acoustic member itself such as a speaker or microphone.

[0069] 4. The product according to aspects 1 and 2, which may include synthetic monofilament technical textile materials of different structures of PET, PA6, PA6.6, PP, PEN, PBT, PE, PEEK, PPS, PI, which textile materials have variable thread counts / cm, thread diameters, weaving, and finishing.

[0070] 5. Aspect 4 is easily extendable to textile constructions with any desired weave structure and geometry.

[0071] 6. Aspect 4 is also easily extendable to starting fabrics which are optionally finished, for example dyed for decorative purposes, and coated with hydrophobic, hydrophilic, antistatic and antimicrobial coatings.

[0072] 7. Aspect 4 is also easily extended to a starting fabric coated with a thin layer of metals, oxides, carbides, nitrides such as aluminum, steel, copper, chromium, titanium and mixtures thereof, optionally by physical or chemical deposition systems.

[0073] 8. The textile product according to aspects 1-2, wherein the glue material used to make the multilayer construction is a water-based polyurethane, the cross-linking of which is locked or shut down during the deposition step.

[0074] 9. The textile product according to aspects 1-2, wherein the glue material of the textile product is sprayed by a spraying method, using fine spraying or atomization to provide ultrafine dispersion of glue droplets on the fabric thread, thereby keeping the acoustic properties of the starting fabric substantially unchanged.

[0075] 10. A textile product according to aspects 1-2, wherein the lamination of two fabric layers suitably manufactured according to aspects 8 / 9 is achieved by using a heated calender.

[0076] 11. The textile product according to aspect 2, wherein the fabric and its effective parts have several sizes and geometric shapes.

[0077] 12. The textile product according to aspect 2, having different band sizes, thicknesses, patterns and chemical properties.

[0078] The present invention also provides the following contents: 1). A method for laminating or joining a first precision fabric layer and a second precision fabric layer, each precision fabric layer being formed by weaving a plurality of synthetic monofilaments to provide a textile structure comprising two textile structure layers, the textile structure being specifically to be applied to a speaker and a microphone of a general electronic device, the electronic device having at least an audio function for transmitting and receiving sound, voice or music, and the textile structure being used to protect the electronic device from the intrusion of water and solid particles and to maintain the sound transmission and reception characteristics designed for the electronic device, the method being characterized in that the method comprises the step of spraying an adhesive material on the synthetic monofilaments of at least one of the first precision fabric layer and the second precision fabric layer, thereby joining the first layer and the second layer in a diffusion manner.

[0079] 2). The method according to 1), wherein the method comprises the step of spraying the glue material onto the synthetic monofilaments of both the first precision fabric layer and the second precision fabric layer, the glue material being a water-based polyurethane material.

[0080] 3). The method according to 1) and 2), wherein the method comprises the steps of: a) providing rolls of the first synthetic monofilament precision fabric layer and the second synthetic monofilament precision fabric layer; b) providing a plurality of spraying stations, each of which comprises a corresponding plurality of spraying and atomizing nozzles for spraying and atomizing the water-based glue material; c) Provide drying tunnel furnace equipment; d) providing an unwinding system upstream of the spraying station and a winding system downstream of the drying tunnel oven, respectively; e) providing a conveying device for conveying the first fabric layer and the second fabric layer; f) unwinding the first fabric layer and the second fabric layer from the rolls thereof; g) conveying the first fabric layer and the second fabric layer below the spraying device and spraying and atomizing drops of the aqueous glue material uniformly on the synthetic monofilaments; h) further conveying the first fabric layer and the second fabric layer through the tunnel oven to evaporate water contained in the water-based glue material and dry the first fabric layer and the second fabric layer, the method is further characterized in that the water-based glue material contains a locking catalyst, which is suitable for locking or stopping the cross-linking of the water-based glue material in the spraying step g), and wherein, after the drying step h), the method comprises a further step of: i) Winding the dried first and second fabric layers without any remaining adhesive properties into rolls.

[0081] 4). The method according to 3), wherein the method comprises the further steps of unwinding the first fabric layer and the second fabric layer from the roll, and heating and pressing the first fabric layer and the second fabric layer in a heated calender to reactivate and polymerize the glue material for diffusively gluing the first fabric layer and the second fabric layer to each other.

[0082] 5). The method according to 1) to 4), wherein the first fabric layer and the second fabric layer are synthetic monofilament precision fabric layers, the synthetic monofilament is selected from the group consisting of PET, PA, PP, PEEK, PPS, and has a wire diameter of 19 to 500 μm, a wire / cm density of 260 to 4, a thickness between 35 μm and 1 mm, and a mesh size between 5 μm and 1 mm.

[0083] 6). The method according to 1) to 5), wherein the first fabric layer and the second fabric layer are coated by a coating process to provide the first fabric layer and the second fabric layer with surface properties such as hydrophobicity, antistatic property, hydrophilicity, dirt release and antimicrobial property, and the coating process is selected from dip coating, plasma coating, spray coating, foam coating, blade coating, sol-gel, inkjet coating, physical or chemical deposition of one or more of silver, copper, aluminum, steel, titanium, titanium nitride, chromium and chromium carbide.

[0084] 7). A method for manufacturing a protective component, the protective component is used to protect acoustic equipment, speakers, microphones and any electronic equipment including at least an audio function, the audio function being a sound (voice or music) transmission or reception function, the component having an effective area, the method being characterized in that the method comprises the steps of: a1) providing a textile structure by the method according to any one of 1) to 6); b1) cutting the textile structure into frames preferably having a width of 10 to 50 mm; c1) providing a first roll of a first adhesive strip supported by a respective first supporting element; d1) providing a second roll of a second adhesive strip supported by a respective second support element; e1) unwinding the first adhesive strip from the first roll and applying the first adhesive strip to a first surface of the border of the textile structure; f1) perforating the first adhesive strip and the first supporting element for the first adhesive strip according to the active area of ​​the component; g1) unwinding the second adhesive strip from the second roll and applying the second adhesive strip to an opposing second surface of the frame; h1) perforating the second adhesive strip and the second supporting element for the second adhesive strip; l1) removing one of the first supporting element and the second supporting element; m1) Laminating the components obtained from steps a1) to l1) by coating films.

[0085] 8). A double-layer fabric structure obtained by the method according to 1) to 6), wherein the double-layer fabric structure has a thickness of 170 μm, a weight of 114 g / m 2 Weight, 1330 l / m measured at a pressure drop of 200 Pa 2 s air permeability, 140 Rayleigh acoustic impedance, and uniform delamination resistance of about 3.4 m / 5cm, wherein the weight of the glue material is about 10 g / m 2 .

[0086] 9). The method according to 7), wherein the textile structure of step a1) has a thickness of 170 μm, a 2 Weight, 1330 l / m measured at a pressure drop of 200 Pa 2 s air permeability, 140 Rayleigh acoustic impedance, and a uniform delamination resistance of about 3.4 m / 5cm, wherein the weight of the adhesive material is about 10 g / m 2 .

[0087] 10). A protective component for an audio opening, a speaker, a microphone or any electronic device including at least an audio function, said component being made by the method according to 7).

[0088] Although the invention has been disclosed with reference to presently preferred embodiments thereof, it will be apparent that the disclosed embodiments are susceptible to numerous modifications and variations which fall within the scope of the invention.

Claims

1. A method for laminating or joining a first precision fabric layer and a second precision fabric layer, each precision fabric layer being formed by weaving a plurality of synthetic monofilaments to provide a textile structure comprising two textile structure layers, the textile structure being specifically to be applied to a speaker and a microphone of a general electronic device, the electronic device having at least an audio function for transmitting and receiving sound, voice or music, and the textile structure being used to protect the electronic device from the intrusion of water and solid particles and to maintain the sound emission and reception characteristics designed for the electronic device, the method being characterized in that the method comprises the step of spraying an aqueous polyurethane adhesive material on the synthetic monofilament of at least one of the first precision fabric layer and the second precision fabric layer, thereby joining the first precision fabric layer and the second precision fabric layer in a diffusion manner, the method comprising the steps of: a) providing rolls of the first precision fabric layer and the second precision fabric layer; b) providing a plurality of spraying stations, said plurality of spraying stations comprising a corresponding plurality of spraying and atomizing nozzles for depositing droplets of said aqueous polyurethane glue material, said droplets of said aqueous polyurethane glue material being distributed in a nearly continuous distribution across the fabric threads; c) Provide drying tunnel furnace equipment; d) providing an unwinding system upstream of the spraying station and a winding system downstream of the drying tunnel oven, respectively; e) providing a conveying device for conveying the first precision fabric layer and the second precision fabric layer; f) unwinding the first precision fabric layer and the second precision fabric layer from the rolls; g) conveying the first precision fabric layer and the second precision fabric layer under the plurality of spraying and atomizing nozzles, and uniformly spraying and atomizing droplets of the aqueous polyurethane glue material on the synthetic monofilaments; h) further conveying the first precision fabric layer and the second precision fabric layer through the drying tunnel oven to evaporate the water contained in the water-based polyurethane glue material and dry the first precision fabric layer and the second precision fabric layer, the method is further characterized in that the water-based polyurethane glue material contains a locking catalyst, which is suitable for locking or stopping the crosslinking of the water-based polyurethane glue material in step g), and wherein, after step h), the method comprises another step of: i) Winding the dried first and second precision fabric layers without any remaining adhesive properties into rolls.

2. The method according to claim 1, characterized in that The method includes the further steps of unwinding the first and second precision fabric layers from the roll, and heating and pressing the first and second precision fabric layers in a heated calender to reactivate and polymerize the water-based polyurethane glue material for diffusion gluing the first and second precision fabric layers to each other.

3. The method according to claim 1 or 2, characterized in that: The first precision fabric layer and the second precision fabric layer are synthetic monofilament precision fabric layers, and the synthetic monofilament is selected from the group consisting of PET, PA, PP, PEEK, and PPS, and has a wire diameter of 19μm to 500μm, a wire / cm density of 260 to 4, a thickness between 35μm and 1mm, and a mesh between 5μm and 1mm.

4. The method according to any one of claims 1 to 3, characterized in that The first precision fabric layer and the second precision fabric layer are coated by a coating process to provide the first precision fabric layer and the second precision fabric layer with surface properties such as hydrophobicity, antistatic property, hydrophilicity, dirt release and antimicrobial property, wherein the coating process is selected from the physical or chemical deposition of one or more of dip coating, plasma coating, spray coating, foam coating, blade coating, sol-gel, inkjet coating, silver, copper, aluminum, steel, titanium, titanium nitride, chromium and chromium carbide.

5. The method according to any one of claims 1 to 4, characterized in that The second precision fabric layer has a mesh arrangement that is larger than a mesh arrangement of the first precision fabric layer.

6. The method according to any one of claims 1 to 5, characterized in that The first and second precision fabric layers to be laminated are passed under the plurality of spray and atomizing nozzles at a set speed, whereby the amount of glue deposited can be accurately determined by adjusting the fabric feeding speed and the spraying or atomizing of the water-based polyurethane glue material.

7. The method according to any one of claims 1 to 6, characterized in that After the spraying step, the fabric is passed through the drying tunnel oven at a set speed to evaporate the water present in the water-based polyurethane glue material.

8. The method according to any one of claims 1 to 7, characterized in that The method further comprises the step of providing a double-layer fabric structure having a thickness of 170 μm, a thickness of 114 g / m 2 Weight, 1330 l / m measured at a pressure drop of 200 Pa 2 s air permeability, 140 Rayleigh acoustic impedance, and uniform delamination resistance of about 3.4 m / 5cm, wherein the weight of the waterborne polyurethane adhesive material is about 10 g / m 2 .

9. A method for manufacturing a protective component, the protective component is used to protect acoustic equipment, speakers, microphones and any electronic equipment including at least an audio function, the audio function being a sound (voice or music) transmission or reception function, the component having an effective area, the method being characterized in that the method comprises the steps of: a1) Providing a textile structure by a method according to any one of claims 1 to 8; b1) cutting the textile structure into frames preferably having a width of 10 mm to 50 mm; c1) providing a first roll of a first adhesive strip supported by a respective first supporting element; d1) providing a second roll of a second adhesive strip supported by a respective second support element; e1) unwinding the first adhesive strip from the first roll and applying the first adhesive strip to a first surface of the border of the textile structure; f1) perforating the first adhesive strip and the first supporting element for the first adhesive strip according to the active area of ​​the component; g1) unwinding the second adhesive strip from the second roll and applying the second adhesive strip to an opposing second surface of the frame; h1) perforating the second adhesive strip and the second supporting element for the second adhesive strip; l1) removing one of the first supporting element and the second supporting element; m1) Laminating the components obtained from steps a1) to l1) by coating films.

10. The method according to claim 9, characterized in that The textile structure of step a1) has a thickness of 170 μm, a 2 Weight, 1330 l / m measured at a pressure drop of 200 Pa 2 s air permeability, 140 Rayleigh acoustic impedance, and uniform delamination resistance of about 3.4 m / 5cm, wherein the weight of the waterborne polyurethane adhesive material is about 10 g / m 2 .

11. A protective component for an audio opening, a loudspeaker, a microphone or any electronic device comprising at least an audio function, said component being made by the method according to claim 9.

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