Future Apple products could have carbon composite mold design
TweetFollow Us on Twitter

Future Apple products could have carbon composite mold design

An Apple patent (number 20100119634) for a carbon composite mold design has appeared at the US Patent & Trademark Office. The invention relates generally to the formation of carbon composite based components, and, more particularly, to the use of molds to form such carbon composite based components.

A mold assembly or system includes a moldbase that holds mold inserts and has embedded fluid lines to facilitate cooling during part formation. Mold inserts combine to form mold cavities that receive carbon fiber and resin components to form a carbon composite based part. A permanent release coating along a mold component surface that contacts the carbon fiber and resin components facilitates the release of the finished part from the mold component.

Guide pins and guide pin receiving holes facilitate accurate alignment of mold components. Ejector pins within respective ejector pin shafts help eject a finished part from a respective mold component. An ejector pin shaft cover transfers force from an ejector pin to eject a finished part and also prevents substantial passage of resin into the ejector pin shaft. A fluid actuated ejection system provides fluid based mechanical forces to the ejector pins to facilitate finished part ejection. The inventors are Paul Choiniere, Glenn Aune, John Difonzo, Daniel Hong and Kevin Kenney.

Here's Apple's background and summary of the invention: "There are currently a wide number of known ways to form aesthetically pleasing parts and components for items made from various materials across many industries. For example, general part formation can be had by way of machining, casting, stamping, extrusion, cold drawing and injection molding, among numerous other alternatives. Where particularly strong parts or components are desired, another common part formation process can involve composite molding.

"Composite molding generally involves molding a combination of different materials, each having a particular mechanical strength in a different direction, to form a final product that has mechanical strengths in multiple directions. Many popular forms of composite molding involve the use of carbon fibers or another similar component and a resin material, the molded combination of which results in a relatively strong part or component, particularly with respect to the weight of the part. Generally, fibers and resin are placed over or into a mold and are then cured under increased heat and pressure. Fibers typically come in sheet form, which can include "prepreg" or resin impregnated sheets, and are often layered into the mold sheet by sheet. Such a layering process is often performed manually by an operator, as are other steps in a typical composite molding of a part.

"Because resins tend to stick to mold surfaces, removal of a finished part from a mold can be a tricky process that often also involves manual intervention by an operator. Despite the application of a temporary release coating to inner mold surfaces prior to placing in the composite materials, the removal of a finished part from a composite mold still can involve prying and peeling the part away from the inner mold surfaces. Surface defects and blemishes on composite molded parts often occur as a part of the molding and mold removal process, which results in many parts having unique defects or appearances.

"Further, temperature discrepancies from molded part to molded part using traditional composite molding processes can also result in blemishes or defects that are different for each part. Due to these particular examples and other concerns that relate to composite molding, many composite molding processes are highly manual labor intensive by nature, and often result in the formation of parts that are not fully consistent from part to part.

"This is unfortunate in that many manufacturers might desire the mass production of consistent parts that have the strength of carbon composite components. As but one example, it would be particularly helpful if portable electronic device housings and components could be stronger and more durable than what is now typically provided in plastic parts that are formed via ordinary plastic injection molding processes. In particular, it would be beneficial if laptops, notebook computers, and other relatively large and heavy portable computing devices could have outer housings that are better able to protect the entire device from drops and other mechanical shocks.

"Although a material having the toughness of a good carbon composite would be useful, the ability to mass produce laptop housings that are consistent in appearance and performance from such a material would be difficult. Of course, there are a myriad of other examples of parts where it would be desirable to form them from a stronger material such as a carbon composite.

"While many designs and methods of manufacture for providing composite molded parts and components have generally worked well in the past, there is always a desire to provide new and improved designs and processes that result in functional and aesthetically pleasing composite parts that can be mass produced. In particular, it is desirable to provide a carbon composite molding apparatus and process that allows for a more automated mass production of consistent carbon composite parts, such as for computer housings and the like.

"The present invention provides systems and methods that facilitate the mass production of consistent and aesthetically pleasing composite molded parts, such as carbon fiber and resin based composite parts. Such parts can be used for a variety of applications, such as to form outer housings for a laptop computer or other similar device. This can be accomplished by providing a variety of manufacturing techniques and features to traditional composite mold processes, so as to streamline the manufacturing process and to result in the mass manufacture of consistent parts.

"In various embodiments, the invention can include an apparatus adapted to form carbon composite based parts, with the apparatus having a first mold portion including a first mold cavity, a second mold portion adapted to mate with the first mold portion so that composite parts can be formed therebetween, a plurality of ejector pins located within a plurality of respective ejector pin shafts that are formed within one of the mold portions, and an ejector pin shaft stopper fitted within at least one of the plurality of ejector pin shafts.

"The plurality of ejector pins can be adapted to aid in the ejection of a carbon composite based part from one or both of the mold portions, while the ejector pin shaft stopper can be adapted to transfer a mechanical force from a respective ejector pin to the actual carbon composite part for ejection of the part from a respective mold portion. Also, the ejector pin shaft stopper can be further adapted to prevent the substantial passage of any resin component into its respective ejector pin shaft during the formation of the carbon composite based part.

"In various detailed embodiments, a mold assembly for forming carbon composite parts can further include a variety of items. A moldbase can be adapted to hold one or more mold inserts, with the moldbase having one or more internal fluid lines embedded therein to facilitate a fluid based cooling of components during the formation of a carbon composite based part. A plurality of mold inserts, at least one of which is held by the moldbase, can combine to form one or more mold cavities there between while held by the moldbase such that one or more materials including a carbon fiber component and a resin component can be placed therein for the formation of the carbon composite based part.

"At least one of the mold inserts can include a permanent release coating along a surface that contacts the carbon fiber and resin materials to facilitate the release of the carbon composite based part therefrom. One or more guide pins and guide pin receiving holes can be located on at least one of the moldbase and/or plurality of mold inserts, with the one or more guide pins and guide receiving holes being adapted to facilitate the accurate alignment of mold inserts with each other for the formation of the carbon composite based part. Again, a plurality of ejector pins located within a plurality of respective ejector pin shafts having an ejector pin shaft stopper fitted therewithin can be used.

"Also, a fluid actuated ejection system adapted to provide fluid based mechanical forces to the plurality of ejector pins to facilitate the ejection of the carbon composite based part from a respective mold insert can be incorporated into the system. In some embodiments, the fluid actuated ejection system can operate using a gas to provide gas based mechanical forces to the ejector pins.

"In various embodiments, a removable film can be positioned proximate to the permanent release coating, wherein the removable film is adapted to facilitate the release of a carbon composite based part from its respective mold insert, and wherein the removable film can be readily removed from both its respective mold insert and the carbon composite based part. Such a removable film can also serve as an ejector pin shaft cover or stopper by covering the top of one or more of the ejector pin shafts during the formation of a carbon composite based part. In some embodiments, the removable film can be used in addition to or in lieu of the ejector pin shaft stoppers placed within the ejector pin shafts. In some embodiments, the removable film has a thickness of about 10 to 20 microns.

"In various embodiments, the permanent release coating or layer can be formed from nickel-teflon, titantium-nitride, an amorphous carbon/diamond like material, chrome or chrome alloy, or NEDOX. The permanent release coating can have a thickness of about 1 to 5 microns, although other suitable thicknesses may also be used. The permanent release coating or layer can be situated on one mold insert or component or multiple mold components."

 

Community Search:
MacTech Search:

Software Updates via MacUpdate

BBEdit 11.0.3 - Powerful text and HTML e...
BBEdit is the leading professional HTML and text editor for the Mac. Specifically crafted in response to the needs of Web authors and software developers, this award-winning product provides a... Read more
Microsoft Office Preview 15.8 - Popular...
Welcome to the new and modern Microsoft Office for Mac. You will receive regular updates automatically until the official release in the second half of 2015. With the redesigned Ribbon and your... Read more
Yosemite Cache Cleaner 9.0.5 - Clear cac...
Yosemite Cache Cleaner is an award-winning general purpose tool for OS X. YCC makes system maintenance simple with an easy point-and-click interface to many OS X functions. Novice and expert users... Read more
ExpanDrive 4.3.2 - Access cloud storage...
ExpanDrive builds cloud storage in every application, acts just like a USB drive plugged into your Mac. With ExpanDrive, you can securely access any remote file server directly from the Finder or... Read more
RapidWeaver 6.0.8 - Create template-base...
RapidWeaver is a next-generation Web design application to help you easily create professional-looking Web sites in minutes. No knowledge of complex code is required, RapidWeaver will take care of... Read more
Artlantis Studio 5.1.2.7 - 3D rendering...
Artlantis Studio is a unique and ideal tool for performing very high resolution rendering easily and in real time. The new FastRadiosity engine now lets you compute images in radiosity-even in... Read more
MacUpdate Desktop 6.0.5 - Search and ins...
MacUpdate Desktop 6 brings seamless 1-click installs and version updates to your Mac. With a free MacUpdate account and MacUpdate Desktop 6, Mac users can now install almost any Mac app on macupdate.... Read more
BitTorrent Sync 2.0.82 - Sync files secu...
BitTorrent Sync allows you to sync unlimited files between your own devices, or share a folder with friends and family to automatically sync anything. File transfers are encrypted. Your information... Read more
Google Drive 1.20 - File backup and shar...
Google Drive is a place where you can create, share, collaborate, and keep all of your stuff. Whether you're working with a friend on a joint research project, planning a wedding with your fiancé, or... Read more
Simon 4.0.3 - Monitor changes and crashe...
Simon monitors websites and alerts you of crashes and changes. Select pages to monitor, choose your alert options, and customize your settings. Simon does the rest. Keep a watchful eye on your... Read more

Bored? MyLeisure FreeTime Maximizer Will...
Bored? MyLeisure FreeTime Maximizer Will Take Care of That! Posted by Jessica Fisher on March 5th, 2015 [ permalink ] iPhone App - Designed for the iPhone, compatible with the iPad | Read more »
New Publisher Allstar Games Heads West w...
Allstar Games has announced its first mobile title designed for western audiences, Allstar Heroes. The game will be a massive online battle arena (MOBA) that offers dozens of heroes for you to collect and pit against your opponents. As each hero has... | Read more »
RAD Boarding Review
RAD Boarding Review By Jennifer Allen on March 5th, 2015 Our Rating: :: NEARLY RADUniversal App - Designed for iPhone and iPad RAD Boarding isn’t quite one of the greats, but it has potential.   | Read more »
Presenting the International Mobile Gami...
11th Annual International Mobile Gaming Awards ceremony, hosted by actress Allison Haislip, gathered mobile game developers and publishers from around the world. They chose 13 winners out of the 93 nominations. British studio USTWO won the the Grand... | Read more »
AG Drive Review
AG Drive Review By Tre Lawrence on March 5th, 2015 Our Rating: :: FUTURISTIC STREET RACING.Universal App - Designed for iPhone and iPad Futuristic racing… interstellar style.   | Read more »
GDC 2015 – Nightmare Guardians is an Int...
GDC 2015 – Nightmare Guardians is an Interesting Hybrid of MOBA and Lane Defense Posted by Rob Rich on March 5th, 2015 [ permalink ] I have to say that lane defense (i.e. | Read more »
Overkill 3 Review
Overkill 3 Review By Tre Lawrence on March 5th, 2015 Our Rating: :: WHO'S NEXT?Universal App - Designed for iPhone and iPad Cover system gameplay in the third-person.   Developer: Craneballs Price: Free Version Reviewed: 1.1.6... | Read more »
Warner Bros. Interactive Entertainment A...
Warner Bros. has some exciting games coming down the pipe! | Read more »
GDC 2015 – Star Trek Timelines will Prob...
GDC 2015 – Star Trek Timelines will Probably Make Your Inner Trekkie Squeal With Glee Posted by Rob Rich on March 4th, 2015 [ permalink ] Any popular fictional universe has its fair share of fan fiction – where belo | Read more »
Protect Yourself from an Onslaught of Ca...
Surprise Attack Games has announced a Cat-astrophic new physics puzzler called Fort Meow! In the game, a young girl named Nia finds her grandfather’s journal which triggers an all mighty feline attack! Why do the cats want the journal? Who knows,... | Read more »

Price Scanner via MacPrices.net

Apple restocks refurbished 15-inch Retina Mac...
The Apple Store has restocked Apple Certified Refurbished 2014 15″ Retina MacBook Pros, available for up to $400 off the cost of new models. An Apple one-year warranty is included with each model,... Read more
Roundup of MacBook Air sale prices, models up...
B&H Photo has MacBook Airs on sale for up to $100 off MSRP. Shipping is free, and B&H charges NY sales tax only: - 11″ 128GB MacBook Air: $799 100 off MSRP - 11″ 256GB MacBook Air: $999 $100... Read more
New Firstrade Mobile App Enables On-The-Go Tr...
Firstrade Securities Inc. has announced its new mobile app, which gives investors immediate access to the company’s trading platform on all mobile devices. The app was developed in-house and was... Read more
Sonnet Introduces USB 3.0 + eSATA Thunderbolt...
Sonnet has announced the launch of its new USB 3.0 + eSATA Thunderbolt Adapter for easy connectivity to USB 3.0 devices and eSATA storage, and USB 3.0 + Gigabit Ethernet Thunderbolt Adapter for easy... Read more
Apple restocks refurbished 27-inch 5K iMacs f...
The Apple Store has restocked Apple Certified Refurbished 27″ 3.5GHz 5K iMacs for $2119 including free shipping. Their price is $380 off the cost of new models, and it’s the lowest price available... Read more
Free Clean Reader Mobile App Hides Swear Word...
The new Clean Reader app, now available in the Apple App Store and Google Play, delivers the opportunity of reading any book without being exposed to profanity. By selecting how clean they want their... Read more
Kinsa Launches “Groups” App to Monitor Illnes...
Kinsa, makers of the first FDA approved app-enabled smartphone thermometer thst won the 2013 Cleveland Clinic Medical Innovation Grand Prize and recently appeared in Apple’s “Parenthood” TV... Read more
iPad: A More Positive Outlook – The ‘Book Mys...
It’s good to hear someone saying positive things about the iPad. I’ve been trying to bend my mind around how Apple’s tablet could have gone from zero to bestselling personal computing device on the... Read more
Mac Pros on sale for up to $279 off MSRP
Amazon has Mac Pros in stock and on sale for up to $279 off MSRP. Shipping is free: - 4-Core Mac Pro: $2725.87, $273 off MSRP (9%) - 6-Core Mac Pro: $3719.99, $279 off MSRP (7%) Read more
Sale! 13-inch Retina MacBook Pros for up to $...
B&H Photo has 13″ Retina MacBook Pros on sale for up to $205 off MSRP. Shipping is free, and B&H charges NY sales tax only: - 13″ 2.6GHz/128GB Retina MacBook Pro: $1219.99 save $80 - 13″ 2.... Read more

Jobs Board

*Apple* Retail - Multiple Positions (US) - A...
Sales Specialist - Retail Customer Service and Sales Transform Apple Store visitors into loyal Apple customers. When customers enter the store, you're also the Read more
*Apple* Solutions Consultant - Retail Sales...
**Job Summary** As an Apple Solutions Consultant (ASC) you are the link between our customers and our products. Your role is to drive the Apple business in a retail Read more
Position Opening at *Apple* - Apple (United...
…Summary** As a Specialist, you help create the energy and excitement around Apple products, providing the right solutions and getting products into customers' hands. You Read more
Position Opening at *Apple* - Apple (United...
**Job Summary** The Apple Store is a retail environment like no other - uniquely focused on delivering amazing customer experiences. As an Expert, you introduce people Read more
*Apple* Solutions Consultant - Retail Sales...
**Job Summary** As an Apple Solutions Consultant (ASC) you are the link between our customers and our products. Your role is to drive the Apple business in a retail Read more
All contents are Copyright 1984-2011 by Xplain Corporation. All rights reserved. Theme designed by Icreon.