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

BusyContacts 1.0.2 - Fast, efficient con...
BusyContacts is a contact manager for OS X that makes creating, finding, and managing contacts faster and more efficient. It brings to contact management the same power, flexibility, and sharing... Read more
Capture One Pro 8.2.0.82 - RAW workflow...
Capture One Pro 8 is a professional RAW converter offering you ultimate image quality with accurate colors and incredible detail from more than 300 high-end cameras -- straight out of the box. It... Read more
Backblaze 4.0.0.872 - Online backup serv...
Backblaze is an online backup service designed from the ground-up for the Mac.With unlimited storage available for $5 per month, as well as a free 15-day trial, peace of mind is within reach with... Read more
Little Snitch 3.5.2 - Alerts you about o...
Little Snitch gives you control over your private outgoing data. Track background activity As soon as your computer connects to the Internet, applications often have permission to send any... Read more
Monolingual 1.6.4 - Remove unwanted OS X...
Monolingual is a program for removing unnecesary language resources from OS X, in order to reclaim several hundred megabytes of disk space. If you use your computer in only one (human) language, you... Read more
CleanApp 5.0 - Application deinstaller a...
CleanApp is an application deinstaller and archiver.... Your hard drive gets fuller day by day, but do you know why? CleanApp 5 provides you with insights how to reclaim disk space. There are... Read more
Fantastical 2.0 - Create calendar events...
Fantastical is the Mac calendar you'll actually enjoy using. Creating an event with Fantastical is quick, easy, and fun: Open Fantastical with a single click or keystroke Type in your event details... Read more
Cocktail 8.2 - General maintenance and o...
Cocktail is a general purpose utility for OS X that lets you clean, repair and optimize your Mac. It is a powerful digital toolset that helps hundreds of thousands of Mac users around the world get... Read more
Direct Mail 4.0.4 - Create and send grea...
Direct Mail is an easy-to-use, fully-featured email marketing app purpose-built for OS X. It lets you create and send great looking email campaigns. Start your newsletter by selecting from a gallery... Read more
jAlbum Pro 12.6 - Organize your digital...
jAlbum Pro has all the features you love in jAlbum, but comes with a commercial license. With jAlbum, you can create gorgeous custom photo galleries for the Web without writing a line of code!... Read more

Appy to Have Known You - Lee Hamlet Look...
Being at 148Apps these past 2 years has been an awesome experience that has taught me a great deal, and working with such a great team has been a privilege. Thank you to Rob Rich, and to both Rob LeFebvre and Jeff Scott before him, for helping me... | Read more »
MLB Manager 2015 (Games)
MLB Manager 2015 5.0.14 Device: iOS Universal Category: Games Price: $4.99, Version: 5.0.14 (iTunes) Description: Guide your favorite MLB franchise to glory! MLB Manager 2015, officially licensed by MLB.com and based on the award-... | Read more »
Breath of Light (Games)
Breath of Light 1.0.1421 Device: iOS Universal Category: Games Price: $2.99, Version: 1.0.1421 (iTunes) Description: Hold a quiet moment. Breath of Light is a meditative and beautiful puzzle game with a hypnotic soundtrack by... | Read more »
WWE WrestleMania Tags into the App Store
Are You ready to rumble? The official WWE WrestleMania app, by World Wrestling Entertainment, is now available. Now you can get all your WrestleMania info in one place before anyone else. The app offers details on superstar signings, interactive... | Read more »
Bio Inc's New Expansion is Infectin...
Bio Inc., by DryGin Studios, is the real time strategy game where you infect a human body with the worst virus your evil brain can design. Recently, the game was updated to add a whole lot of new features. Now you can play the new “Lethal”... | Read more »
The Monocular Minion is Here! Despicable...
Despicable Me: Minion Rush, by Gameloft, is introducing a new runner to the mix in their latest update. Now you can play as Carl, the prankster minion. Carl has a few new abilities to play with, including running at a higher speed from the start.... | Read more »
Dungeon of Madness (Games)
Dungeon of Madness 1.0.0 Device: iOS Universal Category: Games Price: $1.99, Version: 1.0.0 (iTunes) Description: Dungeon of Madness is an action game where you rotate tiles to create our own route. Help the hero by connecting the... | Read more »
Filters for iPhone (Photography)
Filters for iPhone 1.0 Device: iOS iPhone Category: Photography Price: $.99, Version: 1.0 (iTunes) Description: | Read more »
Jump'N'Shoot Attack (Games)
Jump'N'Shoot Attack 1.0 Device: iOS Universal Category: Games Price: $1.99, Version: 1.0 (iTunes) Description: A mobile game for gamers! Join Louise Lightfoot, the legendary "Master of Jumping and Shooting", on her mission to save... | Read more »
Space Bounties Inc. (Games)
Space Bounties Inc. 1.4 Device: iOS Universal Category: Games Price: $1.99, Version: 1.4 (iTunes) Description: SuperGameDroid: 4/5 "Satisfying futuristic RPG combat, high replay value, and a heavy dose of nostalgia make Space... | Read more »

Price Scanner via MacPrices.net

iMacs on sale for up to $205 off MSRP
B&H Photo has 21″ and 27″ iMacs on sale for up to $205 off MSRP including free shipping plus NY sales tax only: - 21″ 1.4GHz iMac: $1019 $80 off - 21″ 2.7GHz iMac: $1189 $110 off - 21″ 2.9GHz... Read more
Färbe Technik Offers iPhone Battery Charge LI...
Färbe Technik, which manufactures and markets of mobile accessories for Apple, Blackberry and Samsung mobile devices, is offering tips on how to keep your iPhone charged while in the field: •... Read more
Electronic Recyclers International CEO Urges...
Citing a recent story on CNBC about concerns some security professionals have about the forthcoming Apple Watch, John Shegerian, Chairman and CEO of Electronic Recyclers International (ERI), the... Read more
Save up to $380 with Apple refurbished iMacs
The Apple Store has Apple Certified Refurbished iMacs available for up to $380 off the cost of new models. Apple’s one-year warranty is standard, and shipping is free: - 27″ 3.5GHz 5K iMac – $2119 $... Read more
Logitech Says MX Master Is Its Most Advanced...
Logitech’s new MX Master Wireless Mouse incorporates the best of Logitech’s many computer mouse innovations into a striking hand-sculpted design. The company claims that the MX Master creates a new... Read more
Save up to $300 on a new Mac, $30 on an iPad,...
Purchase a new Mac or iPad at The Apple Store for Education and take up to $300 off MSRP. All teachers, students, and staff of any educational institution qualify for the discount. Shipping is free,... Read more
Apple refurbished 2014 MacBook Airs available...
The Apple Store lowered prices on Apple Certified Refurbished 2014 MacBook Airs recently, with models now available starting at $679. An Apple one-year warranty is included with each MacBook, and... Read more
Mac Notebook Evolution; A Desktop Replacement...
More often than not right from the beginning, Apple’s Macs have tended to skew toward small. The original Macs were called “compacts,”, and notwithstanding a few exceptions like the honking Big Mac... Read more
13-inch 1.4GHz/128GB MacBook Air (Apple refur...
The Apple Store has Apple Certified Refurbished 2014 13″ 1.4GHz/128GB MacBook Airs available for $759 including free shipping plus Apple’s standard one-year warranty. Their price is $240 off original... Read more
YEP! Alternative Browser for iOS Now Supports...
Pfaeffikon, Switzerland based Power App AG has announced the release of an update to their Yep! Web Browser (v1.3.0) for iOS8 iPhone and iPad. Yep! hit the App Store shortly after the release of iOS... 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
Sr. Technical Services Consultant, *Apple*...
**Job Summary** Apple Professional Services (APS) has an opening for a senior technical position that contributes to Apple 's efforts for strategic and transactional Read more
Lead *Apple* Solutions Consultant - Retail...
**Job Summary** Job Summary The Lead ASC is an Apple employee who serves as the Apple business manager and influencer in a hyper-business critical Reseller's store Read more
*Apple* Pay - Site Reliability Engineer - Ap...
**Job Summary** Imagine what you could do here. At Apple , great ideas have a way of becoming great products, services, and customer experiences very quickly. Bring 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.