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."

 
AAPL
$99.26
Apple Inc.
+0.08
MSFT
$45.91
Microsoft Corpora
+0.01
GOOG
$569.90
Google Inc.
+1.63

MacTech Search:
Community Search:

Software Updates via MacUpdate

Dropbox 2.10.30 - Cloud synchronization...
Dropbox is an application that creates a special Finder folder that automatically syncs online and between your computers. It allows you to both backup files and keep them up-to-date between systems... Read more
Twitter 3.1 - Official Twitter client fo...
Twitter (was Tweetie) is a Twitter client with a variety of features. Important Note: As of January 2011, AteBit's Tweetie application has been acquired and renamed by Twitter. Version 1.2.8 of the... Read more
Cocktail Family License (5 Macs) 7.6.1 -...
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
Cocktail 8.0 Beta 2 - General maintenanc...
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
QuickBooks 2015 16.0.0.1352 R1 - Financi...
QuickBooks 2015 helps you manage your business easily and efficiently. Organize your finances all in one place, track money going in and out of your business, and spot areas where you can save.... Read more
Mac DVDRipper Pro 5.0.1 - Copy, backup,...
Mac DVDRipper Pro is the DVD backup solution that lets you protect your DVDs from scratches, save your batteries by reading your movies from your hard disk, manage your collection with just a few... Read more
Apple OS X bash Update 1.0 - Fix for sec...
The OS X bash Update fixes a security flaw in the bash UNIX shell on OS X 10.9.5 (also on OS X 10.8 and 10.7 [see Related Links below]). OS X 10.9.5 or later Downloads for OS X 10.8 and OS X 10.7 in... Read more
SyncTwoFolders 2.0.5 - Syncs two user-sp...
SyncTwoFolders simply synchronizes two folders. It supports synchronization across mounted network drives and it is a possibility to run a simulation showing in a log what will be done. Please visit... Read more
FinderPop 2.5.7 - Classic Mac utility, n...
FinderPop is a Universal preference pane that extends OS X's contextual menus using a FinderPop Items folder much as the Apple Menu Items folder used to do for the Apple menu. It has other features... Read more
VueScan 9.4.45 - Scanner software with a...
VueScan is a scanning program that works with most high-quality flatbed and film scanners to produce scans that have excellent color fidelity and color balance. VueScan is easy to use, and has... Read more

Latest Forum Discussions

See All

Ms.Pac-Man Goes Pink for National Breast...
Ms.Pac-Man Goes Pink for National Breast Cancer Foundation Campaign Posted by Ellis Spice on October 2nd, 2014 [ permalink ] | Read more »
The Maze Runner Review
The Maze Runner Review By Lee Hamlet on October 2nd, 2014 Our Rating: :: A NICE CHANGE OF PACEUniversal App - Designed for iPhone and iPad The Maze Runner is a surprisingly enjoyable movie tie-in that will succeed in keeping... | Read more »
RPG Soul of Deva (Games)
RPG Soul of Deva 1.0.0 Device: iOS Universal Category: Games Price: $3.99, Version: 1.0.0 (iTunes) Description: SPECIAL PRICE56% OFF(USD 8.99 -> USD 3.99)!!! Demons attack humans, and humans live in fear of them...Set off on a... | Read more »
Banner Saga (Games)
Banner Saga 1.0.17 Device: iOS Universal Category: Games Price: $9.99, Version: 1.0.17 (iTunes) Description: NOTE: The Banner Saga does NOT run on iPhone 4. iPhone 4S and more modern devices recommended. | Read more »
Beatbuddy HD (Games)
Beatbuddy HD 1.0.2 Device: iOS Universal Category: Games Price: $4.99, Version: 1.0.2 (iTunes) Description: **IMPORTANT** Beatbuddy runs only on iPhone 6, 6 Plus, 5, 5c, 5s, iPad 4, iPad Mini Retina and iPad Air. | Read more »
Spirits of Spring (Games)
Spirits of Spring 1.0.1 Device: iOS Universal Category: Games Price: $4.99, Version: 1.0.1 (iTunes) Description: From the creators of the award-winning empathy game, Papo & Yo, comes a tale about finding strength. | Read more »
I am a brave knight (Games)
I am a brave knight 1.0 Device: iOS Universal Category: Games Price: $.99, Version: 1.0 (iTunes) Description: Do you have ten minutes to live a life? | Read more »
iKeywi - Customizable 5-Row Keyboard (U...
iKeywi - Customizable 5-Row Keyboard 1.0 Device: iOS Universal Category: Utilities Price: $.99, Version: 1.0 (iTunes) Description: Want to add an extra row to your iPhone/iPad? One of the most popular keyboard extension in iOS... | Read more »
Manage Your Cloud – Wunderlist Now Suppo...
Manage Your Cloud – Wunderlist Now Supports Dropbox Posted by Jessica Fisher on October 1st, 2014 [ permalink ] Universal App - Designed for iPhone and iPad | Read more »
Nexticy Review
Nexticy Review By Jennifer Allen on October 1st, 2014 Our Rating: :: IDEAL FORM CREATIONiPad Only App - Designed for the iPad Nexticy allows you to make your own forms for research purposes or to organize your business better. It’s... | Read more »

Price Scanner via MacPrices.net

Apple drops prices on refurbished 27-inch iMa...
The Apple Store has dropped prices on Apple Certified Refurbished 27″ iMacs, now available for up to $340 off the cost of new models. Apple’s one-year warranty is standard, and shipping is free: - 27... Read more
Logitech Type+ iPad Air Keyboard Case: Laptop...
If you want to make your iPad Air look and feel more like a laptop for productivity use, as well as protect it from impacts, spills, and scratches while on the move, the new Logitech Type+, a... Read more
ASUS, Lenovo, and Amazon Slug It Out For Tabl...
According to market intelligence firm ABI Research, Apple and Samsung have led the touchscreen tablet market by a substantial margin since Apple energized the category back in 2010. However, ABI says... Read more
Branded Tablet Growth Expected to Disappoint...
ABI Research says the 200 million annual shipments milestone for branded tablets continues to elude OEM vendors, and overall growth for 2014 is set to come in at a disappointing 2.5 percent. Apple... Read more
Amazon offers 13-inch MacBook Air for $899, $...
Amazon.com has the 13″ 1.4GHz 128GB MacBook Air on sale for $100 off MSRP including free shipping: - 13″ 1.4GHz 128GB MacBook Air: $899.99 Read more
Apple resting On Its iPhone Laurels? – The ‘B...
Apple calls its new iPhone 6 and 6 Plus “The Biggest Advancements in iPhone History,” but does reality live up to the hype? “Seldom have so many waited so breathlessly for so little,” tweeted veteran... Read more
Roundup of Apple Mac and iPad Education disco...
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 Boycotts German Magazine Computer Bild...
Apple has revoked its PR accreditation of Germany’s Computer Bild, Europe’s best-selling PC magazine, in reaction to Bild’s posting of a “#Bentgate” YouTube video. Axel Telzerow, editor in chief of... Read more
iPhone 6 & iPhone 6 Plus Available in Chi...
Apple has announced that iPhone 6 and iPhone 6 Plus will be available in China beginning Friday, October 17 from the Apple Online Store (http://www.apple.com), Apple’s retail stores, and an expansive... Read more
MacBook Airs on sale for $100 off MSRP, start...
Best Buy has the new 2014 MacBook Airs on sale for $100 off MSRP on their online store. Choose free home shipping or free local store pickup (if available). Prices valid for online orders only, in-... 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* Retail - Multiple Positions (US) - A...
Job Description: Sales Specialist - Retail Customer Service and Sales Transform Apple Store visitors into loyal Apple customers. When customers enter the store, Read more
Senior Event Manager, *Apple* Retail Market...
…This senior level position is responsible for leading and imagining the Apple Retail Team's global event strategy. Delivering an overarching brand story; in-store, Read more
*Apple* Solutions Consultant (ASC) - Apple (...
**Job Summary** The ASC is an Apple employee who serves as an Apple brand ambassador and influencer in a Reseller's store. The ASC's role is to grow Apple Read more
Project Manager / Business Analyst, WW *Appl...
…a senior project manager / business analyst to work within our Worldwide Apple Fulfillment Operations and the Business Process Re-engineering team. This role will work Read more
All contents are Copyright 1984-2011 by Xplain Corporation. All rights reserved. Theme designed by Icreon.