Apple on Tuesday received a patent for a molded carbon fiber that could one day be used to make parts of devices such as laptop cases or panels of mobile devices from lightweight material.
US Patent No. 8.257.075, Design and Shapes of Carbon Composite Products, describes the systems and methods needed to produce “aesthetically pleasing” portions of carbon fiber and other resin-based composite products.
There are quite a few places of use for carbon fiber composites today. The invention can be applied to "create forms of external cases for laptop computers and the like." This patent may prove useful as the demand for thin and light devices with relatively heavy and large screens increases over time in the computer industry. For example, the acclaimed next-generation iPhone 5 is expected to have a four-inch screen, possibly framed by a carbon fiber body.
It is likely that this invention is aimed primarily at larger devices such as the MacBook, and aims to surpass Sony's thin and light Vaio Z series of carbon fiber.
The patent notes that a traditional resin-based composite material is made by layering sheets of resin impregnated sheets in or through a mold, which is then set under elevated temperature and pressure conditions. Removing one part can be problematic as the resin adheres to the mold surface, which often requires manual handling and cleaning by the operator. As a result, surface stains and other physical defects are common.
Apple's proposed method will allow for mass production of carbon fiber parts that will be given the appropriate appearance by optimizing the manufacturing process.
The invention provides for two parts of the mold, one of them is a cavity, and the second part is "adapted to work in tandem with the first", which allows forming the component parts between them. After hardening, ejector rods, located on one or both parts of the mold, separate the finished product from the mold.
While Apple has shown no signs of using advanced carbon fiber technology in its upcoming devices, thanks to this patent, the company may well do so and begin making lighter, more durable devices.
