THERMOPLASTIC COMPOSITE MATERIALS FOR PORTABLE INFORMATION HANDLING SYSTEM ENCLOSURES

• US 20160159046A1
• Filed: 12/08/2014
• Published: 06/09/2016
• Est. Priority Date: 12/08/2014
• Status: Active Grant

• Current Assignee: Dell Products LP (Dell Technologies Inc.)
• Original Assignee: Dell Products LP (Dell Technologies Inc.)
• Inventors: Abbatiello, Nicholas D., Aurongzeb, Deeder M., Ramirez, Ernesto
• Granted Patent: US 10,500,814 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 43/146 for making multilayered articles
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29K 2269/00 Use of PC, i.e. polycarbonates or derivatives thereof as reinforcement
• CPC Class Codes: B29K 2281/06 PSU, i.e. polysulfones or derivatives thereof; PES, i.e. polyethersulfones, or derivatives thereof
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29K 2309/08 Glass
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/712 Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2307/58 Cuttability
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2398/20 Thermoplastics
• CPC Class Codes: B32B 2429/00 : Carriers for sound or information
• CPC Class Codes: B32B 2457/00 : Electrical equipment
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 38/10 : Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: H05K 5/0091 : Housing specially adapted for small components for resistors H01C; for capacitors H01G; for integrated circuits H01L23/00
• CPC Class Codes: H05K 5/03 : Covers

Abstract

Enclosure parts for portable information handling systems may be made by heat pressing material layers together. The material layers may include outer fiber-reinforced thermoplastic layers and a core thermoplastic layer comprising a plurality of thermoplastic film layers. The core thermoplastic layer may be die cut to create voids that reduce weight of the enclosure part. A finishing layer may be added, along with attachment features.

Claims

1. A method for manufacturing enclosure parts for portable information handling systems, the method comprising:

heat pressing material layers to form an enclosure part for a portable information handling system, wherein the material layers comprise;

a first fiber-reinforced thermoplastic outer layer;

a core thermoplastic layer comprising a plurality of thermoplastic film layers; and

a second fiber-reinforced thermoplastic outer layer.

2. The method of claim 1, further comprising:

prior to the heat pressing, die cutting the core thermoplastic layer to remove thermoplastic material and reduce a density of the core thermoplastic layer, wherein the die cutting hexagonally patterns the core thermoplastic layer.

3. The method of claim 1, wherein the heat pressing consolidates the material layers, and wherein each of the material layers comprise at least one of:

polycarbonate and polysulfonate.

4. The method of claim 1, further comprising:

prior to the heat pressing, treating the thermoplastic film layers with a foaming agent to generate a foam structure in the thermoplastic film layers that reduces a density of the thermoplastic film layers.

5. The method of claim 1, wherein the first fiber-reinforced thermoplastic outer layer and the second fiber-reinforced thermoplastic outer layer each comprise woven-fiberglass-reinforced thermoplastic material.

6. The method of claim 1, wherein the first fiber-reinforced thermoplastic outer layer and the second fiber-reinforced thermoplastic outer layer each comprise:

a first thermoplastic tape layer comprising unidirectional carbon fibers having a first orientation of the unidirectional carbon fibers; and

a second thermoplastic tape layer comprising unidirectional carbon fibers having a second orientation of the unidirectional carbon fibers, wherein the second orientation is different from the first orientation.

7. The method of claim 1, wherein the material layers further comprise:

a finishing layer covering the first fiber-reinforced thermoplastic outer layer, wherein the finishing layer is an exterior surface of the enclosure part.

8. The method of claim 1, wherein the material layers further comprise:

a thermoplastic attachment feature bonded to the second fiber-reinforced thermoplastic outer layer, wherein the thermoplastic attachment feature enables assembly of the enclosure part to the portable information handling system.

9. The method of claim 8, wherein the thermoplastic attachment feature includes a thermoplastic attachment layer covering the second fiber-reinforced thermoplastic outer layer.

10. The method of claim 1, wherein the enclosure part is rectangularly shaped, and wherein a ratio of a maximum diagonal dimension to a minimum thickness of the enclosure part is between 170 and 400.

11. An enclosure part for portable information handling systems, the enclosure part comprising:

a plurality of material layers formed together in a rectangular shape, wherein the material layers comprise;

a first fiber-reinforced thermoplastic outer layer;

a core thermoplastic layer comprising a plurality of thermoplastic film layers; and

a second fiber-reinforced thermoplastic outer layer,

wherein the enclosure part is rectangularly shaped, and wherein a ratio of a maximum diagonal dimension to a minimum thickness of the enclosure part is between 170 and 400.

12. The enclosure part of claim 11, wherein the core thermoplastic layer further comprises:

a hexagonal pattern of voids, wherein the hexagonal pattern of voids reduces a density of the core thermoplastic layer, wherein a wall thickness of the hexagonal pattern of voids is at least one half of an open span of the hexagonal pattern of voids.

13. The enclosure part of claim 11, wherein each of the material layers comprise at least one of:

polycarbonate and polysulfonate.

14. The enclosure part of claim 11, wherein the thermoplastic film layers further comprise:

a foam structure in the thermoplastic film layers that reduces a density of the thermoplastic film layers.

15. The enclosure part of claim 11, wherein the first fiber-reinforced thermoplastic outer layer and the second fiber-reinforced thermoplastic outer layer each comprise woven-fiberglass-reinforced thermoplastic material.

16. The enclosure part of claim 11, wherein the first fiber-reinforced thermoplastic outer layer and the second fiber-reinforced thermoplastic outer layer each comprise:

a first thermoplastic tape layer comprising unidirectional carbon fibers having a first orientation of the unidirectional carbon fibers; and

a second thermoplastic tape layer comprising unidirectional carbon fibers having a second orientation of the unidirectional carbon fibers, wherein the second orientation is different from the first orientation.

17. The enclosure part of claim 11, wherein the material layers further comprise:

a finishing layer covering the first fiber-reinforced thermoplastic outer layer, wherein the finishing layer is an exterior surface of the enclosure part.

18. The enclosure part of claim 11, wherein the material layers further comprise:

a thermoplastic attachment feature bonded to the second fiber-reinforced thermoplastic outer layer, wherein the thermoplastic attachment feature enables assembly of the enclosure part to the portable information handling system.

19. The enclosure part of claim 18, wherein the thermoplastic attachment feature includes a thermoplastic attachment layer covering the second fiber-reinforced thermoplastic outer layer.