Patent Application
20080042109
For a more complete understanding of the present invention, and the objects and advantages thereof, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:
The preferred embodiments of the present invention and the advantages thereof are best understood by referring to
In the embodiment illustrated in
In the embodiment illustrated in
Preferably, top cover 12 and bezel 14 are fabricated by injection molding using a resin such as, but not limited to, a blend of polycarbonate and acrylonitrile butadiene styrene (“PC/ABS”). Embodiments of the present invention employ a predetermined amount of magnesium silicate hydroxide (Talc) mixed with the PC/ABS to improve flatness (e.g., to substantially reduce or eliminate the component from warping during manufacturing, especially in instances where the component is thin), to improve impact strength and rigidity of the component, to reduce shrinkage, to reduce the manufacturing cycle times of the component (e.g., to reduce the time required to fabricate the component due to increased rate of hardening of the resin), and to increase the accuracy in which each component is fabricated (e.g., the increased repeatability of fabricating components with minimal or no dimensional inconsistencies sometimes caused by the component shrinking). Preferably, the resin mixture comprises fifteen percent (15%) by volume Talc (i.e., precisely or approximately 15%); however, it should be understood that a greater or lesser amount of Talc may be mixed with the PC/ABS to obtain the desired structural characteristics. In addition, embodiments of the present invention employ a predetermined amount of glass and/or carbon mixed with the PC/ABS (and also PC/ABS/Talc mixture) to obtain the desired structural characteristics. Accordingly, components such as top cover 12 and display bezel 14 may be manufactured substantially thinner without compromising the overall stability of the part (e.g., less susceptible to warping, shrinking, etc., while providing increased strength, etc.).
Preferably, top cover 12 and display bezel 14 are injection-molded using an in-mold lamination (“IML”) process or an in-mold decoration process (“IMD”). The IML and IMD processes comprise inserting a liner inside the injection mold cavity followed by injection of the resin/Talc mixture into the cavity. The resin melts and adheres to the inner side of the liner, thereby producing a part with the final finish defined by the decorative liner. After the resin melts and cools, top cover 12/display bezel 14 is removed from the mold for further processing and/or coupling to computer device 10. It should be understood that other methods of manufacturing are available, such as traditional injection molding (e.g., without IML or IMD).
Thus, embodiments of the present invention enable the manufacture of structural components with improved flatness (e.g., to substantially reduce or eliminate the component from warping during manufacturing, especially in instances where the component is thin), with improved impact strength and rigidity and with minimal or no shrinkage. Further, embodiments of the present invention reduce the manufacturing cycle times of each component (e.g., reduce the time required to fabricate the component due to increased rate of hardening of the resin), and increase the accuracy in which each component is fabricated (e.g., increased repeatability of fabricating components with minimal or no dimensional inconsistencies).
