High performance carbon fiber laminate enclosure part for an information handling system

Abstract

An enclosure part for an information handling system is disclosed that may include materials formed together into a rectangular shape. The enclosure part may have a void on a core side and a flatness equal to or less than 0.5 mm. The materials may include a sheet of carbon fiber, a piece of non-woven carbon fiber, and a piece of non-woven glass fiber. A method for manufacturing an enclosure part using through-plane temperature control may include inserting into a mold a sheet of carbon fiber and a piece of non-woven carbon fiber, heat pressing the sheet of carbon fiber with the piece of non-woven carbon fiber, and cooling a first portion of the mold including the sheet of carbon fiber and the piece of non-woven carbon fiber more quickly than a second portion of the mold including the sheet of carbon fiber, and removing the enclosure part from the mold.

What is claimed is: 
     
         1 . An enclosure part for an information handling system, the enclosure part comprising a plurality of materials formed together into a rectangular shape with a flatness equal to or less than 0.5 mm and a void on a core side of the enclosure part, the materials comprising:
 a sheet of carbon fiber;   a first piece of non-woven carbon fiber; and   a piece of non-woven glass fiber.   
     
     
         2 . The enclosure part of  claim 1 , wherein the materials further comprise a carbon fiber hinge between the sheet of carbon fiber and a second piece of non-woven carbon fiber. 
     
     
         3 . The enclosure part of  claim 1 , wherein the core side of the enclosure part is opposite a cavity side of the enclosure part. 
     
     
         4 . The enclosure part of  claim 1 , wherein the sheet of carbon fiber comprises a plurality of carbon fiber layers placed in a laminate. 
     
     
         5 . The enclosure part of  claim 1 , wherein the sheet of carbon fiber comprises a plurality of continuous fibers. 
     
     
         6 . The enclosure part of  claim 1 , wherein the sheet of carbon fiber, the first piece of non-woven carbon fiber, and the piece of non-woven glass fiber are made of thermoset polymer. 
     
     
         7 . The enclosure part of  claim 1 , wherein the sheet of carbon fiber, the first piece of non-woven carbon fiber, and the piece of non-woven glass fiber are thermoplastics, made from a common polymer, wherein the common polymer is polycarbonate. 
     
     
         8 . The enclosure part of  claim 1 , wherein the core side of the enclosure part comprises a lip. 
     
     
         9 . The enclosure part of  claim 1 , wherein the first piece of non-woven carbon fiber comprises at least one of:
 short fibers; or   long fibers.   
     
     
         10 . The enclosure part of  claim 1 , wherein the piece of non-woven glass fiber comprises a matrix of non-continuous fibers. 
     
     
         11 . The enclosure part of  claim 2 , wherein the first piece of non-woven carbon fiber and the second piece of non-woven carbon fiber are pre-impregnated with a thermoplastic, made from a common polymer, wherein the common polymer is polycarbonate. 
     
     
         12 . The enclosure part of  claim 2 , wherein the carbon fiber hinge is molded between the sheet of carbon fiber and a second piece of non-woven carbon fiber without a fastener. 
     
     
         13 . The enclosure part of  claim 3 , wherein the materials further comprise a surface finish on at least one of:
 the cavity side of the enclosure part; or   the core side of the enclosure part.   
     
     
         14 . The enclosure part of  claim 5 , wherein the continuous fibers are oriented across the width of the rectangular shape, corresponding to a longer side of the enclosure part. 
     
     
         15 . The enclosure part of  claim 5 , wherein the continuous fibers are oriented across the height of the rectangular shape, corresponding to a shorter side of the enclosure part. 
     
     
         16 . The enclosure part of  claim 13 , wherein the surface finish comprises at least one of:
 a sealant;   a colored paint;   a clear-coat paint; or   a textured paint;