Information handling system magnesium housing manufacture with a hot runner die cast

Abstract

A portable information handling system housing portion is manufactured by a process that injects a magnesium aluminum alloy (Mg—Al) from a hot runner having plural outtakes into a mold having a spree at each of the plural outlets. In one example embodiment a housing lid portion is injection molded at a midpoint on opposing sides of a longest side of a rectangular shape. In another example embodiment a housing cover portion is inject molded from six sprues placed around a perimeter of a keyboard location having openings through which keys of the keyboard extend.

Description

BACKGROUND OF THE INVENTIONField of the Invention

[0001] The present invention relates in general to the field of portable information handling systems, and more particularly to an information handling system magnesium housing manufacture with a hot runner die cast.Description of the Related Art

[0002] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and / or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.

[0003] Portable information handling systems integrate processing components, a display and a power source in a portable housing to support mobile operations. Portable information handling systems allow end users to carry a system between meetings, during travel, and between home and office locations so that an end user has access to processing capabilities while mobile. Tablet configurations typically expose a touchscreen display on a planar housing that both outputs information as visual images and accepts inputs as touches. Convertible configurations typically include multiple separate housing portions that couple to each other so that the system converts between closed and open positions. For example, a main housing portion integrates processing components and a keyboard and rotationally couples with hinges to a lid housing portion that integrates a display. In a clamshell configuration, the lid housing portion rotates approximately ninety degrees to a raised position above the main housing portion so that an end user can type inputs while viewing the display. After usage, convertible information handling systems rotate the lid housing portion over the main housing portion to protect the keyboard and display, thus reducing the system footprint for improved storage and mobility.

[0004] In order to minimize the weight of a portable housing, a magnesium and aluminum alloy (Mg—Al) is sometimes used. Existing Mg—Al housing tooling designs tend to use a conventional sprue for injection molding of heated material to die cast housing portions. A conventional sprue injects heated material into a mold from one side and parallel to the plane of the mold. Due to the limitation of material flowing into the mold from one side, the housing tends to form with an uneven thickness and has excessive material running through the sprue area as waste. In addition, conventional die casting has around 10% molding shrinkage defects with an appearance quality loss and 5% of cracking issues that cannot be completely resolved. These difficulties increase manufacturing cost by wasting material and involving refurbishment that increases manual handling of material and reduces the quality of the housings that are manufactured. Further, extra material to increase the thickness of the housing and improve the quality of the housing that it produces tends to increase the housing weight.SUMMARY OF THE INVENTION

[0005] Therefore, a need has arisen for a system and method which improves efficiency and reduces material waste.

[0006] In accordance with the present invention, a system and method are provided which substantially reduce the disadvantages and problems associated with previous methods and systems of die casting an information handling system housing portion. A hot runner module injects Mg—Al material into a die cast mold through plural sprues for improved housing portion quality with reduced defects and waste.

[0007] More specifically, a hot runner manufacturing system, process and product by process die casts Mg—Al housing portions for an information handling system with plural sprues interfaced to a mold through plural hot runner outtakes. In one example embodiment, two sprues inject molten Mg-Al at opposing sides of a housing lid portion with the sprues located midway of the longest side of the rectangular shape of the housing lid portion. In another example embodiment, six sprues inject molten Mg—Al from above a housing cover portion at a perimeter of a keyboard key opening matrix. For each type of housing portion with different size and thickness configurations, the hot runner process adjusts sprue material, sprue hardness, sprue dimensions, heat insulation of the mold plate and hot runner manifold plate, sprue temperature, hot runner manifold plate thickness and hot runner temperature setup.

[0008] The present invention provides a number of important technical advantages. One example of an important technical advantage is that an information handling system housing portion is die cast with injected Mg—Al through a hot runner system that improves product quality and reduces material wastage. In one example embodiment, a housing cover portion is die cast by injection of Mg—Al into a mold through six sprues with a savings of 118 g of Mg—Al in each molding output and a 26% reduction in material wastage when compared with a single sprue injection from one side of a mold. Improved molding efficiency reduces manufacturing costs and increases sustainability.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.

[0010] FIG. 1 depicts an exploded perspective view of a portable information handling system having housing portions of die cast magnesium aluminum alloy;

[0011] FIGS. 2A, 2B and 2C depict a system for die casting of a housing lid portion with a hot runner injection molding through plural sprues; and

[0012] FIGS. 3A, 3B and 3C, a system is depicted for die casting of a housing cover portion 38 with a hot runner injection molding through plural sprues 62.DETAILED DESCRIPTION

[0013] A portable information handling system housing portion is die cast with magnesium aluminum alloy (Mg—Al ) through plural sprues of a runner module. For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and / or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I / O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.

[0014] Referring now to FIG. 1, an exploded perspective view depicts a portable information handling system 10 having housing portions of die cast magnesium aluminum alloy. Portable information handling system 10 is built in a portable housing 12 having a lid portion 14 rotationally coupled to a main portion 20 by a set of hinges 18. In alternative embodiments other types of information handling system configurations may be used, such as tablet systems. Housing lid portion 14 is a planar piece of die cast Mg—Al that accepts a display panel 16 that presents information as visual images. Housing main portion defines an interior within sidewalls that provides room to contain processing components that cooperate to process information. For example, a motherboard 22 interfaces a central processing unit (CPU) 24 that executes instructions to process information with a random access memory (RAM) 26 that stores the instructions and information. A solid state drive (SSD) 28 provides persistent storage of instructions and information, such as an operating system and applications that are retrieved to RAM 26 at power up of the system by an embedded controller 30. A radio in a wireless network interface controller (WNIC) 32 supports communication with external devices and networks, such as through WIFI and BLUETOOTH.

[0015] The processing components in housing main portion 20 are enclosed by a housing cover portion 38 having a planar form that fits over the interior of housing main portion 20. Housing cover portion 38 supports an end user's wrist weight while the end user types at a keyboard 34 coupled under cover portion 38 and makes pointer inputs to a touchpad 36. Housing cover portion 38 has a matrix of key openings 40 through which the keys of keyboard 34 extend up to accept end user inputs. A touchpad opening 42 provides access to a touchpad 36 exposed through the opening. In alternative embodiments, a keyboard and / or touchpad may rest on the housing cover portion. In the example embodiment, housing lid portion 14, main portion 20 and cover portion 38 are each die cast Mg—Al manufactured by a process that injects Mg—Al from a runner module through plural outlets and plural sprues into a mold as described in greater detail below.

[0016] Referring now to FIGS. 2A, 2B and 2C, a system is depicted for die casting of a housing lid portion 14 with a hot runner injection molding through plural sprues 62. In the example embodiment, a hot runner chassis 52 holds a hot runner module 50 above a cavity plate 58 and mold 60 to inject molten Mg—Al down and into the mold chamber shaped to form the housing lid portion. FIG. 2A depicts that chassis 52 with an intake 54 of a hot runner module 50 exposed at an upper surface to accept Mg—Al and melt the material within the heated chassis body and cavity plate 58. FIG. 2B depicts runner module 50 separate from chassis 52 illustrating that Mg—Al material enters through intake 54, is melted to flow into first and second outtakes 56 and enter a mold 60 through first and second sprues 62. FIG. 2C depicts housing lid portion 14 with two sprues 62 interfaced with the outtakes above and mold 60 to inject the molten Mg—Al into the mold to form the housing lid portion. In the example embodiment, lid housing portion 14 has a rectangular shape and sprues 62 that are located on opposing sides at a midpoint of the longest sides of the rectangle so that material feeds efficiently from above into the mold. This arrangement enhances the quality of the die cast housing portion and minimizes the material wastage. A variety of factors are adjusted to accomplish the die cast in an efficient manner that minimizes waste, including sprue material, sprue hardness, sprue dimensions, heat insulation to manage thermal conditions for the injection, sprue temperature at the injection, the hot runner manifold plate thickness and the hot runner temperature setup. Each of these factors are deterministically adjusted through experimentation that may vary on the conditions at the system and the type of mold involved to adapt to a particular die cast housing portion characteristics.

[0017] Referring now to FIGS. 3A, 3B and 3C, a system is depicted for die casting of a housing cover portion 38 with a hot runner injection molding through plural sprues 62. In the example embodiment the hot runner chassis 52 has a similar configuration with a hot runner module 50 supported in a cavity plate 58 to accept Mg—Al material at intake 54 and inject into the die cast mold 50. FIG. 3A depicts a sectional view of the hot runner chassis with hot runner module 50 enclosed in a heated container to maintain desired thermal conditions for communicating molten Mg—Al through sprues 62 into mold 60 vertically arranged above the mold. FIG. 3B depicts hot runner module 50 separate from the chassis to illustrate the relative position of six outtakes 56 and sprues 62 that inject the molten Mg-Al into mold 60. Housing cover portion 38 includes an area where keys of the keyboard extend up through a matrix of finely delineated lines of material. To help ensure a good flow of material into the fine portions of the mold at the key openings 40, the six outtakes 56 and sprues 62 are position at a perimeter of the keyboard location. FIG. 3C depicts housing cover portion 38 and the location at the perimeter of sprues 62. Exact positioning of sprues 62 are deterministic through experimentation that may vary on the conditions at the system and the type of mold involved. As an example, a housing main portion may have a bottom side of the housing portion located closest to the sprues, and sprues may be located at each of four corners to ensure that the sidewalls receive a good distribution of material. Factors that may adjust include sprue material, sprue hardness, sprue dimensions, heat insulation of the manifold plate, sprue temperature, hot runner manifold plate thickness and hot runner temperature setup.

[0018] Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. A system for die cast of a magnesium aluminum alloy (Mg—Al ) information handling system housing portion, the system comprising:a hot runner module having an intake to accept the Mg—Al from above and plural outtakes to inject the Mg—Al to below;plural sprues, each outtake injecting the Mg—Al through one of the plural sprues; anda mold below the hot runner module and the plural sprues, the mold having a chamber shaped to form the housing portion, the plural sprues injecting Mg—Al into the mold to form the housing portion.

2. The system of claim 1 further comprising:two outtakes and two sprues; andthe mold having injection of the Mg—Al from opposing sides of the housing portion.

3. The system of claim 2 wherein the housing portion comprises a lid portion and each sprue is located at a midpoint of a longest side of the lid portion.

4. The system of claim 1 further comprising:six outtakes and six sprues; andthe mold having injection of the Mg—Al from above the housing portion.

5. The system of claim 4 wherein the housing portion comprises a housing cover portion that couples over a main housing portion to enclose processing components.

6. The system of claim 4 wherein the housing cover portion has a central region with plural openings formed to expose keys of a keyboard coupled below the cover portion through the plural openings.

7. The system of claim 6 wherein the six sprues couple to the mold along a perimeter of a keyboard that couples below the plural openings.

8. The system of claim 1 wherein housing portion comprises a housing main portion.

9. The system of claim 8 wherein the plural sprues inject the Mg—Al at a bottom side of the housing main portion.

10. A method for forming an information handling system housing portion, the method comprising:accepting Mg—Al at a hot runner intake above a mold;directing the Mg—Al to plural outtakes of the hot runner; andinjecting the Mg—Al from each of the plural outtakes through a sprue at each of the plural outtakes into a mold having a chamber shaped to form the housing portion.

11. The method of claim 10 further comprising:injecting the Mg—Al into the mold through two outtakes and two sprues; andlocating the sprues for the injecting into the mold at opposing sides of the housing portion.

12. The method of claim 11 wherein the housing portion comprises a lid portion and each sprue is located at a midpoint of a longest side of the lid portion.

13. The method of claim 10 further comprising:injecting the Mg—Al into the mold through six outtakes and six sprues; andlocating the sprues for injecting into the mold from above the housing portion.

14. The method of claim 13 wherein the housing portion comprises a housing cover portion that couples over a main housing portion to enclose processing components.

15. The method of claim 14 wherein the housing cover portion has a central region with plural openings formed to expose keys of a keyboard coupled below the cover portion through the plural openings, the six sprues coupled to the mold along a perimeter of a keyboard that couples below the plural openings.

16. An information handling system housing portion product manufactured by a process comprising:accepting Mg—Al at a hot runner intake above a mold;directing the Mg—Al to plural outtakes of the hot runner; andinjecting the Mg—Al from each of the plural outtakes through a sprue at each of the plural outtakes into a mold having a chamber shaped to form the housing portion.

17. The information handling system housing portion product of claim 16 further manufactured by the process comprising:injecting the Mg—Al into the mold through two outtakes and two sprues; andlocating the sprues for the injecting into the mold at opposing sides of the housing portion.

18. The information handling system housing portion product of claim 17 wherein the housing portion comprises a lid portion and each sprue is located at a midpoint of a longest side of the lid portion.

19. The information handling system housing portion product of claim 16 further manufactured by the process comprising:injecting the Mg—Al into the mold through six outtakes and six sprues; andlocating the sprues for injecting into the mold from above the housing portion.

20. The information handling system housing portion product of claim 19 wherein:the housing portion comprises a housing cover portion that couples over a main housing portion to enclose processing components; andthe housing cover portion has a central region with plural openings formed to expose keys of a keyboard coupled below the cover portion through the plural openings, the six sprues couple to the mold along a perimeter of a keyboard that couples below the plural openings.

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