Antenna windows in carbon fiber enclosures

In example implementations, an enclosure is provided. The enclosure includes a first layer of carbon fiber and a second layer of a carbon fiber pattern fabricated from a plastic. The first layer of carbon fiber is formed in a shape of a portable electronic device. An antenna window is formed in the first layer of the carbon fiber. The second layer of the carbon fiber pattern has a same shape and a same size as the first layer of carbon fiber.

BACKGROUND

Portable computing devices, such as laptop computers, may include various electrical components that are enclosed by a housing or an enclosure. The housing may provide protection to the components of the portable computing device. The electrical components may include devices such as processors, circuit boards, graphical processors, memory devices, interface cards, antennas, and the like.

DETAILED DESCRIPTION

Examples described herein provide carbon fiber enclosures with an antenna window. As discussed above, portable computing devices may have various electrical components that are enclosed by a housing or an enclosure. Some devices use a carbon fiber enclosure that provides a benefit of a strong outer protective shell, but having a light weight.

However, the carbon fiber material may be conductive. As a result, the carbon fiber enclosure can interfere with operation of wireless antennas inside of the carbon fiber enclosure. For example, the wireless antenna signals may be blocked or reduced by the carbon fiber enclosure. As a result, the operational range of the wireless antennas, or the overall functionality of the wireless antennas inside of the carbon fiber enclosure may be reduced.

Some previous solutions have used non-conductive materials in combination with the carbon fiber enclosure. For example, non-conductive materials may be located around a perimeter of a housing formed of the carbon fiber material. Consumers may prefer the feel and look of a total carbon fiber enclosure. The general application of non-conductive materials around a perimeter with the carbon fiber enclosure may not provide the same look as the all carbon fiber enclosure. Some solutions may paint the surface to hide the non-conductive materials. However, painting the surface may not provide the same feel and look of an all carbon fiber enclosure.

Examples herein provide a carbon fiber enclosure that includes an antenna window to prevent interference of the wireless antenna signals by the carbon fiber enclosure. For example, the antenna window may allow clear transmission and reception of wireless signals. The antenna window may have a variety of different shapes and dimensions based on the size of the wireless antennas inside of the enclosure. The location of the antenna window may also be based on a location of the wireless antennas within the enclosure.

In addition, a white carbon fiber pattern may be adhered over the carbon fiber enclosure with the antenna window to provide a clean appearance. The carbon fiber pattern may have the look and feel of real carbon fiber even though the pattern may be fabricated from plastic. The white carbon fiber pattern may allow the carbon fiber enclosure to be suitable and/or desirable for healthcare laptop applications.

FIG. 1illustrates a block diagram of an apparatus100having a carbon fiber layer with an antenna window108of the present disclosure. The apparatus100may be any type of portable electronic device, such as a lap top computer, a tablet computer, a smartphone, and the like. The apparatus100may include a display110to provide a user interface.

The apparatus100may include a processor (e.g., a central processing unit (CPU))102that is in communication with an antenna104. The antenna104may be any type of wireless antenna. For example, the antenna104may be a Wi-Fi antenna, a Bluetooth radio, and the like. The antenna104may be deployed in various shapes and sizes. For example, the antenna104may have a coil structure, a printed dipole or monopole structure, a helical antenna structure, a wire structure, a patch structure, and the like. The antenna104may be a stand-alone component or be integrated into a printed circuit board as part of a larger component.

It should be noted that the apparatus100has been simplified for ease of explanation. The apparatus100may include additional electronic components that are not shown. For example, the apparatus100may include a non-transitory computer readable memory, network interface cards, graphics processors, a power supply, and the like.

In one example, the processor102, the antenna104, and any other components (not shown) may be enclosed by a housing106. In one example, the housing106may be a carbon fiber enclosure with a layer of carbon fiber and a layer of a carbon fiber pattern adhered to the carbon fiber. As noted above, carbon fiber may be conductive. When the antenna104is enclosed by a conductive material, the conductive material may block, interfere with, or reduce, the wireless signal strength of the antenna104.

In one example, an antenna window108may be formed in the housing106. The antenna window108may provide a path for wireless signals from the antenna104to pass through the housing106without interference or without the wireless signals being blocked or reduced by the housing106, or a portion thereof. In other words, even if the housing106is fabricated from a conductive material, such as a carbon fiber, the antenna104may operate as intended. As a result, the antenna104may operate at maximum efficiency as intended without any blocking or interference from the housing106.

In one example, the antenna window108may be fabricated from a clear non-conductive material. For example, the antenna window108may be fabricated from a glass, a clear plastic (e.g., polycarbonate), and the like. The antenna window108may be injection molded into an opening that is cut into the housing106. In one example, the antenna window108may be formed and coupled to the opening via a glue or adhesive. In one example, the antenna window108may be formed and mechanically coupled to the opening. For example, mechanical fasteners, clips, and the like, may be used to couple the antenna window108to the opening that is cut into the housing106. In one example, the mechanical fasteners and clips may be molded into the housing106.

The antenna window108may be located adjacent to, or over, the antenna104. In some instances, the antenna window108may be located along a bezel of the housing106. The antenna window108may be formed by using non-conductive materials for the keys that form the keyboard on the housing106, or some keys that are located over the antenna104. If the antenna104were located behind the display110, the antenna window108may be located behind the display110or along a bezel of the display110. In other words, the location of the antenna window108in the housing106may be a function of the location of the antenna104. In addition, the dimensions of the antenna window108(e.g., the size and the shape) may be a function of the dimensions of the antenna104. In other words, the antenna window108may be sized and shaped similar to the size and shape of the antenna104.

Thus, the antenna window108may allow for clear transmission of wireless signals transmitted by the antenna104. In addition, the antenna window108may allow for clear reception of incoming wireless signals transmitted to the antenna104. The antenna window108may allow the antenna104to operate at maximum efficiency (e.g., maximum operating signal range).

AlthoughFIG. 1illustrates that the antenna104is in the lower portion of the housing106where the keyboard may be located, it should be noted that the antenna104may also be located in the “A” cover where the display110is located. Thus, when the antenna104is located in the “A” cover the antenna window108may be located in the “A” cover rather than the lower portion of the housing106.

FIG. 2illustrates a top view of an example housing106. In one example, the housing106may be fabricated from a first layer comprising a carbon fiber material112. The carbon fiber material112may be textured as desired for the apparatus100.

As discussed above, an opening may be cut out of the carbon fiber material112. The carbon fiber material112may be a unidirectional carbon fiber composite (e.g., the carbon fibers are all grown or extend in the same direction) or a multi-directional weaved carbon fiber composite (e.g., the carbon fibers are weaved in a perpendicular direction or cross-hatch pattern). The antenna window108may be injection molded into the opening cut out of the carbon fiber material112.

As noted above, the antenna window108may be a function of the size and shape of the antenna104. InFIG. 2it is illustrated as a rectangular shape. However, the antenna window108may have any shape based on the antenna104, such as, an “L” shape, a “T” shape, a rounded shape, a generally elongated shape, an irregular shape, and the like.

FIG. 3illustrates a top view of a second layer of the housing106. The second layer of the housing106may be a decorative carbon fiber pattern114that is adhered to the carbon fiber material112illustrated inFIG. 2. In one example, an adhesive may be applied to the carbon fiber material112and the decorative carbon fiber pattern114may be applied on top of the adhesive. In one example, the decorative carbon fiber pattern114may be adhered to the carbon fiber material112via an out-mold decoration process. The carbon fiber pattern114may provide a smooth and/or visibly continuous surface that may be aesthetically desirable for housings of portable electronic devices.

In one example, the carbon fiber pattern114may have the appearance, texture, and feel of real carbon fiber. However, the carbon fiber pattern114may be fabricated from plastic. The carbon fiber pattern114may be any color. In one example, the carbon fiber pattern114may be white.

The carbon fiber pattern114may have a same shape and a same size as the first layer of the carbon fiber material112. As illustrated inFIG. 3, the surface of the carbon fiber material112is not visible. The carbon fiber pattern114covers the entire area of the carbon fiber material112. In addition, the antenna window108is hidden (as shown by dashed lines inFIG. 3) under the carbon fiber pattern114.

FIG. 4illustrates a side cross-sectional view of the example housing106of the apparatus100. In one example, the carbon fiber material112may be formed to a desired shape of the housing106, or a portion thereof, and have a volume118to enclose electronic devices. For example, the antenna104may be located inside of the volume118of the housing106and the carbon fiber material112.

FIG. 4illustrates an example of the antenna window108that is located adjacent to the antenna104. For example, the antenna window108may be located over the antenna104. As a result, the wireless signals transmitted from the antenna104may pass through the housing106via the antenna window108without interference or other negative effects. In other words, the antenna window108may allow the antenna104to clearly transmit and receive wireless signals.

In one example, an adhesive layer116may be applied between the first layer of the carbon fiber material112and the second layer of the carbon fiber pattern114. The adhesive layer116may be any type of adhesive. In one example, the adhesive may be cured to couple the carbon fiber pattern114onto the carbon fiber material112.

In one example, the adhesive layer116may be part of the carbon fiber material112. In other words, the carbon fiber material112may be formed as a “sticker” that can be stuck on the carbon fiber material112. In one example, the carbon fiber pattern114may be adhered to the carbon fiber material112via an out-mold decoration process or an in-mold decoration process.

In one example, the carbon fiber pattern114may be relatively thin compared to the carbon fiber material112. For example, the carbon fiber pattern114may have a thickness that is less than a thickness of the carbon fiber material112. The carbon fiber pattern114may have a thickness that is less than a millimeter and the carbon fiber material112may have a thickness that is several millimeters or centimeters thick.

Thus, the housing106for the apparatus100of the present disclosure provides a non-conductive signal path for wireless signals emitted by the antenna104. In addition, the housing106provides the benefits (e.g., strength, light weight, easily workable, etc.) of using carbon fiber materials112to form the housing106. The antenna window108eliminates the previous drawbacks to using carbon fiber materials112for the housing106. In addition, the carbon fiber pattern114provides a finished clean cosmetic look that hides the antenna window108, yet still provides the look and feel of carbon fiber to a user touching the exterior of the housing106.

As noted above, the antenna window108may be located in the “A” cover with the display110. When the antenna window108is located in the “A” cover, the “A” cover may also be designed with the carbon fiber materials112and the carbon fiber pattern114, as described above or using the methods described below.

FIG. 5illustrates a flow diagram of an example method500for fabricating carbon fiber enclosure with an antenna window. In one example, the method500may be performed by control of a processor or controller that controls operations of different tools or machines in an assembly line.

At block502, the method500begins. At block504, the method500cuts a carbon fiber material into a shape of a portable electronic device. For example, a block of the carbon fiber may be provided and the carbon fiber may be cut to a desired shape and volume associated with a housing of the portable electronic device. In one example, the carbon fiber may be molded into a desired shape and volume to form a housing to enclose electronic components of the portable electronic device.

At block506, the method500cuts an opening in the carbon fiber material in a location where a wireless antenna of the portable electronic device is located. In one example, the opening may be formed by cutting the carbon fiber material with a laser at a location where the antenna window will be located. In one example, the opening may be formed via molding process.

At block508, the method500injection molds an antenna window into the opening. For example, antenna window may be formed from a non-conductive material such as a glass fiber or a plastic. An example of a plastic that may be used is polycarbonate. The glass or the plastic may be melted and set in the opening using any type of injection molding process.

At block510, the method500applies an adhesive layer over the carbon fiber material and the antenna window. In one example, after the antenna window is set or hardened, an adhesive layer may be applied to the carbon fiber material and the antenna window Any type of adhesive material may be used.

At block512, the method500applies a carbon fiber pattern onto the adhesive layer. In one example, the carbon fiber pattern may have a texture, look, and feel of real carbon fiber, but fabricated from plastic. The carbon fiber pattern may have any desired color. The carbon fiber pattern may have a same shape and a same size as the housing fabricated from the carbon fiber material.

At block514, the method500adheres the carbon fiber pattern onto the carbon fiber material via an out-mold decoration process that cures the adhesive layer. For example, the out-mold decoration process may be used to apply heat and/or pressure to the adhesive layer. The adhesive layer may be cured to couple the carbon fiber pattern onto the carbon fiber material.

In one example, the out-mold decoration process may be used to provide any texture, shapes, designs, and the like, into the surface of the carbon fiber pattern and the carbon fiber material. In other words, the out-mold decoration process may be used to add a texture to the housing106and set the adhesive layer at the same time.

The finished housing may have an antenna window that allows an antenna to clearly transmit and receive wireless signals. In addition, the entire housing may have the feel and look of a carbon fiber enclosure that is desirable for certain applications. The housing may have the benefits of the antenna window to maximize operation of the antenna and the carbon fiber material to provide a lightweight strong housing material, yet have the carbon fiber pattern to hide the appearance of the antenna window.

In addition, the carbon fiber pattern may be easily decorated, colored, textured, and the like, compared to decorating, coloring, and texturing the actual carbon fiber material. At block516, the method500ends.