Re: Patent... really!
Claims shown below. The first claim is probably too general to stand up when tested but they time you get to claim 5 or so it is sounding pretty specific to a non expert like me and may be innovative. Any carbon fibre experts here? I really don't know if this is genius innovation or completely obvious but I fail to see the similarity to the concept of a cardboard box (although if you have a better way to make a cardboard box that nobody has demonstrated or published before the patent office is waiting for your application).
1. A housing, comprising: a frame formed from a first material; a skin formed from the first material separately from the frame and bonded to the frame; wherein the skin is formed from multiple layers of the first material; and a portion of the skin covers at least a wall of the frame.
2. The housing of claim 1, wherein the first material is a composite of at least fiber and a matrix suspending the fiber.
3. The housing of claim 2, wherein the first material is a carbon fiber reinforced plastic.
4. The housing of claim 2, wherein: an outer edge of each of the multiple layers form at least one stair-step pattern; the frame defines a tapered segment; and the multiple layers are adjacent the tapered segment.
5. The housing of claim 4, wherein: the frame is solid in cross-section; and at least a part of each layer of the multiple layers lies adjacent a unique portion of the tapered segment.
6. The housing of claim 4, wherein at least a portion of the stair-step pattern encircles at least a portion of the tapered segment.
7. The housing of claim 2, wherein: the frame defines at least one corner flange extending from at least one corner; and a portion of the skin overlies a portion of the corner flange.
8. A method for manufacturing an object, comprising: forming a frame from a fiber-in-matrix material; forming a skin from at least a first layer and a second layer of the fiber-in-matrix material; wrapping at least a portion of the skin about at least a portion of the frame; and bonding the skin to the frame.
9. The method of claim 8, wherein: the first layer comprises a first plurality of substantially aligned fibers in a matrix; the second layer comprises a second plurality of substantially aligned fibers in a matrix; the first plurality of fibers extends along a first axis; and the second plurality of fibers extends along a second axis different from the first axis.
10. The method of claim 9, wherein the fiber-in-matrix material is carbon fiber reinforced plastic.
11. The method of claim 9, further comprising removing at least a portion of the second layer prior to wrapping at least the portion of the skin about at least the portion of the frame.
12. The method of claim 9, wherein the operation of forming a frame from a fiber-in-matrix material comprises: placing a granularized fiber-in-matrix material in a mold, the granularized fiber-in-matrix material comprising a fiber and a matrix; closing the mold; heating the mold until the matrix melts; and solidifying the matrix about the fibers to form the frame.
13. The method of claim 12, wherein the operation of forming a skin comprises: cutting the first layer into a first cross shape; cutting the second layer into a second cross shape; and bonding the first layer to the second layer, such that the second cross shape exposes a portion of the first cross shape, thereby creating a stair-step pattern on the skin.
14. The method of claim 13, wherein the operation of forming a frame from a fiber-in-matrix material further comprises forming a taper on at least a segment of the frame.
15. The method of claim 14, wherein the operation of wrapping at least a portion of the skin about at least a portion of the frame comprises wrapping the stair-step pattern on the skin about the taper.
16. The method of claim 8, wherein: the frame defines at least a first, second and third edge of a three-dimensional object; the first edge and second edge define a first plane extending therebetween; the second edge and third edge define a second plane extending therebetween; the first edge and third edge define a third plane extending therebetween; and none of the first, second and third planes are parallel or overlapping.
17. A object, comprising: a frame defining four corners and four struts, each strut extending between two corners, thereby forming a rectangular shape.; and a cross-shaped skin comprising a plurality of layers, each layer of the plurality of layers having a smaller surface area than the layer below, the cross-shaped skin at least partially adjacent and bonded to at least a segment of the frame; wherein the cross-shaped skin encompasses the four struts; the four corners are exposed; and the frame and cross-shaped skin are formed from a fiber-in-matrix material.
18. The object of claim 17, wherein the skin forms a bottom surface of the object.
19. The object of claim 18, wherein the frame and cross-shaped skin are separately formed from the fiber-in-matrix material.
20. The object of claim 19, wherein each of the four corners comprises an inwardly-extending flange substantially parallel to the bottom surface.