Aluminum Display Enclosure Modular Design
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Solution Overview
Problem
The rapid changes in technology and display sizes lead to frequent redesigns, increased costs, and prolonged lead times in manufacturing multi-touch display screens, as existing methods require extensive redesigning, prototyping, and manufacturing of aluminum enclosures for each component change.
Innovation Solution
A method involving aluminum extrusion, metal casting, and sheet metal fabrication to create scalable and adaptable display screen enclosures, using aluminum extrusion profiles, corner metal castings, and sheet metal back panels, allowing for production of various sizes and designs with shared raw components, reducing design and engineering workloads, and lowering material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional aluminum enclosure manufacturing methods are used for each component change, then manufacturing precision and reliability are maintained, but design and manufacturing lead times increase significantly and costs rise
Solution Approach 1:
The enclosure is divided into modular components: standard aluminum extrusion profiles and customizable corner pieces. This segmentation allows the majority of the enclosure structure to remain standardized while only the corner pieces need customization for different display configurations, dramatically reducing redesign time.
Solution Approach 2:
The aluminum extrusion profiles are designed as universal components that can be used across multiple display sizes and configurations. The standardized profiles with consistent mounting features and dimensions allow them to serve multiple functions in different enclosure configurations, reducing the need for custom manufacturing.
2Reliability
If traditional aluminum enclosure manufacturing methods are used for each display size change, then product quality is maintained, but manufacturing costs increase due to frequent redesigns
Solution Approach 1:
By segmenting the enclosure into standardized profiles and customizable corners, the system maintains reliable performance through proven standard components while reducing manufacturing costs by minimizing custom fabrication requirements.
Solution Approach 2:
The system maintains reliability by keeping critical structural parameters standardized in the aluminum profiles while allowing non-critical parameters (corner configurations) to be changed easily to accommodate different display sizes and technologies, reducing manufacturing costs.
3Manufacturing precision
If extensive redesigning and prototyping is performed for each component change, then manufacturing precision is ensured, but productivity decreases due to repeated design cycles
Solution Approach 1:
The modular segmentation allows most components to be produced through standardized processes without repeated design cycles, while only small corner components require customization, thereby maintaining assembly precision while significantly improving productivity.
Solution Approach 2:
The standardized aluminum extrusion profiles are pre-designed with universal mounting features and dimensions, eliminating the need for repeated design and prototyping cycles for each new display configuration, thus improving productivity while maintaining precision through proven designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces design and manufacturing lead times, lowers overall costs, and enhances adaptability by enabling the production of multiple sizes and designs using a shared set of components, resulting in a 50-80% reduction in metal manufacturing costs and minimizing labor involvement.
Implementation Method 1
preheating raw aluminum ingots to a temperature below the melting point of the raw aluminum ingots
Implementation Method 2
preheating a tool die with a hole to the same temperature
Implementation Method 3
pressing the raw aluminum ingots into the tool die with a predetermined force, wherein temperature and pressure makes the raw aluminum ingots malleable
Implementation Method 4
cooling the liquid metal inside of the tool or mold until it is a solidified metal
Data Source
AI summary
A method of manufacturing display screens/display screen enclosures (and concomitant display screens/display screen enclosures thus produced) comprising extruding metal to create metal extrusion profiles of the display screen enclosures, casting metal to create metal castings for corners of the display screen enclosures, joining the metal castings to the metal extrusion profiles together forming a frame, and fabricating a sheet metal back panel for structural rigidity and to provide a mounting surface within the frame.