Aluminum Enclosure Segmentation for Rigidity and Weight
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Solution Overview
Problem
Portable computing systems face challenges in designing outer enclosures that are both aesthetically pleasing, lightweight, and durable, while also providing structural rigidity and electromagnetic interference shielding, as lighter enclosures tend to be flexible and prone to damage, and heavier ones compromise portability and aesthetics.
Innovation Solution
A portable computing system design featuring a multipart housing made from strong and durable materials like aluminum, with a tapered shape for improved ergonomics and reduced weight, incorporating a keyboard assembly with low-travel key mechanisms and a touch-sensitive user interface with force sensors and haptic feedback, and a metal enclosure that acts as a Faraday cage for RF shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the outer enclosure is made lighter and thinner, then portability and aesthetics are improved, but structural rigidity decreases and the enclosure becomes prone to buckling and bowing
Solution Approach 1:
The enclosure is divided into multiple segments including a unibody lower enclosure portion and a separate upper enclosure portion that can be pivotally coupled. This segmentation allows each portion to be optimized independently - the lower portion provides structural strength while the upper portion can be made lighter for portability.
Solution Approach 2:
The patent employs nested structural elements where reinforcement features are integrated within the enclosure walls. Internal ribs, gussets, and strengthening elements are nested within the outer shell, providing structural rigidity without increasing external dimensions or weight significantly.
2Strength
If the outer enclosure is made stronger and more rigid, then durability is improved, but weight increases and portability decreases
Solution Approach 1:
Rather than uniformly strengthening the entire enclosure, the patent applies local quality by placing reinforcement features only where structurally necessary. Internal ribs and gussets are positioned at critical stress points, allowing thin-walled construction in non-critical areas for weight reduction while maintaining strength where needed.
Solution Approach 2:
The enclosure utilizes composite construction combining different materials and structural features. The unibody lower portion may use metal construction for maximum strength, while the upper portion can use lighter materials, creating a composite structure that optimizes the strength-to-weight ratio across the entire enclosure.
3Weight of moving object
If the enclosure is made thinner, then portability and aesthetics are improved, but electromagnetic interference shielding effectiveness decreases
Solution Approach 1:
The enclosure is segmented into multiple portions with separate EMI shielding capabilities. The unibody lower enclosure portion provides a grounded shield, while the upper portion can be independently shielded, allowing thin construction while maintaining EMI protection through multiple discrete shielding layers.
Solution Approach 2:
The patent introduces intermediary EMI shielding elements such as conductive gaskets, shielding foams, or conductive coatings at the interfaces between enclosure portions. These intermediary elements provide continuous EMI shielding across joints and seams, compensating for the reduced thickness of individual enclosure walls.
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
The design achieves a balance of aesthetics, portability, and durability by using aluminum for the housing, enhancing user interaction with improved ergonomics and providing effective RF shielding, while maintaining structural integrity and reducing material usage.
Implementation Method 1
a metal enclosure that acts as a Faraday cage for RF shielding
Data Source
AI summary
A portable electronic device having several features is disclosed. The device can include a retention member that retains flexible circuits extending from a top portion to a bottom portion of the device, thereby allowing some components to be moved from a top portion of the device to a bottom portion. The device may include a cover plate can be secured with a display in the top portion to cover the retention member and other internal components. The device can include an omni-directional port designed to receive a connector different orientations and provide power to the device. The device can include a flexible keyboard having butterfly keycaps. The device can include an array of openings for an audio driver, with some of the array including through holes and blind holes. The device can also include a touch pad having a force feedback sensor and a haptic device.