Extruded Chassis Frame Assembly for Low-Waste Electronic Housings
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Solution Overview
Problem
The unibody design of electronic apparatus chassis, which is commonly formed by CNC processing, results in high energy consumption, long processing times, and low material efficiency, contributing to environmental loads and increased production costs.
Innovation Solution
A manufacturing method involving the use of extruded materials to form a flat rectangular chassis with a side wall frame and plate frame, where at least three side walls are bent from the extruded material, and covers are attached to create a chassis with high material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If CNC processing is used to form the chassis in unibody design, then the chassis structure is integrated and strong, but energy consumption is large and processing time is long
Solution Approach 1:
The chassis is divided into multiple components: extruded material blocks forming side walls, plate frames for reinforcement, and cover members for top and bottom surfaces. These segmented components are assembled together to create the complete chassis structure, avoiding the need for energy-intensive CNC processing of a single large block while maintaining structural strength through the combination of extrusion-formed sides and plate-reinforced connections.
Solution Approach 2:
The side walls are pre-formed through extrusion processing into blocks with predetermined shapes and reinforced corners, and the plate frames are pre-prepared with attachment features. These preliminary actions allow the components to be quickly assembled without requiring high-energy machining operations during final chassis formation, significantly reducing overall energy consumption.
2Strength
If CNC processing is used to form the chassis in unibody design, then the chassis structure is integrated, but processing time is long
Solution Approach 1:
The chassis manufacturing process is segmented into independent parallel operations: extrusion of side wall blocks, fabrication of plate frames, and assembly operations. This segmentation allows multiple components to be prepared simultaneously and assembled quickly, dramatically reducing total processing time compared to sequential CNC machining of a monolithic chassis while maintaining structural integrity through precise assembly of the segmented components.
3Quantity of substance
If CNC processing is used to form the chassis, then the chassis is produced, but material efficiency is very low due to large cutting amount
Solution Approach 1:
The side walls are pre-formed through extrusion processing into blocks that closely match the final chassis geometry, and plate frames are pre-fabricated with optimized material distribution. This preliminary shaping through extrusion rather than subtractive CNC processing minimizes material waste from the outset, as the material is formed into the desired shape additively rather than being cut away from a large block.
Solution Approach 2:
The manufacturing approach changes from subtractive processing (CNC cutting) to formative processing (extrusion and assembly). This parameter change in the manufacturing method fundamentally improves material efficiency by shaping material into the final form with minimal waste, rather than removing large portions of material through cutting operations.
4Ease of manufacture
If molding is adopted to form the chassis, then production is simplified, but material efficiency is not sufficiently improved and product cost increases
Solution Approach 1:
The chassis is segmented into extruded side wall blocks and plate frame components that are assembled together. This segmentation allows each component to be optimized for its specific function with efficient material usage, while the assembly process remains simple and cost-effective, avoiding the material inefficiencies and high costs associated with attempting to mold the entire chassis as a single piece.
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 method reduces environmental load and production costs by utilizing extrusion molding, which achieves high material efficiency and minimizes energy consumption compared to CNC processing.
Implementation Method 1
obtaining a side wall frame by bending an extruded material to form at least three side walls
Data Source
AI summary
An electronic apparatus includes: a flat rectangular chassis that includes a side wall frame in which at least three side walls are formed by bending an extruded material, a first cover configured to form one surface of the chassis by being combined with the side wall frame, a second cover configured to form another surface of the chassis by being combined with the side wall frame, and a plate frame that has a plate shape and is provided between facing portions of the three side walls.