Extruded Chassis Frame Structure for Low-Waste Electronic Housings
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Solution Overview
Problem
The current unibody design of electronic apparatuses, such as laptop PCs, is energy-intensive and inefficient in material usage, leading to high environmental loads and increased production costs due to CNC processing and low material efficiency, with recycling also consuming significant energy.
Innovation Solution
The design incorporates a flat rectangular chassis with a side wall frame formed by bending an extruded material and a plate frame with intersecting partition walls, using extrusion molding to create a strong and efficient structure that reduces material waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CNC processing is used to form the chassis, then the chassis can be manufactured with precise dimensions, but energy consumption is large and processing time is long
Solution Approach 1:
The patent changes the manufacturing method from CNC machining to extrusion molding, fundamentally altering the production parameters. The chassis is formed by extruding aluminum alloy material through a mold, which consumes significantly less energy and time compared to CNC processing while maintaining precise dimensions through mold-based forming
Solution Approach 2:
The patent extracts the chassis manufacturing process from the category of subtractive machining (CNC) and transitions to additive/formative manufacturing (extrusion). This extraction allows the use of a different technological approach that is inherently more energy-efficient and time-effective while preserving manufacturing precision
2Manufacturing precision
If CNC processing is used to form the chassis, then the chassis can be manufactured with precise dimensions, but processing time is long
Solution Approach 1:
The patent changes the manufacturing method from CNC machining to extrusion molding, fundamentally altering the production parameters. The chassis is formed by extruding aluminum alloy material through a mold, which consumes significantly less energy and time compared to CNC processing while maintaining precise dimensions through mold-based forming
Solution Approach 2:
The patent applies preliminary action by pre-forming the chassis structure through extrusion molding before final assembly. The extrusion process creates the basic chassis shape and dimensions in advance, eliminating the need for time-consuming CNC machining operations later in the production process
3Manufacturing precision
If a material block is cut by CNC processing, then the chassis can be formed, but the material efficiency for the material block is very low
Solution Approach 1:
The patent changes the manufacturing method from subtractive CNC machining to formative extrusion molding. Instead of cutting away material from a block, the chassis is formed by extruding material through a mold that defines the final shape, dramatically reducing material waste while maintaining form accuracy
Solution Approach 2:
The patent inverts the traditional manufacturing approach by switching from subtractive manufacturing (cutting material away) to additive/formative manufacturing (building the shape directly). This inversion fundamentally changes how material is utilized, transforming the process from one that generates significant waste to one that is highly material-efficient
4Use of energy by moving object
If molding is adopted to form the chassis, then energy consumption is reduced, but material efficiency is not sufficiently improved and product cost increases
Solution Approach 1:
The patent optimizes the molding parameters by using extrusion molding with aluminum alloy material and specific mold designs. This approach achieves both low energy consumption and high material efficiency simultaneously, overcoming the limitation of conventional molding methods that sacrificed material efficiency for energy savings
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 environmental impact and production costs by enhancing material efficiency and minimizing energy consumption, while maintaining structural integrity and allowing for easy component replacement.
Implementation Method 1
a side wall frame in which at least three side walls are formed by bending an extruded material
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 cover configured to form one 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. The plate frame includes two partition walls having an angle intersecting with a plate-shaped portion, and forms a space surrounded on three sides by the plate-shaped portion and the two partition walls. A stop block is fitted into the space from a side. A portion of an edge portion of the cover is sandwiched between the side wall frame and the stop block. An IO connector is provided at the stop block.