Extruded Side Wall Chassis Structure With Lower Manufacturing Waste
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Solution Overview
Problem
The current unibody design for electronic apparatus chassis consumes high energy during manufacturing and processing, has low material efficiency, and increases environmental load due to large cutting amounts and recycling energy consumption.
Innovation Solution
The chassis is formed using a side wall frame created by bending extruded materials, combined with a first and second cover to reduce material waste and energy consumption, utilizing extrusion molding for high material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If CNC cutting is used to form the chassis in unibody design, then the chassis structure is achieved, but energy consumption is large and processing time is long
Solution Approach 1:
The patent replaces the mechanical CNC cutting system with a forming system that shapes the chassis from sheets through folding and joining operations. This substitution eliminates the need for high-energy removal processes and uses lower-energy forming operations instead, directly resolving the contradiction between achieving chassis structure and reducing energy consumption
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from material removal (cutting) to material forming (folding and shaping). By transforming the chassis from sheets through controlled deformation rather than cutting, the process achieves the same structural outcome with significantly reduced energy consumption and processing time
2Strength
If CNC cutting is used to form the chassis in unibody design, then the chassis structure is achieved, but material efficiency is very low due to large cutting amount
Solution Approach 1:
The patent replaces the subtractive cutting mechanism with an additive forming mechanism that shapes sheets into the chassis form. This substitution minimizes material waste by utilizing the full sheet material through folding and joining, directly resolving the contradiction between achieving chassis structure and improving material efficiency
Solution Approach 2:
The patent transforms the manufacturing approach from material removal to material forming, changing the fundamental parameter of material utilization. By shaping sheets through folding rather than cutting, the process achieves high material efficiency while maintaining chassis structural integrity
3Loss of substance
If molding is adopted to form the chassis, then material efficiency is improved, but product cost increases
Solution Approach 1:
The patent segments the chassis into multiple sheet components that are formed and joined separately. This segmentation allows for simpler, lower-cost forming operations on individual sheets rather than complex mold operations, resolving the contradiction between improving material efficiency and controlling product cost
Solution Approach 2:
The patent employs dynamic folding and joining operations that are more flexible and adaptable than fixed molding processes. This dynamic approach reduces tooling costs and allows for easier manufacturing adjustments, achieving good material efficiency without the high costs associated with molding
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 enhancing material efficiency and minimizing energy consumption, while maintaining structural integrity.
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 first cover configured to form one surface of the chassis by being combined with the side wall frame, and a second cover configured to form another surface of the chassis by being combined with the side wall frame.