Lightweight Electronics Rack Using Corrugated Plastic Housing
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Solution Overview
Problem
Industry-standard electronics racks are heavy and expensive due to their metal construction, which poses challenges in terms of weight and cost efficiency.
Innovation Solution
A lightweight electronics rack is designed using a housing made of corrugated plastic with metal rack rails attached, where the plastic is folded from a single cut sheet and secured with adhesive, providing a cost-effective and lightweight solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal construction is used for electronics racks, then structural strength and stability are improved, but weight and cost increase
Solution Approach 1:
The patent applies composite materials by combining corrugated plastic for the housing with metal rack rails and mounting brackets. This hybrid approach provides the structural strength needed to support electronic modules while significantly reducing the overall weight compared to traditional all-metal racks. The corrugated plastic housing with integrated metal supports creates a composite structure that balances strength requirements with weight reduction goals.
2Strength
If metal construction is used for electronics racks, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses composite materials combining corrugated plastic housing with metal rack rails and mounting brackets. This approach reduces manufacturing cost compared to traditional all-metal racks while maintaining the structural strength needed to support electronic modules. The corrugated plastic housing with integrated metal supports provides a cost-effective alternative that meets strength requirements.
Solution Approach 2:
The patent segments the rack structure into distinct functional components: corrugated plastic housing for the main body, metal rack rails for module mounting, and separate mounting brackets for support. This segmentation allows each component to be optimized independently and assembled together, reducing overall manufacturing cost while maintaining structural integrity.
3Weight of moving object
If corrugated plastic housing is used, then weight and cost are reduced, but structural integrity may be compromised
Solution Approach 1:
The patent applies composite materials by combining corrugated plastic housing with metal rack rails and mounting brackets. This hybrid structure provides the structural strength needed to support electronic modules while significantly reducing the overall weight compared to traditional all-metal racks. The metal components are strategically placed at critical load-bearing points to reinforce the lighter plastic housing.
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 solution results in a lightweight and cost-efficient electronics rack that maintains structural integrity while supporting industry-standard electronics modules, addressing the weight and cost issues of traditional metal racks.
Implementation Method 1
The plastic is preferably corrugated plastic folded from a single cut sheet and secured with adhesive
Data Source
AI summary
A lightweight plastic housing with metal rack rails attached within to support industry-standard electronics modules. The plastic is preferably corrugated plastic folded from a single cut sheet and secured with adhesive. The sheet is folded to make an enclosure having a rectangular cross section, and a fifth short panel overlaps a first panel. Box closures, possibly auto-locking box closures, form the top and bottom of the housing. Metal rack rails and supports for the rack rails are installed through a front opening of the housing and are attached to and supported by the plastic housing. Supports include lengths of asymmetric channel stock extending between the top and the bottom of the housing at four corners to maintain the rack rails spaced apart from the sides of the housing. Upper and lower cross supports extend between front and rear supports.