Modular PCB Enclosure Template Generator

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Solution Overview

Problem

Current methods for designing and manufacturing printed circuit board (PCB) enclosures are inefficient, requiring separate entities for the PCB and enclosure, leading to increased time, cost, and complexity, with inadequate electromagnetic interference shielding and requiring specialized equipment or long lead times.

Innovation Solution

A turnkey modular PCB enclosure system that uses a template generator to create a shielded, rigid enclosure template with a manufacturing file, allowing for easy incorporation of a PCB into the enclosure design, reducing assembly steps and acquisition time, and eliminating the need for separate PCB and enclosure fabrication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate PCB and enclosure fabrication is used, then design flexibility is improved, but manufacturing time and cost increase

Engineering Contradiction:
Improvedesign flexibilityVSAvoidmanufacturing time
Core Design Contradiction:
Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent combines the PCB and enclosure into a single integrated structure where the enclosure serves as both mechanical housing and circuit board substrate. This merging eliminates the need for separate fabrication processes and assembly steps, directly reducing manufacturing time while maintaining design flexibility through unified modification capability.

Inventive Principle:
Principle #5Merging (Combining)

2Manufacturing precision

If specialized equipment is used for in-house manufacturing, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:
Improvemanufacturing precisionVSAvoidequipment complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The integrated PCB-enclosure structure can be manufactured using standard PCB fabrication processes that are already widely available, eliminating the need for specialized enclosure manufacturing equipment. The single structure serves multiple functions (housing, mounting, circuit carrier), allowing existing PCB fabrication capabilities to produce both components simultaneously without requiring additional specialized equipment.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If additive manufacturing is used for enclosure production, then customization capability is improved, but electromagnetic shielding performance deteriorates

Engineering Contradiction:
Improvecustomization capabilityVSAvoidelectromagnetic interference shielding
Core Design Contradiction:
Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs metal materials for the integrated enclosure-PCB structure to provide inherent electromagnetic shielding properties. Metal enclosures naturally block electromagnetic interference, and when integrated with the PCB, they maintain both customization capability and EMI shielding performance without relying on additive manufacturing limitations.

Inventive Principle:
Principle #40Composite materials

4Manufacturing precision

If commercial enclosures are customized, then fit precision is improved, but acquisition cost increases

Engineering Contradiction:
Improvefit precisionVSAvoidacquisition cost
Core Design Contradiction:
Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The integrated PCB-enclosure design allows manufacturers to produce custom enclosures in-house using standard PCB fabrication processes, eliminating the need to purchase and modify commercial enclosures. This self-service approach reduces acquisition costs by removing intermediate purchasing and customization steps while maintaining precise fit through direct design control.

Inventive Principle:
Principle #25Self-service

Data Source

PatentUS11586795B2Modular printed circuit board enclosure
Publication Date: 2023.02.21 THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY
  • US11586795B2 patent drawing
  • US11586795B2 patent drawing
  • US11586795B2 patent drawing

AI summary

Systems and methods are provided for a turnkey modular printed circuit board enclosure that is generated using a template generator. The template generator accepts a user input comprising an enclosure parameter, based on which a manufacturing file may be generated. The manufacturing file may be provided to a fabricator for fabricating the enclosure or the manufacturing file may be modified in a printed circuit board design environment to incorporate a printed circuit board into the enclosure. The printed circuit board may be a separate printed circuit board that is inserted into the enclosure or it may be embedded in a face of the enclosure.