Nested Enclosure Weld Joint Hides Flash
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Solution Overview
Problem
Existing electronic device enclosures with visible seams are prone to damage and separation, especially when housing high-voltage components, and struggle with uniformity and aesthetic control during high-volume production.
Innovation Solution
The use of a nested structure with a tongue of an inner component welded to a groove within an outer component, forming a double shear weld joint that is hidden within the enclosure, providing a strong and aesthetically pleasing seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional seam joining methods are used for enclosure components, then the enclosure can be assembled, but the seams are visible and aesthetically displeasing while also creating weak regions prone to damage and separation
Solution Approach 1:
The patent applies nesting by placing one enclosure component inside another, specifically receiving the first enclosure component within the second enclosure component. This nested arrangement allows the weld joint to be positioned inside the enclosure structure, making it invisible from the exterior while maintaining structural strength through the integrated join between components.
2Ease of manufacture
If visible seams are used in enclosure components, then assembly is simpler, but the enclosure has weak regions that are prone to damage and separation, especially problematic for high-voltage electronic components
Solution Approach 1:
The patent extracts the weld joint from the exterior surface of the enclosure and positions it internally by receiving one component within another. This extraction removes the harmful visible seam and weak external region while maintaining the structural connection, thereby improving reliability without significantly complicating the manufacturing process.
3Strength
If traditional welding methods are used for joining enclosure components, then the components can be joined, but weld residue is visible and distortion occurs affecting aesthetic appearance
Solution Approach 1:
By receiving the first enclosure component within the second enclosure component, the weld joint is formed inside the nested structure where it is not visible from the exterior. This nesting approach allows strong welding while preventing weld residue from affecting the external aesthetic appearance, as the joint is concealed within the enclosure components.
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 results in a stronger, more uniformly manufactured enclosure with reduced distortion and external visibility of weld residue, enhancing structural integrity and aesthetic consistency while protecting high-voltage electronic assemblies.
Implementation Method 1
a tongue of an inner component is welded to a groove within an outer component such that the entire weld joint is hidden within the enclosure
Data Source
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AI summary
An enclosure for an electronic device includes a housing having a wall that defines a cavity that is configured to receive an electronic assembly therein. The wall includes tongue formed at a distal end. A cover includes a top wall and a side surface extending from the top wall to form a chamber. The housing is at least partially received within the chamber and the tongue of the housing is welded to a groove positioned within the chamber. Flash from the weld is contained within the enclosure so that no weld flash is visible on the exterior surface of the enclosure.