Sheet Metal Enclosure Inner Extensions Eliminate Gap Fillers
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Solution Overview
Problem
The manufacturing cost of enclosures for power supply circuit boards increases due to the need for a gap filling member made of a flame-retardant resin material to fill gaps between sheet metal members, which is costly and not necessary if the design could prevent such gaps from forming.
Innovation Solution
The enclosure design includes inner extensions on the sheet metal members that form a separation distance between the power supply circuit board and the main body, preventing electrical short circuits and eliminating the need for a gap filling member by ensuring the sheet metal members can be combined without forming gaps that exceed fireproofing standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gap filling members made of flame-retardant resin material are used to fill gaps between sheet metal members, then fireproofing standards are met, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the gap filling member from the enclosure structure by redesigning the sheet metal members to inherently prevent gap formation. The inner extensions with bent portions create a self-contained structure that maintains fireproofing without requiring additional flame-retardant materials, thus removing the cost burden while maintaining reliability
Solution Approach 2:
Instead of adding gap filling members to address gaps, the invention inverts the approach by designing the sheet metal members themselves to prevent gap formation through their geometric configuration. The inner extensions with bent portions facing each other create a structure where gaps are prevented by design rather than filled afterward, eliminating the need for expensive flame-retardant resin materials
2Strength
If sheet metal members are combined to form enclosure, then structural integrity is achieved, but gaps may form between members requiring additional components
Solution Approach 1:
The invention merges the functions of structural support and gap prevention into a single integrated sheet metal member design. The inner extensions with bent portions serve both to provide structural integrity to the enclosure and to prevent gap formation between members, eliminating the need for separate gap filling components and simplifying the overall device structure
Solution Approach 2:
The inner extensions are nested within the enclosure structure formed by the sheet metal members. The bent portions of the inner extensions are positioned to face each other from opposite sides, creating a nested configuration that prevents gap formation while maintaining the structural integrity of the overall enclosure without requiring additional external components
3Reliability
If inner extensions with bent portions are used to support circuit board, then separation distance is ensured preventing short circuits, but manufacturing complexity of sheet metal member increases
Solution Approach 1:
The sheet metal member is segmented into distinct functional portions: the main body and the inner extensions with bent portions. This segmentation allows each portion to be optimized for its specific function - the main body provides structural support while the inner extensions provide electrical insulation and circuit board support, making the overall manufacturing process more efficient despite the added geometric complexity
Solution Approach 2:
The invention changes the geometric parameters of the sheet metal member by adding bent portions to the inner extensions. These parameter changes create the necessary separation distance for electrical insulation while the bent portions are designed to be formed using standard sheet metal forming processes, minimizing the impact on manufacturing complexity
Data Source
AI summary
An enclosure for a power supply circuit board includes a plurality of sheet metal members combined to accommodate a power supply circuit board. The plurality of sheet metal members includes a first sheet metal member. The first sheet metal member includes a main plate having a flat plate shape, and an inner extension connected to the main plate through a bent portion located at an end of the main plate. The inner extension includes a circuit board support for supporting the power supply circuit board. The circuit board support faces the main plate and is separated from the main plate in a direction perpendicular to the main plate. The circuit board support is located within an inner space surrounded by the plurality of sheet metal members.