Two-Piece Exoskeleton Shell for Mobile Devices
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Solution Overview
Problem
Conventional exoskeleton shells for mobile devices face issues with deformation due to absorption of cleaning chemicals and hand oils, leading to loss of structural integrity and flexibility, and are difficult to manufacture without permanent deformation, especially when using rigid plastic designs that require undercut areas for securement.
Innovation Solution
A two-part shell design with interlocking hooks and guide rails provides a rigid and durable protection while allowing easy installation and removal, using a full plastic ring for structural integrity and minimizing reliance on rubber for flexibility, ensuring clear fields-of-view and shock protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece exoskeleton shell is used to protect mobile devices, then the device receives continuous protection, but the shell deforms over time due to absorption of cleaning chemicals and hand oils, leading to loss of structural integrity
Solution Approach 1:
The shell is divided into two separate housings (first housing and second housing) that can be independently removed and replaced. This segmentation allows one housing to be replaced when deformed, extending the overall service life while maintaining structural integrity of the remaining housing.
2Strength
If a rigid plastic design is used for the exoskeleton shell, then structural integrity is improved, but the shell becomes difficult to manufacture and requires undercut areas that cause permanent deformation
Solution Approach 1:
Dividing the shell into two housings eliminates the need for complex undercut areas in a single-piece design. Each housing can be manufactured separately with simpler geometry, reducing manufacturing difficulty while maintaining the rigid plastic construction for structural integrity.
Solution Approach 2:
The two housings are designed to be removable and replaceable, transforming the static single-piece shell into a dynamic system where components can be independently serviced. This allows the rigid structure to be maintained without permanent deformation issues.
3Ease of operation
If flexible materials are used to allow easy removal of the shell, then ease of operation is improved, but the materials deform with repeated use and lose flexibility
Solution Approach 1:
The shell is segmented into two housings connected by a hinge mechanism, allowing one housing to be removed and replaced when deformed. This maintains ease of operation through simple removal while preserving flexibility retention in the remaining housing.
Solution Approach 2:
When a housing becomes deformed and loses flexibility, it can be discarded and replaced with a fresh housing, thereby recovering the flexibility and ease of operation without needing to replace the entire shell assembly.
Data Source
AI summary
An example disclosed protective shell for a device includes a first housing and a second housing. The first housing including a front perimeter edge, a side wall adjacent to the front perimeter edge, at least one recess area adjacent to a ledge, and at least one guide rail. The second housing including at least one tab and at least one receiving rail. The first housing and the second housing combine to secure the device by meshing the at least one guide rail and the at least one receiving rail, and securing the at least one tab to the ledge such that the tab is located within the at least one recess.