Two-Piece Housing Assembly for Compact Repairable Electronics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturers face challenges in reducing the size of handheld electronic devices while maintaining enhanced functionality, particularly due to the complexity of integrating numerous components.
Innovation Solution
A portable electronic device design featuring a tilt assembly and housing assembly with a frame overmolded on metal frame struts, retention clips, and elastomeric gaskets to protect components, allowing non-destructive disassembly for rework or repair, and using metal clips and springs for secure engagement without damaging components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If manufacturers reduce the size of components to achieve smaller form factor devices, then device compactness is improved, but manufacturing precision and assembly difficulty worsen
Solution Approach 1:
The device is divided into two main assemblies: a tilt assembly containing the display unit and a housing assembly containing the battery and electronic components. This segmentation allows each assembly to be manufactured and tested independently, then joined through non-destructive engagement members, reducing overall complexity and improving manufacturing precision despite compact dimensions.
Solution Approach 2:
The tilt assembly is inserted into and nested within the housing assembly, with the frame of the tilt assembly fitting within the housing. This nested configuration maximizes space utilization in the compact device while maintaining clear assembly boundaries for manufacturing precision.
2Strength
If traditional permanent bonding methods are used to secure components, then structural strength is improved, but ease of repair worsens
Solution Approach 1:
The engagement members include flexible elements such as springs and elastomeric gaskets that provide dynamic, reversible connection between assemblies. The elastomeric gasket compressed between the bezel and housing provides continuous pressure to maintain structural strength while allowing the assemblies to be separated and reconnected multiple times without damage.
Solution Approach 2:
The non-destructive engagement members are designed to be reusable rather than single-use. The springs, clips, and elastomeric gaskets can be recovered and reused when assemblies are disassembled for repair or rework, eliminating the need to discard fastening components and enabling repeated assembly cycles.
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
Enables the assembly of compact electronic devices with improved mechanical tolerances and ease of repair, reducing waste and complications during manufacturing.
Implementation Method 1
an elastomeric gasket may be interposed between the bezel and the cover glass
Implementation Method 2
The springs may have spring prongs that flex during assembly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Portable electronic devices are provided. Each device may be formed from two parts. A first part may be provided with components such as a display, a touch screen, a cover glass, and a frame. A second part may be provided with a plastic housing, circuit boards containing electrical components, and a bezel. Engagement members may be connected to the first and second parts. The engagement members may be formed from metal clips with holes and springs with flexible spring prongs that mate with the holes in the clips. The metal clips may be welded to frame struts on the frame and the springs may be welded to the bezel. During assembly, the first part may be rotated into place within the second part. Retention clips attached to the frame may be used to secure the two parts together. Assembly instructions and associated connector numbers may be provided within the devices.