Terminal Case: Difference between revisions

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=Materials=
#REDIRECT [[Electrical Case]]
 
[http://www.amazonsupply.com/dp/B003U6HUO0/ref=sp_dp_g2c_asin Aluminum 6061T6 1/4" x 7" x 72"]
 
[http://www.amazonsupply.com/dp/B000MAMG2I/ref=sp_dp_g2c_asin Pure Tan Gum Rubber 1/8" x 12" x 24"]
 
[http://www.amazonsupply.com/dp/B000ILHW9I/ref=sp_dp_g2c_asin HDPE Natural White 1/4" x 12" x 24"]
 
=Summary=
 
The objective is a waterproof, corrosion-resistant, chemical-resistant, impact-resistant, thermo-resistant, EMP-resistant, lightweight, accessible, versatile, modular container for electronics and other hardware.
 
For recyclability, the use of a single frame material is optimal. Aluminum alloy (ex. Al6061) is corrosion and chemical resistant, machinable and weldable, and has a relatively high strength to weight ratio. A rectangular frame with low height minimizes geometric complexity and material use (for low-height technologies like circuit boards).
 
For maximum waterproofing, the terminal case should have minimal failure points. Accessibility inside the terminal case from just 1 face (ex. top face) provides the greatest waterproofing to accessibility ratio (at least where area-access technologies like circuit boards are concerned).
 
A seal designed for disassembly involves the application and release of tension on a sealing material that surrounds the inner volume. The seal material should be elastic, non-porous, and of a fine stick surface (with low adhesiveness for disassembly) for water-tight contact volume with the frame material. The seal material should also be electrically conductive such that the case frame acts as a faraday cage.
 
The frame should have a mechanism to hold the seal material in place and minimize exposure of the seal material with substances outside the terminal case. A groove or slot (slot is easier to make) along the top face of the perimeter frame material improves seal material holding; provides space into which the seal material can be compressed for reducing the seal exposure and improving the geometric durability of the seal (ex. without a groove/slot, the seal material gets entirely flattened into a thin sheet (resulting in low tensile strength and vertical elasticity), whereas a groove/slot better retains the volume of the seal material along all 3 axes)
 
The seal tension is applied between the base frame and the lid. Tensioning methods include C-Clamps (greater modularity, but more material and greater relationship between impact events and waterproof level - ex. if the CClamps get hit, seal tension changes a lot) and screws with sealing washers (more compact, but more complex, less compatible, and more waterproofing failure points).
 
[[Image: terminalcase3.jpg|500px]]
 
=Mounting Summary=
 
Mounting Interface between PCB Mount and Terminal Case should be tension with inner terminal case surfaces for maximum waterproofing and compatibility with different PCB+PCB Mount Modules. An elastic rectangular bar placed along perpendicular bottom edges of the case would allow boards of a certain size to fit inside through compression-tension of the elastic material, with tolerance based on the working range of the material's width displacement.
 
[[Image: terminalcase3mountingPCB.jpg|500px]]
 
Holes for wires should not be at the lid for sake of ease of disassembly. The holes should not be at the bottom plate for accessibility and bottom-face mounting compatibility. Hence holes are best put at the side walls.
 
[[Image: terminalcase3mountingWires.jpg|500px]]
 
=V1 Repository=
[https://github.com/openspeed/terminal-case Open Source Terminal Case]

Latest revision as of 09:18, 13 December 2012

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