E-PAC ® , Electronic Packaging Assembly Concept is a world wide
patented new chassis and housing concept for electronic devices. DMT as
the exclusive licensee for E-PAC ® took over the responsibility for the
global sub-licensing of selected foam molders. A current list of
licensees is available on your request
Soon the team realizes that often the pure material cost for mechanical parts of i.e. a workstation only plays a minor role. The secondary cost over the life cycle are becoming more and more dominating.
The aggressive goals and objectives for new computer products together
with the results of market studies and functional analysis seem to be
unachievable.
Soon the concentration is directed to form fit as a potential solution to
hold the components in place. One of the main goals is to simplify the
assembly. By drawing analogies from other products, industries and even
from nature the team develops the technical solution.
E-PAC ® - the Concept
E-PAC ® stands for Electronic Packaging and Assembly Concept. E stands for
the electronic industry sector however also for easy, economic and
ecologic.
Objective | Analogy |
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The idea of using foamed plastic for the chassis is fascinating and
motivating the team. The next day a workstation Series 9000 model 710
is being disassembled and the redesign for an E-PAC ® feasibility study
is started. Three weeks later the team is proud to present the same
functionality with revolutionary results.
conventional | with E-PAC ® |
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The Results
The following comparisons and test results are based on the redigned HP
workstation model 710. All required tests, HP internal qualification as
well as all the product specific approvals like UL, CSA, TÜV, etc.
were passed.
The excellent shock absorbing properties not only support the reduction
of transportation packaging requirements. The product itself becomes more
rugged. The foam material can act as a mechanical filter for shocks and
jolts. It is expected that this dampening increases the MTBF of the most
sensitive components, the disk drives.
Besides the ruggedness the foam also dampens structural born noise which
leads to quieter products.
The ability of creating air channels into the foam supports the thermal
management for the product. The average CPU temperature could be lowered
from 54° down to 45°C ( at 20°C ambient).
The part count went down from 36 to only 11. This reduces administration
overhead in the area of sourcing, logistics, and material planning.
The ease of assembly also improves upgrade and service of the product in
the field. Last but not least the weight could be reduced. The chassis
was reduced from 3840 to merely 287 grams.
Some examples for ongoing developments:
Product Quality
Besides the cost advantages there are numerous other advantages and
improvements demonstrated.
Introduction to Volume-Production
Applications
The application as a workstation chassis is only an example for the broad
range of potential applications of E-PAC ®. High potentials have been seen
in:
As a rule of thumb you can say that the potential increases with following
criteria:
Future
EPP foam is a relatively new material ( introduction late 80’s) is
offering high evolution potential. This is true for the raw material (PP)
itself as well as the process and tooling technology.
The following pictures are demonstrating the principle of a typical E-PAC ®
design.