+ ' $$$ &$
!% # %# "&!%
HP-PAC replaces the familiar metal chassis structure with expanded
polypropylene (EPP) foam. Large reductions are realized in mechanical
parts, screw joints, assembly time, disassembly time, transport
packaging, and housing development costs.
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Fig. 1. Parts required for a workstation using the existing packaging
concept.
• 100% recyclability. Granules produced from recycled EPP can
be used for manufacturing other parts such as packaging
material and shock absorbers.
EPP foam parts can be produced in densities of 20 to 100
g/l. Lower density provides excellent shock absorption,
while higher density offers tighter manufacturing tolerances.
Thus design tradeĆoffs are possible.
The next step was to apply this new concept to an already
existing workstation. One workstation seemed suitable for
the conversion. The existing concept (see Fig. 1), consisting
of sheetĆmetal chassis (top and bottom), electrical compoĆ
nents, sheetĆmetal enclosure, EMI liner, and plastic parts,
was transformed into a foam chassis, electrical components,
sheetĆmetal sleeves, integrated EMI liner, and modified plastic
parts (see Fig. 2). In the new technology, all of the compoĆ
nents are held by their own geometry in formĆfitting spaces
in the foam chassis. The connections between them are
achieved through cabling held in foam channels (Fig. 3).
Time was saved by processing the foam chassis, the sheet
metal, and the plastic parts in parallel. To obtain the foam
parts quickly, we rejected the ordinary way of creating drawĆ
ings with the help of a CAD system and instead created a 2D
Fig. 3. Channels in the foam carry cooling air (shown) and cabling.
cardboard layout showing the placement of the components.
A packaging company placed their sample tooling shop at
our disposal for a few days. The first prototype was built
step by step. We milled, cut, and glued, applying a lot of
imagination.
After two days the first prototype was nearly finished. ComĆ
ponents were fixed in the necessary form fit and we were all
aware that we had taken a step in the right direction. Back
at HP we made a few minor changes to the EPP chassis and
the remaining enclosure with the help of a knife and finĆ
ished the prototype.
The major question now was, Will it run?" We ran software
on the workstation and started testing, surrounded by our
production staff. The programs worked!
Next, temperature, humidity, and environmental tests were
performed. Temperature problems were corrected by alterĆ
ing the air channels through cutting and gluing. HP class B2
environmental tests were passed (see Table I and Fig. 4).
Table I
Thermal Test Results
CPU Temperatures (°C)
Test Point
Fig. 2. Parts required for the workstation of Fig. 1 using the HPĆPAC
concept.
August 1994 HewlettĆPackard Journal
HP-PAC
Original
UB7
29.1
32.1
UD15
33.0
37.5
UB20
36.6
44.8
UH25
35.7
46.7
TOĆ220
49.3
59.8
UM10
39.9
44.5
UM25
58.7
67.5
UR30
56.7
73.7
MUSTANG
70.0
82.9
CPU Average
45.44
54.39
SHOCK DATA
Side of DUT:
Waveform:
Duration:
Delta V:
Faired Acc.:
Rear
Half Sine
1.7 ms
246.2 cm/s
240.0 g
MACHINE SETTING
Pressure PROGR.:
Pads:
0.0 MPa
0.9 psi
0.0 kPa
0.0 psi
5.0 in
12.7 cm
1 Thick/1 Thin
Date:
Name:
10.03.92
Bart Dechesne
Pressure LIK:
0
2.5
5
Time (ms)
Height:
Acceleration (g)
50
45
40
35
30
25
20
15
10
5
DEVICE UNDER TEST
Instrument:
Serial No.:
Options:
Prod. Weight:
HP799 HPPAC
02101
H. Disk
9.7 kg
SHOCK DATA
Side of DUT:
Waveform:
Duration:
Delta V:
Faired Acc.:
Rear
Half Sine
7.5 ms
207.9 cm/s
45.1 g
MACHINE SETTING
Pressure PROGR.:
Pads:
0.0 MPa
0.0 psi
0.0 kPa
0.0 psi
5.0 in
12.7 cm
1 Thick/1 Thin
Date:
Name:
10.03.92
Bart Dechesne
DEVICE UNDER TEST
Instrument:
Serial No.:
Options:
Prod. Weight:
HP799 HPPAC
02101
H. Disk
9.7 kg
SHOCK DATA
Side of DUT:
Waveform:
Duration:
Delta V:
Faired Acc.:
Rear
Trapezoidal
28.0 ms
804.7 cm/s
28.3 g
Pressure LIK:
0
5
10
Time (ms)
Height:
(b)
(a)
100
90
80
70
60
50
40
30
20
10
DEVICE UNDER TEST
Instrument:
Serial No.:
Options:
Prod. Weight:
HP799 HPPAC
02101
Chassis
9.7 kg
SHOCK DATA
Side of DUT:
Waveform:
Duration:
Delta V:
Faired Acc.:
Rear
Trapezoidal
23.5 ms
737.2 cm/s
31.7 g
MACHINE SETTING
Pressure PROGR.:
Pads:
2.1 MPa
300.0 psi
0.0 kPa
0.0 psi
30.0 in
76.2 cm
1 Thick/1 Thin
Date:
Name:
10.03.92
Bart Dechesne
Pressure LIK:
0
25
Time (ms)
(c)
Acceleration (g)
HP799 HPPAC
02101
Chassis
9.7 kg
50
Height
Acceleration (g)
Acceleration (g)
500
450
400
350
300
250
200
150
100
50
DEVICE UNDER TEST
Instrument:
Serial No.:
Options:
Prod. Weight:
100
90
80
70
60
50
40
30
20
10
MACHINE SETTING
Pressure PROGR.:
Pads:
2.1 MPa
300.0 psi
0.0 kPa
0.0 psi
30.0 in
76.2 cm
1 Thick/1 Thin
Date:
Name:
10.03.92
Bart Dechesne
Pressure LIK:
0
25
Time (ms)
50
Height:
(d)
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° =8 ° &1>< * E66 5.70=1 8/ /8*6 *= ° @255 +.
66 5870 *= °
&1. 6*=.;2*5 ,1*70.< <=*=. *+8?. ° &1.;6*5 -2<<85>=287
8,,>;< *= ° *7- =1. 2072=287 9827= 2< °
&1.;. @*< 78 9.;6*7.7= -./8;6*=287 27 * =.69.;*=>;. 5889
=.<= ,87<2<=270 8/
18>;< *= °
18>; *= °
18>;< *= °
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18>;< *= ° *7- 1>62-2=B
18>; *= °
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Electrical Properties. ## 1*< 088- .5.,=;2,*5 27<>5*=287 9;89E
.;=2.< &12< 6.*7< =1*= =1. /8*6 9*;=< ,*7 .*<25B *,:>2;. *7
.5.,=;2,*5 ,1*;0. 87<.:>.7=5B 6.=18-< *;. +.270 -.?.5E
89.- =8 9;8->,. *7=2<=*=2, ## &1.;. 2< 78 78=2,.*+5. 27=.;E
/.;.7,. +.=@..7 ## 6*=.;2*5 *7- 1201E/;.:>.7,B ,2;,>2=<
@2=1 <:>*;.E@*?. <207*5< >9 =8 C &.<=< *= ?.;B 1201
/;.:>.7,2.< C 1*?. 78= B.= +..7 ,87->,=.-
). ,*7 27/.; /;86 <852- 985B9;89B5.7. <86. 8/ =1. .5.,=;2,*5
9;89.;=2.< 8/ .A9*7-.- 985B9;89B5.7.
• 2<<29*=287 /*,=8; 8/ 273.,=287E685-.- ## *= C =*7
×
• ;.*4-8@7 ?85=*0. 8/ 273.,=287 685-.- ## 4(,6
• %>;/*,. ;.<2<=*7,. *= ° *7- ;.5*=2?. 1>62-2=B
>7=;.*=.- =8 816<
Chemical Resistance. ## 1*< 088- ,1.62,*5 ;.<2<=*7,. +.E
,*><. 8/ 2=< 787985*; :>*52=2.< = 2< ;.<2<=*7= =8 -25>=.- <*5=
*,2- *7- *54*527. <85>=287< ## ,*7 ;.<2<= 5B. <85>=287<
<85?.7=< *= ,87,.7=;*=287< >9 =8 *7- *5,8185 ;86*=2,
*7- 1*580.7*=.- 1B-;8,*;+87< /8>7- *= 1201 =.69.;*=>;.<
27 0;.*<. 825 *7- @*A ,*><. 2= =8 <@.55 )1.7 ## 2< 62A.@2=1 8=1.; <>+<=*7,.< -*70.;8>< ,1.62,*5 ;.*,=287< -8 78=
=*4. 95*,.
Reaction to Light. 7 0.7.;*5 ## 2< <>//2,2.7=5B ;.<2<=*7= =8
;*-2*=287 *= =1. @*?.5.70=1< 8/ ?2<2+5. 5201=
>0><= .@5.==E#*,4*;- 8>;7*5
Reaction to Humidity and Water. 5-)$)49 (!3 ,)44,% /2 ./ %&&%#4
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