Power Supply Chassis using Structural Foam

Structural foam plastic chassis for the power supplies in the Bell System's DIMENSION® PBX sáves over $900,000 each year. This radical design approach saves approximately $60 per power supply because the chassis parts cost less to manufacture, are accurate thus eliminating many assembly problems, integrate details that were previously separate parts, and require no additional finishing for appearance or corrosion protection. The chassis is designed so that the assembly of electrical parts is fast and convenient. This paper addresses the design details of this power supply and others more recently developed which incorporate advanced assembly and component mounting techniques.