The Challenge

• The system was to be deployed worldwide in a variety
of theaters and thus had to be rugged.

• A custom power system was to be integrated within
the case in a separate custom chassis. The customer’s
proprietary power source was designed to accept power
from sources available worldwide and needed to be
swappable from the case in the event of a failure.

• The case was to be used as a heat sink to cool the
customer’s integral components and power supply.

    
       
       
       
 

• Mission critical security / encryption devices needed to be securely mounted on a panel and brackets with the ability to remove them within seconds.

• A ruggedized laptop needed to be on a sliding tray and accessed from the front of the case (workstation scenario).

• All components needed to be pre-connected without cables being visible or readily accessible.

• The lid was to be both hinged (with a pre-determined “open” angle for stability) and removable.

• A satellite antenna and auxilliary devices were
to be stored in the lid.

• The case had to meet both dimension and weight requirements. It also had to be rugged and take substantial abuse.
 

The Solution

As a number of the customer’s components were associated with sensitive security issues, Impact’s design professionals spent extended periods of time at the customer’s facility to develop the solid model of the case design. Upon completion of the design phase and approval of the virtual concept models, Impact manufactured prototypes for form, fit and function. Subsequent to the approval of the “hard” prototype, the production cases were manufactured.
   

As this application was very specific in nature, Impact’s design professionals approached this from the ground-up. The greatest challenge was to design and manufacture the swappable power source chassis. As this component generated a substantial amount of heat and the case shell was to be used as the primary source of heat dissipation, it was decided that the chassis needed to be securely fastened to the outer case on all common faces and that thermo-conductive pads would be used to facilitate heat transfer. The interior of the chassis consisted of a series of threaded posts, stand-offs, brackets and panels to facilitate installation of customer’s components. The power source chassis was accessible from the back of the case via a hinged panel and removable cover (used when a power source chassis needs to be swapped).

    
 
A retractable laptop tray was designed and manufactured. The tray had both fixed and removable brackets to organize cables and allow rapid removal of the laptop. A main panel covered the power source chassis and cavity for the laptop tray. Components used for security/encryption were installed on separate brackets with captive fasteners to allow rapid removal. A baffle plate was installed above the main panel to cover and protect all associated cabling and connections. The lid had a CNC machined foam insert (with straps) to holdthe satellite antenna and auxiliary components. A retractable handle and recessed wheels were installed in the lid because of geometric and electronic constraints in the base.  
 


Toll Free: 1-800-881-7544 • Phone: 905-470-7888 • Email: info@impactcases.com