“As part of R&D we try to come up with versatile yet fairly specific solution to problems encountered by our customers. Due to the size and nature of our products, small enough boxes are almost impossible to find – or take too long to arrive – leaving a very narrow development window. Evatron is very local and seems to be the only company that supply boxes small enough to be incorporated into our product design.

Recently I’ve had to design a system that allows temperature and humidity to be read inside a wall. It had to be small, discrete yet sturdy enough to last for a couple of years. After a quick phone call, I turned up and was shown a few products that I could use – thank you Jamie!

I incorporated the RX2008, RX2006 and RX2KL06 into the prototypes in the end.  There are several aspects that I like:

-          The box walls are not too thick – a drill and junior hacksaw worked very well!

-          Even with “thin” walls, the boxes are very sturdy.

-          Internal dimensions are perfect for small PCBs and various components.

-          Rounded corners and edges give it more aesthetic appeal.

-          The lid is easy to remove – perfect for developing a prototype!

I’ll definitely be ordering more of these! Thanks guys!”  Elle Titley, Technical Sales Advisor, Homechip Ltd.

Instrument enclosures are of several kinds that are used in different applications. They are available freely in the market and suit many functions that are required in a technical activity. Many varieties of enclosures contain hand held tools that are used by technicians to perform an engineering act in a simple manner. They offer access to finest tuning with other electronic adjustments in machines with the help of the printed circuit that comes as an integral part of the tool. Free hand-held models or rack-supported models are used, which come in aluminium or plastic and are portable.

The choice of the design depends on the specific need of the industry, which should be explored and decided. Some enclosures become part and parcel of products with different styles that corroborate the particular needs of the industrial function. There are customized versions too, which are created for the benefit of the specific industry. 

The system of process instrumentation is extremely sophisticated requiring very high standards of security.  It is important to protect product integrity throughout a variety of environments, which may turn out to be hostile and result in total collapse of the equipment and the process.  To ensure product security, custom enclosures have been developed for complete protection. Quality instrument enclosures provide very vital elements with superior construction and sophisticated material technology to survive the most antagonistic environments during application of the technology.

They are capable of protecting instruments for hydraulic, mechanical, pneumatic and electronic technologies. They can withstand harsh weather conditions of snow, rain, wind in both off shore and on shore and are able to carry on normal activities with security. The operation protects the investment of capital funds and effectively minimizes the cost of maintenance. The system runs consistently because of the thermal stability offered by the enclosure. Use of weatherproof boxes and metal boxes prove to a great advantage in offering sound protection of sophisticated instruments.

The high quality enclosures include incredible project box designs to add longer lifespan of the system and provide extra life to gadgets. The project box can be moulded from materials that are incredibly strong. They are composed of precision materials and have excellent tolerance levels. They consist of oxidation resistant materials and are products of a sophisticated technology.

Materials used for enclosures include steel, abs, polycarbonate and aluminium.  The material may need to be durable and secure, possibly to withstand vandalism or attempted break-in, extreme weather conditions and fire hazards including explosions.

(RX Series shown)

Custom Enclosure If there is no ‘off the shelf’ enclosure suitable to meet the designer’s needs, it will be necessary to tool and mould a custom enclosure.  The designer may require the enclosure to provide environmental control of noise, variations in weather, temperature changes, mildew, dust build-up and rust corrugation due to moisture.  The size will be designed to accommodate the electronic equipment – pcb, batteries, etc.

ABS Plastic This is a material created by combining three resins acrylonihite, butadiene and styrene. Together they comprise a material that is strong, resilient and can withstand extremities of temperature.  ABS plastic is versatile and bonds well with adhesive or solvent cement to create a secure structure. The material is paintable, can be EMC shielded or screen printed to meet any design. Thus ABS plastic is a good material for both aesthetics and outdoor use.

(SB Series shown)

Project Boxes Smaller enclosures are often referred to as ‘project boxes’.  They can be made from various materials and come in a range of shapes and colours to suit the purpose and house the object to be enclosed.  Aluminium extrusions, die cast, abs snap fit, screw fixed or flanged enclosures all have their place as a potential project box.  Sturdy, durable and versatile, these small enclosures are secure and come in a range of sizes to suit many different requirements.

Electronic Enclosure (DE Series shown) When the requirement is to protect delicate electronic equipment or an appliance, an enclosure specific for this purpose is recommended. This enclosure material makes the difference in the overall performance of the equipment. The primary qualities expected may be strength, rigidity and durability.  Alternatively, the most important quality may be flexibility and the ability to expand to accommodate varying degrees of temperature.

The aluminium enclosure is made from non-ferrous aluminium metal forced into a mold cavity through the use of high pressure and this process is known as die cast. The aluminium case can have custom enclosures extruded into the box and a flange mount for a sturdier finish. The rationale behind the die cast is for the ease in assembly, ease in working with the box, and the quick simple production of the boxes. These boxes are light enough to move around from one location to another and simple to work with; making them a very useful tool.

Another great benefit is that the boxes can be electrically grounded without much trouble. The manufacturing of this enclosure is ideal for so many jobs because it is a simple process to install, work with, and even move if necessary. Plus, the enclosures can withstand harsh environments and still protect the material within the box. These details result in many uses for the aluminium boxes.

The sturdy custom made electrically conductive metal boxes can be used for a variety of purposes from domestic environments to industrial environments and everywhere in between. The extruded aluminium can be used in engine compartments in vehicles, computer devices, and a range of electronics, and for many electrical purposes.

IP66

Many types of enclosures exist, but each has a specific purpose it is manufactured to achieve. For instance, the IP66 aluminium case is specifically designed for general industrial and electronic use.  Available in graduated sizes with standard enclosures and accessories like cable glands, joints mounting plates, and many other accessories. The aluminium enclosure is available in varnish as well as powder-coated finish, while leaving the inside of the box rough to ensure electrical continuity.

Aluminium cases have a range of uses and purposes. The cases can be found with various fastenings, closures, and in many sizes to suit every job it is intended to perform. Custom cases can be manufactured when specifications of a particular case are difficult to locate. These electric conducive boxes are uncomplicated to work with, practical and useful in many tasks.

Plastic is highly durable, cost effective and with the material properties to meet electrical device standards.   3D drawings will be required by the tooling/moulding company to ensure the enclosure is made to your exact specification.  Custom plastic enclosures may be moulded in ABS, polycarbonate or the material of your choice, and to flamability test levels UL HB or UL 94V-0.   They can be made with clear lids, include battery compartments, panels or flanges.

ABS is a copolymer of Acrylonitrile, Butadiene, and Styrene.  Its heat-resistance and solvent-resistance is better than HIPS and with greater impact strength, tensile strength and surface hardness.  In general, the higher percentage of Acrylonitrile, the better the heat-resistance, rigidity and solvent-resistance.  These advantages all contribute to make ABS resin an excellent material for electrical/electronics enclosures.   Materials used will have UL and C-UL approval.  There are general-purpose grade, high-flow grade, extrusion grade, flame-retardant grade, high-heat grade and transparent grade.

Polycarbonate, a polymer of Bisphenol A and Diphenyl Carbonate, is manufactured by the non-phosgene melt process. This unique environmentally friendly process not only uses no toxic chemicals such as phosgene but also eliminates waste-water concerns compared to traditional polycarbonate production. Clarity, heat resistance, dimensional stability and superior impact strength make polycarbonate the best choice for extensive applications including electrical parts, office appliance parts, precision machine parts, automotive parts, lighting, sporting goods, recreation goods, and sanitary goods.

EMC shielding may be required and this can be carried at a relatively low cost using nickel, silver, or copper lacquers sprayed onto the internal surface of enclosures.

Silk screening is also available if printed graphics or company logos need to be applied to further customise the enclosure.

A sealing gasket or enclosure door gasket are broad terms that describe the gasket between the base and the top, cover, or door of an electrical enclosure.  The configuration and function of the enclosure can vary from metal to plastic, large to small.  NEMA and IEC International Protection (IP) standards help engineers define the specific IP rating that needs to be met for their specific design requirements.  The designers of outdoor electronic housing units will specify a minimum rating of IP65, IP66/67 or possibly IP68.   This determines the gasket specification which will need to be dust proof and water tight under hose-down or even complete submersion conditions.

Electrical boxes may be located in the floor of buildings.  This can be for aesthetic or safety concerns, but it is also often important that they will be safe in flood conditions.

There are many different types of electrical boxes.  For example,  transformer or power supply cases.  The box around the transformer is a part of the transformer, but it still serves the basic use. The transformer box keeps the harsh environment from damaging the electrical circuits and wires inside.  Another important reason for the heavy duty weather proof box is safety.  An average transformer carries voltage that could injure or even kill a person.

Weatherproof cabinets are similar to these electrical weatherproof boxes in that the cabinets are built to last and withstand harsh weather environments.  The cabinets may be plastic or metal and usually lockable.

Industrial quality electronic enclosures may be made of polyester with a high IP rating.   They are designed to resist not only water and humidity but also any physical damage or abuse.  Hinges may be available to enable wide ranging use in various locations.  They may also be  lockable, to make sure only authorised personnel have access to the internal controls/equipment.   IP67 enclosures will not only protect any controls they have inside from random water falling on them but in fact they can be hosed down and their seal will not allow water inside.

Sometimes when installing an industrial plant or commercial development it is necessary to have an enclosure that will maintain the internal environment to protect the equipment controls.  In come cases, it may be that there is no ‘off the shelf’ enclosure of the correct design to house the product electronics.   However, now it is possible to tool and mould enclosures to a customers own drawings at low cost, making custom enclosures a viable alternative. 

The enclosure can also be silk screened at source, providing the complete ready to use solution.

Large and complicated machines and assembly lines often rely on small enclosures to protect and house various components. There may be many thousands of miles of electrical wiring/controls that must fit into the smallest space possible without compromising the integrity and safety of the equipment.   A whole range of large and small enclosures, as well as power supply cases help in the distribution and organisation of electrical wiring, controls, safety equipment, gadgets and many other useful, necessary pieces of equipment that help to run machinery are installed in them.

A wide range of enclosures may also be present in homes and offices.  Residential applications include the distribution of electricity throughout the home. The electricity comes into the home via the meter and an electric panel, which is housed in an electrical enclosure. From there it is distributed throughout the house in many thinner, smaller wires, that are split, and split again as they come closer to their destination, every time they change direction or divide, they are housed in a small enclosure which has a cover protecting the wiring from water, heat and humidity. If there are repairs or modifications to make to the system, all the electrician does is follow the enclosures in the direction he wants to go.

Enclosures are a very important part of the design in a house, office or industrial construction.  They keep wiring in order, they protect controls and other necessary equipment.  Repairs and maintenance are easier for the electrician.  Enclosures are moulded from different materials and in different sizes.  The electrician or electrical engineer designing your applications will decide which materials and enclosure boxes to use for the project you want. These are necessary pieces of equipment; they are designed to protect the operators of industrial equipment and to protect the buildings and equipment themselves.

This is why it is always necessary for developers and property administrators to follow directions and comply with the electrical codes of the locations where the house or industrial complex is being built or installed. There is an enclosure for every need, but it is important at the prototyping stage to select the correct enclosure and design your PCB and controls into the enclosure.  Otherwise, if the PCB is designed first, it may be difficult to find an off the shelf enclosure made to the correct dimensions for mounting the PCB.

Without enclosures, it would be extraordinarily difficult to store equipment outdoors.  Electronic enclosures used outside need to be made of suitable material and adhere to a certain level of protection – either IP65 or even up to IP67 for extreme conditions.  An IP65 rated enclosure will keep the majority of water and dust out, but is still prone to the ingression of water when submerged.   An enclosure rated to IP67, can resist water ingress even if the enclosure is submerged in water up to 1 metre deep.  This is particularly important for emergency materials stored outdoors.

ABS enclosures are made from acrylnitrile butadiene styrene material.  It is a low cost material that is extremely easy to manipulate with standard tools.  This keeps costs down for designers and engineers, who can use basic equipment to customise the enclosure.  An ABS project box is also easy to colour, both at the moulding stage and subsequently with logos and important usage information.   ABS is also lightweight and resistant to chemical corrosion, which may be important when protecting outdoors equipment.  Due to the fact that it is easy to manipulate with machinery and resistant to corrosion makes it an extremely cost-effective option for many businesses and well prepared homes.

However, the designer or engineer may determine that it is necessary to use a high impact polycarbonate enclosure.   Polycarbonate, a polymer of Bisphenol A and Diphenyl Carbonate, is manufactured by non-phosgene melt process.  This environmentally friendly process not only excludes the use of toxic chemicals such as phosgene but also eliminates waste-water concerns compared to traditional polycarbonate production.  Clarity, heat resistance, dimensional stability and superior impact strength make polycarbonate the best choice for extensive applications including electrical parts, office appliance parts, precision machine parts, automotive parts, lighting, sporting goods, recreation goods, and sanitary goods.

Apart from material, the intended use of the enclosure will also determine what kind of extra features the designers will require.  Security options will differ depending on both the intended content of the enclosure and where it is placed.  Indoor enclosures, for example, will probably have to deal with man-made corrosive material, as opposed to outdoor enclosures, which will have to deal with dirt, rain and snow. If the enclosure holds emergency supplies, it is unlikely to need to be heavily secured, which would delay the use of vital supplies in an emergency situation.  Cabinets or enclosures placed inside a home have less demand placed on them. The home or office building already protects them from the elements and offers a secure environment.   So, it is important to determine the required IP rating and flame retardancy grade of the material.  It may also be necessary to have a clear lid, so that data can be easily accessed without opening the enclosure.  If this is the case and a clear lid is required, the base may be made from ABS and the lid from polycarbonate, which offers the required clarity.