Foam cabinetry for electronic devices

Abstract

The cabinetry of the present invention facilitates lower manufacturing costs, lighter products that are easier to maneuver and less costly to transport, and simpler product assembly by reducing the number parts to be assembled, while maintaining the structural integrity of the cabinetry. The PTV cabinetry of the present invention utilizes molded plastic foam parts formed from expanded polystyrene or phenolic foam. The foam parts are preferably functionally designed to replace the equivalent parts presently being made by wood fabrication or other molded plastic techniques. In a preferred embodiment, a PTV cabinet may be assembled from thee matching molded foam parts. The foam parts in accordance with the present invention may be uniquely located with respect to one another via locating features molded into the foam parts. Once assembled, an external cabinet or cosmetic fascia part may be placed over the foam parts.

What is claimed is:  
     
         1 . A method of forming the cabinetry for consumer electronic devices, comprising the steps of 
 casting a mold of a desired cabinet or cabinet component,    injecting polystyrene beads into the mold,    expanding the beads such that the polystyrene material coalesces into a generally homogeneous structure as it is pressed against the walls of the mold,    releasing the cabinet or cabinet component from the mold, and    coating the released cabinet or cabinet component with a cosmetic material.    
     
     
         2 . The method of  claim 1  wherein the step of casting a mold includes casting the mold from aluminum.  
     
     
         3 . The method of  claim 1  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold at pressures in the range of about five (5) to fifteen (15) psi.  
     
     
         4 . The method of  claim 1  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold at a pressure of about eight (8) psi.  
     
     
         5 . The method of  claim 1  further comprising the step of injecting a blowing agent into the polystyrene beads.  
     
     
         6 . The method of  claim 5  wherein the blowing agent is heptane.  
     
     
         7 . The method of  claim 5  wherein the step of expanding the beads includes heating the blowing agent to expand the blowing agent within the beads.  
     
     
         8 . The method of  claim 1  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold with live steam.  
     
     
         9 . The method of  claim 1  wherein the step of expanding the polystyrene includes expanding the beads to about twenty (20) times their original size.  
     
     
         10 . The method of  claim 1  wherein the step of expanding the polystyrene includes expanding the beads to within a range of about fifteen (15) to thirty (30) times their originally size.  
     
     
         11 . The method of  claim 1  wherein the cosmetic material is plastic.  
     
     
         12 . The method of  claim 1  wherein the cosmetic material is a urethane material.  
     
     
         13 . The method of  claim 1  further comprising the steps of mounting consumer electronic equipment within the cabinet.  
     
     
         14 . The method of  claim 1  wherein the polystyrene beads have a density in a range of about three (3) to six (6) pounds.  
     
     
         15 . A method of forming a television comprising the steps of 
 molding an enclosure from expanded structural polystyrene,    coating the enclosure with a cosmetic material, and    mounting a viewing system in the enclosure.    
     
     
         16 . The method of  claim 15  wherein the viewing system comprises a screen coupled to an optical unit.  
     
     
         17 . The method of  claim 16  wherein the viewing system further comprises a mirror optically coupled to the screen and the optical unit.  
     
     
         18 . The method of  claim 15  wherein the cosmetic material is plastic.  
     
     
         19 . The method of  claim 18  wherein the cosmetic material is a urethane material.  
     
     
         20 . The method of  claim 15  wherein the molding step includes casting a mold of a desired shape.  
     
     
         21 . The method of  claim 20  wherein the molding step further includes injecting polystyrene beads into the mold.  
     
     
         22 . The method of  claim 21  wherein the molding step further includes expanding the beads such that the polystyrene material coalesces into a generally homogeneous structure as it is pressed against the walls of the mold.  
     
     
         23 . The method of  claim 22  wherein the molding step further includes releasing the enclosure from the mold.  
     
     
         24 . The method of  claim 23  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold at pressures in the range of about five (5) to fifteen (15) psi.  
     
     
         25 . The method of  claim 23  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold at a pressure of about eight (8) psi.  
     
     
         26 . The method of  claim 23  further comprising the step of injecting a blowing agent into the polystyrene beads.  
     
     
         27 . The method of  claim 26  wherein the blowing agent is heptane.  
     
     
         28 . The method of  claim 26  wherein the step of expanding the beads includes heating the blowing agent to expand the blowing agent within the beads.  
     
     
         29 . The method of  claim 28  wherein the step of injecting the polystyrene beads into the mold includes injecting the beads into the mold with live steam.