Aluminum Electronic Enclosure – E-Case D Data

Data For Our E-Case D Aluminum Electronic Enclosure

Silver or black anodized aluminum extruded box section to take 160 x 80mm, 160 x 160mm or 160 x 220mm circuit boards. The maximum height of components on a board mounted in the bottom slot is 40mm. This box features dovetail slots down the side that accept a Linc-Lug mounting bracket to facilitate surface mounting. One side of the box features two sets of appearance enhancing grooves. Between the sets of grooves is a shallow (0.5mm deep) recess which could be used for a label.

This is one of a series of sections that includes E-Case A, E-Case B and E-Case C.

E-case-D Dimensions

Non-Standard Lengths: Available. See separate datasheet
Length Tolerance: Nominal length -0mm/+1mm e.g. EDS 80 is not shorter than 80mm and not longer than 81mm.
Material & Finish: Aluminum 6063 T6 (HE9). Silver anodized 5 μm thickness – can be painted directly if required. The inside and cut ends are not anodized. Black anodized is 20 μm thickness, the inside and ends are anodized.
Weight: 3.4 Kg/m. Perimeter: 480mm outside, 516mm inside.

Extrusion Order Codes:

Length Black Silver
80mm EDS 80 EDB 80
160mm EDS 160 EDB 160
220mm EDS 220 EDB 220

Screw ports: Nominal diameter 2.7mm to take a No.4 thread-forming screw with a 3mm major diameter of a type normally used for plastic. They are not suitable for ordinary self- tapping screws that have a 2.9 mm diameter with a wide tolerance. The screw ports can be threaded M3 using a thread-rolling tap, but a thread cutting tap will make a weak thread. Alternatively an M3 thread-forming screw can be used to roll its own thread.

End plate: End plate D is size 169.4 x 53.3 x 2mm to suit the D profile of the E-Case range of extruded enclosures. This includes both standard enclosures and non-standard lengths. The end plate comes with either 5 holes or 4 holes. The original shape 5-hole plate has the extra hole on the centre-line that aligns with the centre screw port on the extrusion. It is designated by the suffix “1”. The 4-hole end plate was introduced because the new bezel interfered with the fifth hole. In bezel applications the extra fixing strength is not required. The 4-hole plate is designated by the suffix “2”. The end plates are available in three finishes, black anodized, silver (clear) anodized and natural. Natural end plates are anodizing grade and have a removable plastic coating on one side to prevent unwanted scratches prior to application. Initially, natural end plates will look the same as silver anodized, but over time will become dull or corrode if used in an application without surface protection. They would be an ideal starting point if a paint or alochrom finish were required. Silver anodized end plates are intended as partners for EDS (silver) electronic enclosures and black anodized end plates are intended as partners for EDB (black) electronic enclosures.

Application Information: The end plates are made using a ‘pierce and blank’ tool and therefore have a front with rounded edges and a back with square edges. They are designed to lie flush with the enclosure top and bottom and overlap the dovetails on the sides. Any Linc-lug inserted in a dovetail will be retained by the end plates.

The dimensions on the end plate drawing do not exactly match those on the extrusion drawing. This is because the extrusion sizes are nominal with a large tolerance. The first samples of the extrusion had dimensions similar to the end plate.

Material of end plate: Aluminum J57S or 5251 H22.
Weight of end plate: PDN1, PDS1, PDB1, PDN2, PDS2, PDB2: 46g.

E-case-D Front Plate Dimensions

Size Black Silver Natural
D (5 hole) PDB 1 PDS 1 PDN 1
D (4 hole) PDB 2 PDS 2 PDN 2

Envelope drawing

The envelope drawing shows the relationship between three things:

  1. The circuit board in the bottom slot of the enclosure.
  2. The envelope within which components must be placed.
  3. The outside of the end plate

E-case-D Internal Dimensions


Bezel – Optional black or silver ABS plastic bezel renders cosmetic improvement for E-Case D. It fits over the end plate and conceals the edges. Screws pass through the bezel as well as the end plate. Inserts conceal the heads of the screws. The bezel is particularly suited to concealing the edges of self-adhesive polycarbonate labels or membrane panels fitted on top of the end plate.

The bezel outline drawing shows the central area of the end plate (dotted line) not covered by the plastic of the bezel.
E-case-D Plastic Bezel End DimensionsGasket set – comprises 2 gaskets and 10 washers to optionally fit under screw heads. Order Code: GED1. Full details are on the E-Case Accessories datasheet.
Linc-Lugs – Silver Order Code: LSS 40 (40mm), LSS 80 (80mm);Black Order Code LSB40 (40mm), LSB80 (80mm). Full details are on the E-Case Accessories datasheet.
Screws – No.4 x 3/8” PlastiteTM posi-pan self-tapping screws: Silver Order Code: SC8 (pack of 8), SC400 (pack of 400). Black Order Code: SCB8 (pack of 8), SCB400 (pack of 400).

M3 x 10 TORX™ thread-forming screws. Silver Order Code: SCT8 (pack of 8), SCT400 (pack of 400). Black Order Code: SCTB8 (pack of 8), SCTB400 (pack of 400).

Plastite™ is a trademark of Research Engineering and Manufacturing, Inc.

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