Air Conditioner Segmented Panel Assembly for Simplified Manufacturing
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Solution Overview
Problem
Existing air conditioners face challenges in achieving a simple structure and high efficiency in assembly, particularly in home units where the separation of indoor and outdoor components complicates the assembly process and affects performance.
Innovation Solution
The air conditioner design incorporates a base rear panel, body rear panel, connector, base front panel, and body front panel with a blowing module, shroud panel, and guide panel to facilitate easy assembly and enhance structural strength, allowing for efficient air flow and discharge while maintaining a simple external structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the air conditioner uses a separated structure with base rear panel and body rear panel, then the assembly process becomes more complex and time-consuming, but the structural strength and stability are improved
Solution Approach 1:
The air conditioner casing is divided into base rear panel, body rear panel, base front panel, and body front panel as separate components. This segmentation allows for easier manufacturing, transportation, and flexible assembly while maintaining structural integrity through proper connection design between panels.
Solution Approach 2:
The connector integrates multiple functions including structural support, electrical connection housing, and mounting interface for the shroud panel. By combining these functions into a single integrated component, the overall assembly complexity is reduced while maintaining structural strength.
2Ease of manufacture
If the air conditioner uses multiple separate panels (base rear, body rear, base front, body front), then the manufacturing and assembly flexibility is improved, but the number of parts and assembly time increases
Solution Approach 1:
The casing is segmented into four main panels that can be manufactured independently using standardized processes, allowing for flexible production scheduling and quality control. Each panel can be produced separately and then assembled through the connector interface.
Solution Approach 2:
The connector is designed with pre-formed connection interfaces and mounting structures that enable quick assembly of the panels. The shroud panel is pre-assembled with the connector, reducing the number of separate assembly steps required during final assembly.
3Reliability
If the shroud panel is coupled to the connector with locking mechanisms, then the structural stability and reliability are improved, but the assembly complexity and part count increase
Solution Approach 1:
The locking mechanism is integrated directly into the shroud panel and connector structure, eliminating the need for separate locking components. The locking features are formed as part of the molding process, providing structural stability without adding assembly complexity or additional parts.
Solution Approach 2:
The shroud panel incorporates self-aligning and self-locking features that automatically engage during assembly. The locking mechanism requires no additional tools or separate operations, as the panel itself provides the locking function through its integrated design.
Data Source
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AI summary
The present invention relates to an air conditioner that is easily assembled in a simple structure and has high efficiency. The air conditioner includes, a base rear panel (110) forming a lower rear external appearance and having a internal space therein, a body rear panel (150) coupled to the upper portion of the base rear panel (110) and forming an upper rear external appearance, the body rear panel (150) has an inlet (151a) for admitting air, a connector (130) coupled to an inside of the base rear panel (110), a base front panel (120) coupled to the connector (130) and forming a lower front external appearance, and a body front panel (190) forming an upper front exteranl appearance and having an outlet (190a) for discharging air, a lower end of the body front panel (190) coupled to the base front panel (120) and a lateral side of the body front panel (190) coupled to the body rear panel (150).