Air handler and method for assembling an air handler
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Solution Overview
Problem
Existing air handling units require complex and time-consuming assembly processes, involving numerous screws and additional sealing operations, which lead to increased logistics and transportation costs, delayed installation times, and reduced rigidity due to excessive screw fastening.
Innovation Solution
The air handler is designed with a modular structure comprising module frames, case panels, and connecting members that allow for simplified assembly through sliding coupling, reducing the number of assembly operations and eliminating the need for extensive screw fastening, while incorporating sealing structures to prevent air and heat leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If panels are coupled to frames using numerous screws to achieve high coupling strength, then air leakage is prevented, but assembly time and complexity increase significantly
Solution Approach 1:
The patent extracts the sealing function from the mechanical fastening process by introducing a separate sealing member (gasket) that is coupled between the panel and frame. This allows the screw fastening to focus solely on structural connection while the gasket handles the sealing requirement, reducing the number of screws needed and simplifying the assembly process.
Solution Approach 2:
The sealing member acts as an intermediary element between the panel and frame. It mediates the connection by providing both sealing functionality and facilitating easier mechanical coupling, thereby reducing the complexity of direct panel-to-frame fastening while maintaining air leakage prevention.
2Reliability
If electrical insulating tape and sealant are applied to prevent air leakage, then sealing is achieved, but the number of assembly operations increases
Solution Approach 1:
The patent merges the sealing function into a single integrated component (sealing member/gasket) that replaces the multiple separate sealing operations of applying electrical insulating tape followed by sealant. This consolidation reduces the number of assembly operations from multiple steps to a single coupling operation.
Solution Approach 2:
The sealing member is designed to provide automatic sealing upon coupling, eliminating the need for manual application of tape and sealant. The component self-performs the sealing function through its design, reducing the complexity of assembly operations.
3Reliability
If all component elements are transported to installation site for complete assembly, then proper assembly is ensured, but logistics and transportation costs increase
Solution Approach 1:
The air handler is divided into modular segments (frames, panels, and pre-assembled module combinations) that can be transported separately and quickly assembled on-site using the simplified coupling mechanism. This segmentation reduces transportation costs while maintaining assembly quality through the standardized, easy-to-follow coupling process.
4Strength
If excessive screw fastening is used to couple panels to frames, then coupling strength is increased, but structural rigidity decreases
Solution Approach 1:
The patent extracts the rigidity-maintaining function from the screw fastening system by introducing reinforcing ribs that are integrally formed with the panel. These ribs provide the necessary structural stiffness without requiring excessive screws, allowing the fastening system to focus on coupling strength while the ribs maintain rigidity.
Data Source
AI summary
An air handler and a method for assembling an air handler are provided, in which a case panel may be assembled with a plurality of module frames via a considerably simplified sliding coupling providing excellent hermetic sealing. As such, manufacturing costs may be reduced due to reduction in a number of components, and assembly time may be remarkably reduced due to a reduced number of assembly operations. This advantageously results in reduced labor cost and enhanced air conditioning efficiency.