Air handler having fan module and separation partition

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Solution Overview

Problem

Existing air handling units require complex assembly processes with numerous screws and additional sealing operations, leading to increased logistics and transportation costs, delayed installation times, and reduced rigidity due to excessive screw fastening, which complicates the management and installation of large capacity air conditioning systems.

Innovation Solution

The air handler is designed with modular components, including module frames, case panels, and connecting members, allowing for simplified assembly through sliding coupling without screws, and a sealing structure that prevents air leakage and heat transfer, reducing the number of assembly operations and eliminating the need for additional sealing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If panels are coupled to frames using numerous screws to achieve high coupling strength, then air leakage prevention is improved, but assembly complexity and assembly time increase

Engineering Contradiction:

Improveair leakage preventionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes screws entirely from the coupling system, extracting the fastening function and replacing it with a snap-fit mechanism where panels are inserted into grooves on frames and secured through elastic deformation of the frame material, eliminating the need for separate fastening components

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical screw-fastening system with an elastic deformation-based securing mechanism, where the frame's elastic properties enable the panel to be held firmly through interference fit and elastic recovery, substituting threaded mechanical connection with elastic-mechanical coupling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If electrical insulating tape and sealant are applied to prevent air leakage, then sealing performance is improved, but assembly time and manufacturing complexity increase

Engineering Contradiction:

Improvesealing performanceVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent removes the need for electrical insulating tape and sealant by integrating the sealing function directly into the frame structure through grooves and elastic securing mechanisms that create inherent air-tight connections between panels and frames

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the mechanical coupling function and the sealing function into a single integrated structure, where the groove-based securing mechanism simultaneously provides both structural attachment and air leakage prevention, eliminating separate sealing operations

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If all component elements are transported to installation site for complete assembly, then assembly flexibility is improved, but logistics costs and transportation time increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidtransportation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent divides the air handler into modular components (frames, panels, and pre-assembled subunits) that can be manufactured separately, transported efficiently, and quickly assembled on-site through simple insertion operations, reducing logistics complexity while maintaining assembly flexibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent enables preliminary assembly of frame and panel components at the manufacturing site before transportation, allowing complex structural elements to be pre-configured and then rapidly finalized through simple field assembly operations

Inventive Principle:

Principle #10Preliminary action

4Strength

If excessive screws are used for coupling, then coupling strength is improved, but rigidity of the structure decreases

Engineering Contradiction:

Improvecoupling strengthVSAvoidstructural rigidity

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent removes screws that were creating stress concentration points and rigid constraints, replacing them with an elastic securing system that maintains coupling strength through elastic deformation while allowing natural stress distribution that preserves structural rigidity

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10443885B2Air handler having fan module and separation partition

Publication Date: 2019.10.15 LG ELECTRONICS INC

AI summary

An air handler having a fan module and a separation partition is 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.