Cassette AC Indoor Unit Outlet Structure for Low Noise Airflow
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Solution Overview
Problem
Cassette type air conditioners experience noise and vibration due to the design of the drain pan and condensate pump, which affects airflow and durability, and the wire arrangement complicates installation and assembly.
Innovation Solution
The design includes a recessed outlet port formed by coupling the inner case and drain pan assembly, minimizing exposed joining portions for reduced noise and vibration, and a supportive structure for the condensate pump with a reduced protrusion to enhance airflow, along with a wire guiding system for simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the drain pan is designed with a panel outlet port by opening the outside, then air discharge function is improved, but the outer surface becomes thin and vulnerable to damage
Solution Approach 1:
The drain pan outlet port is formed by separating the panel from the drain pan body. The panel is detached from the drain pan to create the outlet port, allowing the drain pan outer surface to maintain its original thickness and strength while still providing the required air discharge function.
2Ease of manufacture
If the drain pan and case are coupled with exposed joining portions, then assembly is simplified, but noise and vibration are generated during air discharge
Solution Approach 1:
The panel is extracted or detached from the drain pan to form the outlet port. This separation eliminates the exposed joining portions between the drain pan and case that would otherwise be exposed to the air flow path, thereby preventing noise and vibration generation during air discharge while maintaining simplified assembly through the coupling structure.
3Reliability
If the mount portion protrudes inward to support the condensate pump, then pump support is provided, but airflow is obstructed and noise increases
Solution Approach 1:
The mount portion is designed to extend in a direction that does not obstruct the main airflow path. By changing the spatial dimension or orientation of the mount portion extension, the condensate pump is supported reliably while minimizing interference with air flow, thereby reducing noise generation from airflow obstruction.
4Ease of operation
If wires are arranged without guidance between control box and fan motor, then installation flexibility is improved, but wire arrangement becomes complex and vibration noise occurs
Solution Approach 1:
A wire guide structure is introduced as an intermediary element to manage wire arrangement. The wire guide provides a designated path for wires between the control box and fan motor, simplifying the wiring process while preventing wire chaos and vibration-induced noise, thus resolving the contradiction between installation flexibility and arrangement complexity.
Data Source
AI summary
An indoor unit or device of an air conditioner is provided that may include an outer plate configured to form an exterior of a cabinet configured to be installed at a ceiling of an indoor space; an inner case accommodated inside of the outer plate, and configured to form an internal space of the cabinet; a fan provided inside of the inner case; a heat exchanger provided to cover an outer side of the fan; a panel configured to shield the cabinet, and having an inlet port through which indoor air may be suctioned in and a panel outlet port through which heat-exchanged air may be discharged; and a drain pan assembly seated on an upper end of the inner case, and configured to collect condensate generated from the heat exchanger. An extension that extends to an open end of the outer plate may be formed at a side surface of the inner case corresponding to the panel outlet port, and a recess, which may be recessed in a shape corresponding to the panel outlet port, may be formed at an outer end of the drain pan assembly. Both ends of the extension may be in contact with an inner side surface of the recess, and form an outlet port which is in communication with the panel outlet port.