Ceiling Air Conditioner Drain Pump Fixing to Reduce Manufacturing Cost
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ceiling-embedded air conditioner indoor units face high manufacturing costs due to the need for screw-fixed drain pumps within heat insulating members, requiring sheet metal with screw holes.
Innovation Solution
A low-cost structure for fixing the drain pump using a drain pump fixing member that sandwiches a fixing part, allowing the drain pump to be securely attached without inserting sheet metal with screw holes into the heat insulating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a drain pump is fixed to a heat insulating member with a screw, then the drain pump can be securely fixed, but sheet metal with a screw hole has to be inserted inside the heat insulating member and manufacturing cost is high
Solution Approach 1:
The fixing structure is divided into two separate members: a drain pump fixing member that directly contacts the drain pump, and a heat insulating member that provides thermal insulation. The fixing member is inserted into a groove formed on the heat insulating member, eliminating the need for screws and sheet metal with screw holes. This segmentation allows each component to perform its specific function independently while reducing manufacturing complexity and cost.
Solution Approach 2:
The drain pump fixing member acts as an intermediary component between the drain pump and the heat insulating member. Instead of directly fixing the drain pump to the heat insulating member with screws, the fixing member mediates the connection by being inserted into the groove on the heat insulating member and securing the drain pump through engagement with the fixing part. This intermediary approach eliminates the need for sheet metal with screw holes while maintaining secure fixation.
2Reliability
If a drain pump is fixed using conventional screw method, then the drain pump can be securely attached, but the structure becomes complex and manufacturing cost increases
Solution Approach 1:
The fixing structure is segmented into a heat insulating member with an integrated groove and a separate drain pump fixing member. The groove is formed directly on the heat insulating member, eliminating the need for additional sheet metal components with screw holes. This segmentation simplifies the overall structure by integrating the groove into the existing heat insulating member rather than adding separate fixing components.
Solution Approach 2:
The screw and sheet metal with screw holes are extracted from the fixing mechanism. Instead of using traditional screw fixation that requires punching holes through sheet metal and inserting it into the heat insulating member, the invention uses a groove-based system where the fixing member is inserted into a pre-formed groove. This extraction of unnecessary components (screws, sheet metal) reduces structural complexity and manufacturing steps.
3Reliability
If sheet metal with screw holes is inserted into heat insulating member, then drain pump can be fixed, but manufacturing cost is high
Solution Approach 1:
The groove for receiving the fixing member is merged into the heat insulating member itself, rather than being a separate component. The groove is formed directly on the heat insulating member through molding or other manufacturing processes. This merging eliminates the need for separate sheet metal with screw holes, reducing the number of parts and assembly steps while maintaining fixing stability through the groove-based engagement system.
Solution Approach 2:
The invention replaces expensive sheet metal with screw holes with a simpler, cheaper fixing member that can be made from less costly materials. The fixing member is designed to be inserted into the groove and secured without requiring durable sheet metal components. This substitution with a more economical component reduces manufacturing cost while maintaining adequate fixing functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces manufacturing costs by eliminating the need for sheet metal with screw holes, while enabling compact integration of the UV radiation device and float switch, effectively preventing drain slime and water overflow.
Implementation Method 1
a heat exchanger for exchanging heat with the air suctioned from the air inlet port
Data Source
AI summary
An indoor unit of an air conditioner includes an air inlet port for suctioning air inside a room, a heat exchanger for exchanging heat with the air suctioned from the air inlet port, an air outlet port for blowing the air after heat exchange by the heat exchanger out to the room, a drain pan provided below the heat exchanger, the drain pan being for receiving water generated at the heat exchanger, a drain pump for discharging water collected in the drain pan, and a drain pump fixing member for fixing the drain pump, where the drain pump fixing member is attached in a manner sandwiching a fixing part to which the drain pump is fixed.