Console Box Mounting for Flush Hot Water Front Panels
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Solution Overview
Problem
Conventional hot water supply systems suffer from appearance degradation due to non-uniform clearance between the console box and the front panel, which increases production costs and component count by requiring additional covers to hide misalignment issues.
Innovation Solution
The system incorporates a console box attached to the casing with vertical and horizontal play, allowing it to fit tightly within a window of matching size, eliminating the need for a cover and reducing production costs while ensuring reliable alignment and attachment of the front panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the window is made larger than the console box contour to accommodate misalignment, then the console box can be fitted into the window even with misalignment, but a clearance is produced between the console box and the window which degrades the appearance
Solution Approach 1:
The console box is designed to move vertically and horizontally relative to the casing, transforming from a static fixed component to a dynamic adjustable one. This allows the console box to self-align with the window opening during assembly, eliminating clearance issues while maintaining tight fit appearance, and resolving the contradiction between misalignment tolerance and appearance.
2Shape
If a cover is attached onto the front face of the front panel to hide the clearance, then the appearance is not degraded, but the number of components increases and the production cost also increases
Solution Approach 1:
The cover component is completely removed from the system. Instead of using a cover to hide the clearance, the invention eliminates the clearance itself by allowing the console box to move and self-align with the window opening, thus achieving good appearance without the additional cover component and reducing overall system complexity.
Solution Approach 2:
The console box performs self-alignment with the window opening through its vertical and horizontal movement capability. During assembly, the console box automatically positions itself to eliminate clearance, without requiring external alignment tools or additional components like covers, thereby achieving self-service alignment that simplifies the overall structure.
3Device complexity
If the console box is fixed to the casing, then the structure is simple, but a misalignment between the front panel and the console box causes the console box to interfere with the perimeter of the window, preventing the front panel from being attached to the casing
Solution Approach 1:
The console box is designed with vertical and horizontal movement capability relative to the casing, allowing it to dynamically adjust its position during assembly. This dynamic design enables the console box to accommodate misalignment between the front panel and casing, ensuring reliable attachment without interference with the window opening perimeter.
Solution Approach 2:
The console box is pre-equipped with movement mechanisms that allow it to self-align with the window opening before the front panel is attached to the casing. This preliminary alignment action prevents interference issues during assembly, ensuring that the front panel can be reliably attached without console box obstruction.
Data Source
AI summary
A hot water supply system includes: a casing 1 having an opening in a front face; a front panel 2 covering the front face of the casing; and a console box 7 attached to the casing. The front panel has a window into which the console box is to be fitted. The clearance between the window and the console box is eliminated to improve the appearance of the system, and it is provided that the front panel can be attached to the casing without problems. In order to eliminate the clearance between the window 20 and the console box 7, the window 20 has a size enough for the console box 7 to be tightly fitted therein. In order that the console box 7 fitted in the window 20 can move vertically and horizontally together with the front panel 2, a support plate 8 for the console box 7 is attached to the casing 1 with a vertical and a horizontal play.