Electric Control Box Cover Structure for Air Conditioner Waterproofing
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Solution Overview
Problem
The existing electric control boxes in air conditioners are prone to moisture damage due to assembly gaps between the bottom plate and box cover, allowing external water to penetrate and harm the internal electrical components.
Innovation Solution
The electric control box design includes a water blocking member on the inner box cover that protrudes outward to prevent water from flowing into the inner box cover, combined with a drainage system and heat dissipation features to enhance waterproofing and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple box structure with bottom plate and box cover is used, then manufacturing is easy and cost is low, but waterproof performance deteriorates due to assembly gaps
Solution Approach 1:
The box cover is segmented into an outer box cover and an inner box cover, with the inner box cover further divided into multiple functional parts including the water blocking member. This segmentation allows the waterproofing function to be separated from the basic structural function, enabling the assembly gap to be sealed without redesigning the entire box structure.
Solution Approach 2:
A water blocking member is introduced as an intermediary component between the outer box cover and the inner box cover. This water blocking member protrudes from the edge of the inner box cover toward the outer box cover, effectively blocking water flow paths through the assembly gap while maintaining the simplicity of the overall box structure.
2Device complexity
If the box cover is made as a single integrated piece, then assembly is simple, but waterproof performance deteriorates due to inability to block water flow paths
Solution Approach 1:
The box cover is divided into an outer box cover and an inner box cover, allowing different parts to serve different functions. The inner box cover includes a water blocking member that specifically addresses waterproofing, while the outer box cover provides the basic protective enclosure.
Solution Approach 2:
The water blocking member is positioned at specific locations on the inner box cover where water flow paths are most likely to occur. This local enhancement of waterproofing capability allows the box cover to maintain simplicity overall while providing targeted protection at critical areas.
3Reliability
If assembly gaps are reduced to improve waterproofing, then manufacturing precision requirements increase, but manufacturing cost and difficulty increase
Solution Approach 1:
Instead of reducing assembly gaps through tighter tolerances, a water blocking member is introduced as an intermediary element that actively blocks water flow paths. This approach maintains loose assembly tolerances while achieving effective waterproofing.
Solution Approach 2:
The water blocking member changes the parameter of water flow path by introducing a physical barrier that protrudes into the assembly gap. This active blocking mechanism replaces the passive reliance on tight gaps, allowing manufacturing to proceed with standard tolerances.
Data Source
AI summary
An electric control box includes a box body including a bottom plate and a box cover covering the bottom plate. The box cover include an outer box cover and an inner box cover. The inner box cover includes a water blocking member at an edge of the inner box cover. The water blocking member protrudes outward from the edge of the inner box cover toward an edge of the outer box cover. The water blocking member is configured to block water on the outer box cover from flowing into the inner box cover.