Ceiling Air Conditioner Drain Pan Structure for Low-Resistance Air Discharge
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Solution Overview
Problem
Conventional ceiling-embedded air conditioners face limitations in air-discharge performance due to restricted ventilation resistance caused by the design of the drain pan's communication ports, which restrict the area of the opening and hinder efficient air discharge into the room.
Innovation Solution
The drain pan is redesigned with a thermal insulating member and a synthetic resin member, where the outer sidewall at the boundary with the communication port is composed of the resin member, reducing thickness and increasing the lateral dimension of the communication port, thereby enhancing the area of the opening and reducing ventilation resistance, and the engagement portions for the decorative panel are formed integrally with the synthetic resin member to simplify attachment and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the communication port is designed with traditional thermal insulating member structure, then thermal insulation is maintained, but the opening area is restricted and ventilation resistance increases
Solution Approach 1:
The patent applies local quality by using different materials for different parts of the drain pan. The peripheral wall away from the communication port uses thermal insulating member for insulation, while the peripheral wall at the communication port location uses synthetic resin member to reduce thickness and increase opening area. This localized material differentiation resolves the contradiction between maintaining insulation and increasing ventilation efficiency.
Solution Approach 2:
The drain pan employs composite material construction by combining thermal insulating member and synthetic resin member in a single structure. This composite approach allows the pan to simultaneously achieve thermal insulation where needed and minimal thickness at the communication port for improved air discharge performance, effectively resolving the contradiction between insulation requirements and ventilation needs.
2Strength
If the peripheral wall thickness is increased for structural strength, then manufacturing robustness improves, but the communication port opening area decreases and air discharge performance deteriorates
Solution Approach 1:
The patent implements local quality by varying the thickness of the peripheral wall based on location. The wall thickness is reduced specifically at the communication port location to maximize opening area for air discharge, while other portions of the drain pan maintain sufficient thickness for structural strength and manufacturing robustness. This localized thickness variation resolves the contradiction between structural requirements and air discharge performance.
3Ease of manufacture
If separate components are used for drain pan and decorative panel attachment, then manufacturing flexibility is maintained, but assembly complexity increases and manufacturing cost rises
Solution Approach 1:
The patent applies the merging principle by integrating the engagement portions for decorative panel attachment directly into the synthetic resin member of the drain pan. This integration eliminates the need for separate attachment components, simplifying both the drain pan structure and the overall assembly process. The merged design reduces manufacturing complexity and cost while maintaining functional requirements.
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
This design increases the area of the communication port opening, improves air-discharge performance by reducing ventilation resistance, and simplifies the attachment process, leading to enhanced air-conditioning efficiency and cost-effectiveness.
Implementation Method 1
a drain pan which receives drain water produced in a heat exchanger and comprises a thermal insulating member
Data Source
AI summary
According to one embodiment, a ceiling-embedded air conditioner includes a main body incorporating a heat exchanger, a decorative panel attached to a lower edge of the main body and including a discharge port discharging air heat-exchanged in the heat exchanger to a room, and a drain pan including a thermal insulating member and a synthetic resin member coating the thermal insulating member. The drain pan includes a recess for receiving drain water produced in the heat exchanger, a communication port provided on a periphery of the recess and communicating with the discharge port of the decorative panel, and a wall standing between the periphery of the recess and the communication port. The wall is composed of the synthetic resin member.