Indoor Unit Front Panel Reinforcement Against Plastic Warping
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Solution Overview
Problem
Air-conditioning apparatus indoor units with plastic design panels suffer from low rigidity, leading to warping and poor exterior design quality due to the lack of structural support, particularly in the middle part, where engaging projections often fail to engage correctly.
Innovation Solution
Incorporating a reinforcement member with a longitudinal shape extending across the middle part of the design panel, fixed to both the front panel and flange, enhances the panel's rigidity and prevents warping by providing additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the design panel is made of plastic to achieve aesthetic design quality, then the exterior appearance is improved, but the rigidity decreases causing warping and poor engagement
Solution Approach 1:
The patent combines plastic material (for aesthetic appearance) with metal reinforcement members (for rigidity) to create a composite structure. The design panel is made of plastic to maintain good exterior appearance, while metal reinforcement members are embedded within the panel to provide the necessary rigidity and prevent warping, thus resolving the contradiction between aesthetic appearance and structural strength
Solution Approach 2:
The patent applies reinforcement members at specific locations within the design panel rather than making the entire panel rigid. The reinforcement members are strategically positioned to provide local support where rigidity is most needed, allowing the overall panel to maintain its plastic aesthetic quality while having localized areas of enhanced strength to prevent warping
2Area of stationary object
If the design panel size is increased to match larger air-conditioning apparatus, then the coverage area is improved, but the warping tendency increases due to reduced rigidity
Solution Approach 1:
For larger design panels that are more prone to warping, the patent incorporates metal reinforcement members within the plastic panel structure. This composite construction provides the necessary rigidity to large panels, preventing them from warping while maintaining their aesthetic appearance and full coverage area
Solution Approach 2:
The patent divides the large design panel into sections by incorporating multiple reinforcement members at different locations. This segmentation approach allows each section to be supported independently, preventing overall warping of the large panel while maintaining its full size and coverage area
3Reliability
If engaging projections are added at multiple locations including middle part, then the fixation reliability is improved, but the design panel flexes when forcibly engaged due to low rigidity
Solution Approach 1:
The patent uses metal reinforcement members embedded in the plastic design panel to provide the necessary rigidity at locations where engaging projections are positioned. This allows multiple engaging projections (including at the middle part) to be effectively used for fixation without causing the panel to flex during engagement, as the reinforcement members provide structural support
Data Source
AI summary
An air-conditioning apparatus indoor unit includes: a plastic design panel that includes a front panel part having a rectangular shape in front view and a flange part projecting toward a back surface from one longitudinal edge of the front panel part; and a reinforcement member that has a shape extending in the longitudinal direction of the front panel part across a middle part of the design panel and is fixed to the design panel so as to be in contact with a back surface of the front panel part and an inner surface of the flange part.