Integrated Drain Panel Housing for Compact Airflow Air Conditioners
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Solution Overview
Problem
Conventional air conditioners require separate molds and components for the housing and drain panel, leading to increased material usage and complexity, as well as the need for additional support members, which complicates the manufacturing process and results in a heavier product.
Innovation Solution
The integration of the housing and drain panel through injection molding, eliminating the need for a redundant support member and reducing the number of components, while incorporating a mixed-flow fan and heat exchanger design that minimizes interference and optimizes airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the housing and drain panel are prepared separately and combined, then the structural integrity is maintained, but the number of molds and components increases
Solution Approach 1:
The housing and drain panel are integrated into a single unified structure through injection molding, eliminating the need for separate components and assembly processes. This merging reduces the number of molds and components while maintaining structural integrity through the integrated design.
2Ease of manufacture
If separate molds are fabricated for housing and drain panel, then manufacturing flexibility is maintained, but material usage and fabrication complexity increase
Solution Approach 1:
The housing and drain panel are manufactured as a single integrated component through injection molding, eliminating the need for separate molds and assembly processes. This reduces fabrication complexity and material usage while maintaining manufacturing flexibility.
3Stability of the object's composition
If a support member is added to support the drain panel, then structural stability is improved, but product weight increases
Solution Approach 1:
The housing and drain panel are integrated into a single structure that provides inherent structural stability without requiring additional support members. This eliminates redundant components and reduces product weight while maintaining structural integrity.
4Device complexity
If the housing and drain panel are integrated through injection molding, then the number of components is reduced, but manufacturing process complexity increases
Solution Approach 1:
The housing and drain panel are integrated through a single injection molding process that creates a unified structure in one manufacturing step. This reduces the number of components and assembly operations while the injection molding process itself handles the manufacturing complexity efficiently.
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 integration reduces the number of molds and components, results in a lighter product, increases the inner space for additional support, and enhances durability by providing robust structural support, while improving operational efficiency and reducing noise levels.
Implementation Method 1
at least one heat exchanger to exchange heat with external air through the suction inlet
Implementation Method 2
a blower fan to suction the indoor air into the panel and blow the same to the room
Implementation Method 3
a drain panel disposed at a lower portion of the heat exchanger to collect condensate produced during heat exchange
Data Source
AI summary
An air conditioner includes a housing including a front panel provided with at least one opening, and a rear lower panel disposed at a rear side of the front panel, at least one discharge outlet exposed to a front of the front panel through the opening, at least one suction inlet formed in the housing, at least one heat exchanger to exchange heat with external air through the suction inlet, at least mixed-flow fan rotatably disposed between the heat exchanger and the discharge outlet to suction the air having exchanged heat with the heat exchanger and discharge the air through the discharge outlet, and a drain panel disposed at a lower portion of the heat exchanger to collect condensate produced during heat exchange, and integrated with the rear panel through injection molding.