Metal Front Panel Assembly for Quiet Wall-Mounted Air Conditioners
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Solution Overview
Problem
Wall-mounted air conditioner indoor units face issues with vibration-induced noise due to lightweight plastic resin panels and are prone to damage and deformation when coupled with heavier metal panels, leading to coupling failures and contamination concerns.
Innovation Solution
A metal front panel is used with a support frame made of plastic resin, coupled via a bracket to reduce vibration and weight transmission, allowing for easy adjustment of air flow direction and preventing contamination, while maintaining a stylish appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight plastic resin front panel is used, then the total weight of the indoor unit is reduced, but vibration noise increases due to panel vibration
Solution Approach 1:
The invention uses a composite structure combining a metal front panel (for vibration resistance) with a plastic resin support frame (for weight reduction). The metal panel is coupled to the support frame via brackets, creating a hybrid structure that leverages the advantages of both materials: the metal provides stiffness and vibration damping while the plastic frame keeps the overall weight low.
2Object-generated harmful factors
If a heavy metal front panel is used, then vibration noise is reduced, but the panel and coupling structure are prone to deformation and separation
Solution Approach 1:
The invention divides the front panel assembly into separate components: the metal front panel, the plastic support frame, and coupling brackets. This segmentation allows each component to be optimized independently - the metal panel for vibration resistance, the plastic frame for structural support and weight management, and the brackets for secure coupling - while working together as an integrated system that prevents deformation and separation.
Solution Approach 2:
The coupling brackets act as intermediary elements between the metal front panel and the plastic support frame. These brackets are specifically designed to accommodate the different material properties of metal and plastic, providing a secure mechanical connection that prevents the metal panel from deforming or separating while allowing for thermal expansion and contraction differences between the two materials.
3Object-generated harmful factors
If a heavy metal front panel is used, then vibration noise is reduced, but the outdoor unit becomes more expensive and harder to manufacture
Solution Approach 1:
The invention uses a composite structure combining a metal front panel (for vibration resistance) with a plastic resin support frame (for weight reduction). The metal panel is coupled to the support frame via brackets, creating a hybrid structure that leverages the advantages of both materials: the metal provides stiffness and vibration damping while the plastic frame keeps the overall weight low.
Data Source
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AI summary
Provided is an indoor unit of an air conditioner. In the indoor unit of the air conditioner, a front panel made of a metal material may be provided to reduce vibration even if vibration generated in a blower fan is transmitted to the front panel. Also, the front panel may be made of a relatively lightweight aluminum material of the metal materials to relatively reduce the total weight of the indoor unit.