Air handling unit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air handling units face challenges with complex assembly processes, excessive assembly operations, and increased logistics and transportation costs due to the need for precise coupling of multiple panels and frames, which results in delayed installation and higher costs.
Innovation Solution
The air handler is designed with modular components, including an air suction module, mixing module, and air discharge module, which can be assembled using a simplified sliding coupling method between module frames and case panels, reducing the number of assembly operations and eliminating the need for extensive screw fastening and secondary sealing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple panels are coupled to frames using screws to achieve high coupling strength, then air leakage is prevented, but the number of assembly operations increases excessively
Solution Approach 1:
The patent extracts the sealing function from the mechanical fastening process by introducing a separate sealing member (gasket) that is coupled between the panel and frame. This allows the screw to primarily provide mechanical strength while the gasket handles the sealing requirement, reducing the need for excessive screws and complex assembly operations
Solution Approach 2:
The sealing member (gasket) acts as an intermediary element between the panel and frame. It is inserted into a groove on the panel and coupled with the frame, mediating the connection between these two components and providing both sealing and structural support functions
2Reliability
If electrical insulating tape and sealant are applied to prevent air leakage, then sealing is improved, but the assembly process becomes more complicated
Solution Approach 1:
The patent replaces expensive and time-consuming sealing methods (electrical insulating tape and liquid sealant) with a more efficient sealing member (gasket) that provides equivalent or superior sealing performance. The gasket is a pre-formed component that simplifies the assembly process while maintaining reliable sealing
Solution Approach 2:
The invention changes the physical state and form of the sealing element from flexible materials (tape, liquid sealant) to a structured gasket component with a specific groove configuration. This parameter change allows for more consistent sealing performance and easier assembly
3Reliability
If all component elements are transported to installation site and completely assembled on site, then the unit is fully functional, but logistics and transportation costs increase
Solution Approach 1:
The patent segments the air handler into modular components (frames, panels, sealing members, internal components) that can be separately manufactured and transported. These segmented components are then assembled at the installation site, reducing transportation costs while ensuring the unit is fully functional when complete
4Stability of the object's composition
If a plurality of frames and panels are used to define flow passages, then the air handler is structurally sound, but the coupling process requires excessive screws and time
Solution Approach 1:
The patent extracts the sealing function from the screw fastening process by using a dedicated sealing member (gasket) system. This allows fewer screws to be used, as the gasket provides both sealing and structural support, thereby reducing assembly time while maintaining structural integrity
Solution Approach 2:
The sealing member is pre-positioned in a groove on the panel before the frame is attached. This preliminary action ensures proper alignment and sealing from the start of the assembly process, reducing the time needed for adjustment and rework
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An air handler and a fan module for an air handler are provided. The fan module may include a plurality of box frames that form a framework of at least one fan box; a plurality of safety nets coupled to the framework of the at least one fan box formed by the plurality of box frames to form surfaces of the at least one fan box; and at least one box frame connector that interconnects neighboring one of the plurality of box frames to form the framework of the at least one fan box, wherein the at least one box frame connector has a fan box connection end configured to assist connection of the neighboring one of the plurality of fan boxes. As such, manufacturing costs may be reduced due to reduction in a number of components, and assembly time may be remarkably reduced due to a reduced number of assembly operations. This advantageously results in reduced labor cost and enhanced air conditioning efficiency.