Modular Air Handler Sliding Coupling for Fast Sealed Assembly
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Solution Overview
Problem
Existing air handling units face challenges with complex assembly processes, excessive number of assembly operations, and increased logistics and transportation costs due to the need for on-site assembly of multiple components, which leads to delayed installation and higher costs.
Innovation Solution
The air handler is designed as a modular system comprising an air suction module, mixing module, and air discharge module, assembled using a combination of module frames, case panels, and connecting members, allowing for simplified assembly through sliding coupling without screws, reducing the number of assembly operations and eliminating the need for additional sealing operations.
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 prevention is improved, but assembly complexity and assembly time increase
Solution Approach 1:
The patent replaces the mechanical screw fastening system with a friction-based press-fit system. The panel insertion portions are fitted into frame grooves through frictional contact, eliminating the need for screws while maintaining coupling strength. This substitution reduces assembly complexity from multiple screw operations to a simple insertion motion, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The friction-based coupling mechanism is self-service in nature, where the friction force between the panel insertion portion and frame groove automatically provides both the coupling strength and sealing pressure. The system self-regulates the coupling force through material friction properties, eliminating the need for additional fastening components and operations, thus reducing assembly complexity while maintaining reliable air leakage prevention.
2Reliability
If electrical insulating tape and sealant are applied to prevent air leakage, then sealing performance is improved, but assembly time and installation costs increase
Solution Approach 1:
The patent extracts and eliminates the separate sealing operations (electrical insulating tape wrapping and sealant application) by integrating sealing functionality directly into the friction-based coupling mechanism. The friction contact between panel and frame simultaneously provides both mechanical coupling and air leakage prevention, removing the need for additional sealing materials and operations, thus reducing assembly time while maintaining sealing performance.
Solution Approach 2:
The patent merges the coupling function and sealing function into a single friction-based mechanism. The same frictional contact that provides mechanical coupling strength also creates the seal by preventing air passage between panel and frame. This merging of functions eliminates the need for separate sealing operations, directly reducing assembly time while maintaining reliable sealing performance.
3Adaptability or versatility
If all component elements are transported to installation site for complete assembly, then assembly flexibility is improved, but logistics and transportation costs increase
Solution Approach 1:
The patent segments the air handler into modular components (frames and panels) that can be independently manufactured and transported. The simple friction-based coupling mechanism allows these segments to be easily assembled on-site without requiring all components to be transported complete. This segmentation enables flexible local assembly while reducing logistics costs by transporting only essential frame and panel elements rather than pre-assembled units.
Solution Approach 2:
The frames and panels are preliminarily prepared with integrated coupling features (grooves and insertion portions) during manufacturing. This preliminary action embeds the assembly capability directly into the components, allowing rapid on-site assembly through simple insertion operations. The pre-integrated friction coupling mechanism eliminates the need for complex on-site assembly operations, enabling flexible installation while minimizing transportation requirements.
Data Source
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AI summary
An air handler and a method of assembling a fan module are provided, in which a case panel may be assembled with a plurality of module frames via a considerably simplified sliding coupling providing excellent hermetic sealing. 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.