Outdoor Unit Flange Structure to Prevent Rust From Bend Wrinkles
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Solution Overview
Problem
Wrinkles in the upper corner bend portion of outdoor air-conditioning units cause inaccurate fitting of the top panel, leading to reduced workability and potential rust formation due to rubbing and coating damage.
Innovation Solution
Incorporating an inclined portion between the corner bend and linear portions of the flange in the outer shell panel to ensure the wrinkled area lies within the ideal bending line, preventing contact with the top panel and minimizing rust formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the top panel is mounted to the upper side of the outer shell panel, then the casing is completed, but the top panel does not fit accurately due to wrinkles in the upper corner bend portion, resulting in deterioration of workability
Solution Approach 1:
The patent applies preliminary action by pre-forming an inclined portion in the flange before the corner bend portion during the sheet metal forming process. This inclined portion is created in advance to accommodate and hide the wrinkles that will form during bending, preventing them from interfering with the subsequent top panel installation and ensuring accurate fitting without requiring rework.
Solution Approach 2:
The inclined portion acts as an intermediary element between the wrinkled corner bend portion and the top panel. By introducing this intermediate structure, the wrinkles are contained within the inclined portion rather than directly contacting the top panel, thereby mediating the interaction and preserving both workability and fitting accuracy.
2Ease of manufacture
If the top panel is forcefully pushed to fit the upper side of the outer shell panel, then fitting is achieved, but rubbing occurs between the top panel and the wrinkled portion, causing coating to come off and rust to form
Solution Approach 1:
The inclined portion serves as a protective intermediary that prevents direct contact between the top panel and the wrinkled corner bend portion. This intermediary structure eliminates the rubbing action that would otherwise occur during panel installation, preserving the coating integrity and preventing rust formation while still achieving proper fitting.
Solution Approach 2:
The patent applies preliminary anti-action by designing the inclined portion to preemptively prevent the harmful rubbing effect. By structuring the flange with this inclined portion before assembly, the design anticipates and counteracts the potential damage that would occur during panel installation, protecting the coating and preventing rust before the problem can manifest.
3Manufacturing precision
If a cut is made in the upper corner bend portion to reduce its height, then wrinkle formation is minimized, but the structure becomes more complex and workability is deteriorated
Solution Approach 1:
The patent applies local quality by creating an inclined portion only in the specific local area where wrinkles form (the flange leading into the corner bend), rather than applying a global solution like cutting the entire corner bend portion. This localized modification reduces wrinkles effectively while maintaining the overall structural integrity and simplicity of the panel design.
Solution Approach 2:
The inclined portion is formed as part of the preliminary sheet metal forming process, integrating the wrinkle-reduction feature into the base manufacturing step. This preliminary action eliminates the need for subsequent cutting or complex structural modifications, thereby reducing wrinkles without increasing device complexity or deteriorating workability.
Data Source
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AI summary
[Object] To provide an outdoor unit having a structure that prevents formation of rust, without deterioration of workability even with the formation of wrinkles in an upper corner bend portion. [Solution] In an outdoor unit 60, an upper corner bend portion 12b is connected to a linear portion 12g of a flange 12a via an inclined portion 12d that is located inside an ideal bending line 12c of the upper corner bend portion 12b.