Stackable Outdoor Unit Layout for Scalable Air-Conditioning Capacity
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Solution Overview
Problem
The existing outdoor units of air conditioners require large and expensive molds for manufacturing, which increases costs and makes it impractical to produce units with varying air-conditioning capacities, as the demand for larger units is lower than smaller ones.
Innovation Solution
The outdoor unit design allows for the stacking of components in a vertical direction, using small-size parts and molds, enabling the creation of units with varying capacities by combining single-stage, deformed single-stage, and two-stage units, reducing the need for extensive mold investments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large-size molds are used to manufacture outdoor units with large air-conditioning capacity, then the air-conditioning capacity is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The outdoor unit is divided into multiple standardized modules (first outdoor device, second outdoor device, mounting base table) that can be manufactured separately using small-size molds, then assembled to achieve large air-conditioning capacity without requiring large molds
Solution Approach 2:
The patent transitions from horizontal expansion (larger molds for larger capacity) to vertical stacking (stacking multiple standardized modules in vertical direction), enabling large capacity units to be built from small standardized components
2Power
If the size of outdoor units is increased to meet large air-conditioning capacity requirements, then the air-conditioning capacity is improved, but the price rises considerably
Solution Approach 1:
The system is segmented into standardized modules that can be combined in different configurations (single stage, two stages, or more) to meet various capacity requirements, providing price flexibility through modular selection rather than custom large-unit manufacturing
Solution Approach 2:
The standardized modules serve multiple functions - they can be used individually or stacked in series to create units of different capacities, making the same basic component universally applicable across multiple product tiers and price points
3Power
If different sizes of component parts are manufactured to match varying air-conditioning capacity requirements, then the air-conditioning capacity is improved, but the number of mold investments increases
Solution Approach 1:
Instead of changing the physical dimensions of component parts (which would require different molds), the patent changes the quantity and arrangement parameters - stacking multiple identical standardized modules to achieve different capacities while maintaining the same mold specifications
Data Source
Figure 1A
Figure 1B~2A
Figure 2B~2C
AI summary
An object of the present invention is to provide an outdoor unit of an air conditioner which is basically composed of small-size component parts and can have a large air-conditioning capacity by stacking the small-size component parts in a vertical direction in accordance with a required air-conditioning capacity. The outdoor unit of an air conditioner includes an outdoor heat exchanger, an air-blower assembly including an air exchanger, and a housing accommodating the outdoor heat exchanger and the air-blower assembly. The outdoor heat exchanger, the air-blower assembly and the housing, and another outdoor heat exchanger, another air-blower assembly and another housing are configured to be stackable on each other in a vertical direction.