Stackable Outdoor Unit Modules for Flexible AC 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 size of the metal mold increases with capacity, leading to higher prices for larger units with lower demand.
Innovation Solution
The outdoor unit is designed with stackable components, such as heat exchangers, air-blower assemblies, and housings, allowing for the creation of units with varying capacities using smaller molds by stacking these components in a vertical direction, reducing the need for extensive mold investment and enabling flexible capacity adjustments.
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 module, second module, third module, fourth module) that can be independently manufactured using small-size molds. These modules are then stacked in vertical layers to achieve the required air-conditioning capacity, eliminating the need for large-size molds while maintaining high capacity performance.
Solution Approach 2:
Instead of increasing horizontal dimensions to achieve larger capacity, the patent transitions to vertical stacking of standardized modules. This dimensional change allows multiple small modules to be combined vertically to create high-capacity units, thereby avoiding the need for expensive large-size molds while achieving the same or greater air-conditioning capacity.
2Power
If the size of metal mold is increased to produce large capacity outdoor units, then the air-conditioning capacity increases, but the manufacturing cost rises considerably
Solution Approach 1:
A universal standardized module design is created that can serve multiple capacity requirements. The same small-size mold produces modules that can be stacked in different quantities (1 layer, 2 layers, 3 layers, or more) to achieve various air-conditioning capacities, making the mold investment applicable to multiple product specifications and reducing overall manufacturing costs.
Solution Approach 2:
The patent changes the key parameter from mold size to stacking configuration. Instead of using large molds to create single large-capacity units, small molds produce standardized modules whose capacity contribution is adjusted by changing the stacking configuration (number of layers and module arrangement), thereby achieving variable capacity output from fixed small-size molds.
3Ease of manufacture
If standardized small-size modules are stacked vertically to achieve large capacity, then mold investment is reduced, but the device complexity increases
Solution Approach 1:
The outdoor unit is segmented into identical or similar standardized modules with uniform interfaces and connection methods. This segmentation, combined with modular design, simplifies the stacking process despite the increased number of components, as each module follows the same design pattern and connection protocol, reducing the actual complexity of assembly.
Solution Approach 2:
Multiple standardized modules are merged through vertical stacking with standardized connection interfaces. The merging process is simplified by designing modules that can be directly connected in sequence, eliminating the need for complex custom integration for each capacity level, thereby reducing device complexity despite the modular approach.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for the production of outdoor units with large air-conditioning capacities using small-size molds, reducing costs and enabling efficient manufacturing of units that can meet different capacity requirements without the need for extensive mold adjustments, thus providing a cost-effective solution for units of varying sizes.
Implementation Method 1
an outdoor heat exchanger (2)
Data Source
AI summary
According to one embodiment, 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.