Indoor Unit Top Plate Rib Layout to Reduce Spring Back
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Solution Overview
Problem
Existing air conditioner indoor unit top plates face issues with deflection under static pressure and torsion due to lack of consideration for spring back after reinforcement rib formation, leading to increased manufacturing costs and weight.
Innovation Solution
The top plate is enhanced with longitudinal and lateral reinforcement ribs formed through stretch-forming and bending, dividing the plate into regions to minimize torsion and flexure, and edge bending ribs are added to increase rigidity without additional components, thus improving work efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If L-shaped angle bar is spot-welded to the top plate to increase rigidity, then the rigidity of the top plate is improved, but the manufacturing cost and weight increase due to additional components
Solution Approach 1:
The reinforcement function is merged into the top plate itself by forming reinforcement ribs directly on the plate surface. This integrates the reinforcement function into the existing component rather than adding separate reinforcement elements, thereby improving rigidity without increasing component count or weight
Solution Approach 2:
The top plate undergoes stretch-forming process that changes its geometric parameters by creating raised reinforcement ribs with specific cross-sectional shapes. This parameter change in the plate geometry provides the necessary rigidity enhancement without requiring additional materials or components
2Strength
If reinforcement ribs are formed on the top plate to increase rigidity, then the manufacturing cost and weight increase, but the deflection and spring back are not adequately addressed
Solution Approach 1:
The top plate is divided into multiple regions by forming longitudinal and lateral reinforcement ribs that create distinct zones. This segmentation provides targeted reinforcement at specific locations, effectively controlling deflection and spring back in different areas of the plate through localized geometric features
Solution Approach 2:
The reinforcement ribs are formed with specific curved cross-sectional profiles through stretch-forming. The curved geometry of the ribs provides better resistance to deflection and spring back compared to flat reinforcements, as the curved shape distributes stresses more effectively and reduces elastic recovery
3Strength
If multiple reinforcement ribs are formed on the top plate, then the rigidity is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
Multiple reinforcement ribs (both longitudinal and lateral) are formed in a single integrated stretch-forming operation rather than through separate manufacturing steps. This combining of multiple reinforcement features into one manufacturing process simplifies production and reduces manufacturing time while achieving the desired rigidity enhancement
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 configuration significantly increases the overall rigidity of the top plate, reduces deflection and spring back, and simplifies the mounting process while maintaining cost-effectiveness and reducing weight.
Implementation Method 1
deflection of the top plate caused by static pressure and torsion and flexure of the top plate caused by spring back after the top plate is formed
Implementation Method 2
If the lateral reinforcement ribs 15, 16 are formed by stretch-forming, one or more first lateral reinforcement ribs 15 and one or more second lateral reinforcement ribs 16, which are formed in the first region 13a and the second region 13b, respectively, decrease torsion and flexure of the top plate 13 caused by spring back after the first and second lateral reinforcement ribs 15, 16 are formed
Data Source
Figure 1~2
Figure 3(a)~4
AI summary
An air conditioner indoor unit A includes a body casing 1, which accommodates a fan 2 and a heat exchanger 3. A top plate 13 is arranged in an upper portion of the body casing 1. A longitudinal reinforcement rib 14, which divides the top plate 13 into a first region 13a and a second region 13b, is formed in the top plate 13. A first lateral reinforcement rib 15, which extends between the longitudinal reinforcement rib 14 and a corresponding one of side edges 13c of the top plate 13, is formed in the first region 13a. A second lateral reinforcement rib 16, which extends between the longitudinal reinforcement rib 14 and the other side edge 13c of the top plate 13, is formed in the second region 13b. The reinforcement ribs 14, 15, 16 thus significantly increase the rigidity of the top plate 13 as a whole. Further, if the first and second lateral reinforcement ribs 15, 16 are formed by stretch-forming, torsion and flexure of the top plate 13 caused by spring back after the ribs 15, 16 are formed are decreased. As a result, the top plate 13 is mounted with increased work efficiency.