Vertical Control Box Layout for Compact Air Conditioner Assembly

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Solution Overview

Problem

Conventional air conditioners are bulky due to a large control box that occupies space, and electronic components within the control box are prone to heat damage and difficult to assemble, making them inefficient and hard to move.

Innovation Solution

The air conditioner design features a control box mounted vertically across the main drain pan, with electronic components exposed to airflow for cooling and a side that can be folded for improved assembly and reduced wire length, enhancing space efficiency and installation stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the control box is enclosed by a cover, then the electronic components are protected from external damage, but the heat generated and accumulated in the control box may damage the electronic components

Engineering Contradiction:

Improveprotection of electronic componentsVSAvoidheat damage to electronic components

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The control box is divided into two parts: an enclosed control unit housing the electronic components, and an exposed capacitor. This segmentation allows the capacitor to be cooled by airflow while the electronic components remain protected within the enclosed housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The capacitor is extracted from the enclosed control box and positioned externally. This extraction removes the heat-generating component from the enclosed space, allowing it to be cooled by ambient airflow while the electronic components remain protected inside the enclosed housing.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If the control box occupies a large space, then the electronic components can be properly housed, but the overall size of the air conditioner increases

Engineering Contradiction:

Improvehousing of electronic componentsVSAvoidoverall size of air conditioner

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The control box is reoriented from a horizontal arrangement to a vertical arrangement, standing upright on the base pan. This dimensional change allows the control box to utilize vertical space more efficiently, reducing its horizontal footprint and thereby decreasing the overall size of the air conditioner.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

One side of the control box is designed to be foldable, transforming the rigid structure into a flexible one. This flexibility allows the control box to be compact during operation while facilitating easier assembly and disassembly, reducing the space required for manufacturing and handling.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the control box is enclosed, then the electronic components are protected, but the assembling capability is deteriorated due to small inner space

Engineering Contradiction:

Improveprotection of electronic componentsVSAvoidassembling capability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

One side of the control box is designed to be foldable, transforming the rigid structure into a flexible one. During assembly, this side can be unfolded to provide access to the electronic components, making assembly easier. Once assembly is complete, the side can be folded back to enclose and protect the components.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The foldable side is designed to be unfolded during the assembly process, providing preliminary access to the electronic components before they are permanently installed. This preliminary action facilitates easier assembly while maintaining protection during operation.

Inventive Principle:

Principle #10Preliminary action

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 results in a more compact air conditioner, prevents electronic component damage from heat, improves assembly capabilities, reduces manufacturing costs, and enhances product reliability by minimizing wire length and preventing short circuits.

Implementation Method 1

a capacitor exposed out of the control box by penetrating a side of the control box and thus cooled by air flowing in the air conditioner

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS7735332B2Air conditioner

Publication Date: 2010.06.15 LG ELECTRONICS INC

AI summary

There is provided an air conditioner. The air conditioner includes a main drain pan dividing an inner space of the air conditioner into upper and lower halves, a base pan defining a lower outer appearance of the air conditioner, an indoor blower unit that is installed on an upper portion of the main drain pan to guide introduction and discharge of indoor air, and a control box in which a plurality of electronic components controlling the operation of the air conditioner are installed. The control box is installed vertically across the main drain pan.