DESC:AN INTEGRATED FRONT GRILL FOR AIR COOLER

FIELD OF INVENTION
[001] The present subject matter described herein relates to an integrated front cover structure of an air cooler. More particularly the present subject matter related to the integrated cover structure of the air cooler encompassing louvers and all the electrical connections and knobs and a method of producing the same thereof.

BACKGROUND
[002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] An air cooler is used for cooling effects or to cool the place. Further, the air cooler is provided with a grill on the front to provide the direction to the flowing air and the front grill also carries the operating knobs required to operate the air cooler. But these knobs further add up to the space required for the air cooler as these are arranged on the outside of the front grill.
[004] Thus more space is required for the air cooler to accommodate in a confined space. Furthermore, a separate assembly is required to be attached to the air cooler while assembling the air cooler on the production line. Then the knobs are separately attached to the front grill which again requires extra time on the production line. In short, the assembly process of the front grill and the knobs consumes a significant amount of time on the production line, leading to a reduction in overall productivity.
[005] Another related issue is the placement of the knobs outside the grill, along with the external positioning of the electrical connections which can potentially lead to operational problems. Additionally, there is a concern about the excessive space required for this arrangement.
[006] Thus there is a need to solve the above drawbacks and provide a cover structure that integrates the front grill having louvers to give direction to the flowing air, and accommodate electrical connections and knobs without acquiring extra space.

OBJECTS OF THE INVENTION
[007] It is therefore the object of the subject matter to overcome the aforementioned and other drawbacks in prior device/system/apparatus.
[008] The principal objective of the present subject matter is to provide an integrated front cover structure that accommodates louvers, electrical connections, and knobs.
[009] Another object of the present subject matter is to provide an integrated front cover structure so that electrical connections are not easily accessible for safety purposes.
[0010] Yet another object of the present subject matter is to provide an integrated front cover structure that has a sleek design.
[0011] Yet another object of the present subject matter is to provide an integrated grill so that the space requirement of the air cooler can be decreased.
[0012] Yet another object of the present subject matter is to provide an integrated grill comprising of louvers so that cost-cutting can be done in the air cooler.
[0013] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY
[0014] A solution to one or more drawbacks of existing technology and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0015] The present disclosure provides a solution in the form of an integrated front cover structure for an air cooler includes a base surface with an opening. A grill frame is defined around the outer periphery of the opening, comprising a first horizontal portion that extends forward from the base surface, a vertical portion that extends perpendicularly downward from the first horizontal portion, and a second horizontal portion that extends perpendicularly inward from the vertical portion towards the base.
[0016] In an aspect, the grill frame defines a plurality of ribs on outer surface of the vertical portion.
[0017] In an aspect, the first horizontal portion defines a width ‘W1’, the vertical portion has a width ‘W2’ and the second horizontal portion has a width ‘W3, wherein the width ‘W3’ is greater than the width ‘W1’ and the width ‘W2’, wherein the width ‘W2’ is greater than the width ‘W1’.
[0018] In an aspect, a plurality of switch mountings is provided on the base surface.
[0019] In an aspect, the opening defines a shape selected from rectangular, circular, oval, polygonal shape.
[0020] In an aspect, plurality of holes are provided on the second horizontal portion of the grill frame to receive a plurality of vertical and horizontal louvers, wherein the plurality of holes provided for the plurality of vertical louvers are defined at distance ‘D1’ from the lateral edge of the vertical portion, wherein the plurality of holes provided for the plurality of horizontal louvers are defined at distance ‘D2’ from the lateral edge of the vertical portion, wherein the distance ‘D1’ is greater than the distance ‘D2’.
[0021] In an aspect, a flange extends perpendicularly inward from each of the lateral side edges of the base.
[0022] In an aspect, the plurality of ribs starts from the outer edge of the vertical portion and end before the inner edge of the vertical portion.
[0023] In another aspect of the invention, a method of producing an integrated front cover structure of an air cooler is disclosed. The method comprises blanking a sheet of a material to obtain a base with an opening, embossing the blanked sheet to obtain an embossed frame with a predetermined geometry for the integrated front cover structure, piercing the embossed frame to create a plurality of openings such as a plurality of switch mountings and a plurality of holes, embossing the pierced sheet to obtain a grill frame having a first horizontal portion, a second horizontal portion, and a vertical portion; bending the embossed and pierced sheet on at least two lateral sides to form flanges to obtain the integrated front cover structure.
[0024] In an aspect of the invention, the sheet of material is selected from a group consisting of metal, plastic, composite, or a combination thereof.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0025] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0026] Fig. 1a illustrates a perspective front view of an integrated front cover structure according to the present disclosure;
[0027] Fig. 1b illustrates a perspective back view of the integrated front cover structure according to the present disclosure;
[0028] Fig. 2 illustrates a section view of a grill frame according to the present disclosure;
[0029] Fig. 3 illustrates a perspective view of the grill frame according to the present disclosure;
[0030] Fig. 4 illustrates the mounting of the vertical and horizontal louvers on the integrated front cover structure according to the present disclosure;
[0031] Fig. 5 and Fig. 6 illustrate a method of producing an integrated front cover structure according to the present disclosure.
[0032] The figures depict embodiments of the present subject matter for illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein

DETAILED DESCRIPTION OF INVENTION
[0033] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0034] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0035] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0036] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0037] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration of specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0038] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure.
[0039] The present invention relates to an integrated front cover structure of an air cooler. The integrated front cover structure of the air cooler functions as an orifice for airflow and also acts as a front grill since the horizontal and vertical louver assembly is integrated into its functionality. Further, the integrated front cover structure also has the assembly for all the product-related critical electrical connections required for the functioning of the present invention. As the functionality of the components is merged into one, the integrated front cover structure of an air cooler becomes sleek and elegant.
[0040] An embodiment of the present subject matter is presented here, focusing on a rectangular base for illustrative purposes. It is crucial to highlight that the scope of the present subject matter extends far beyond this specific configuration. This embodiment serves as an example of the application and functionality, underscoring its compatibility with a rectangular base. Nevertheless, it is essential to recognize that this depiction does not limit the subject matter’s potential to rectangular bases alone. The design flexibility of the invention seamlessly accommodates a variety of base shapes, making it a versatile solution for an array of air cooler designs. Whether the base takes on the form of a circle, oval, polygon, or others, the fundamental concepts of the invention remain adaptable and applicable, transcending specific geometries.
[0041] Fig. 1 (a) and Fig. 1 (b) illustrate the integrated front cover structure (100). The integrated front cover structure (100) is designed for air coolers, offering enhanced functionality and aesthetics. The integrated front cover structure (100) comprises a base surface (101) featuring an opening (102), that serves as a key inlet for air circulation.
[0042] The opening (102) of the integrated front cover structure (100) offers versatility, available in various shapes such as rectangular, circular, oval, or polygonal. The positioning of the opening (102) is carefully aligned with the design of the air cooler to optimize air intake. Further, the integration of switch mountings (201) on the base surface (101) enhances user convenience by allowing easy access to controls and switches.
[0043] Furthermore, the invention has a flange (104a, 104b) that extends perpendicularly inward from each lateral side of the base (101), further enhancing structural stability and enabling seamless integration with the air cooler assembly.
[0044] Refer to Fig. 2. A grill frame (105) is defined around the periphery of the opening (102) The grill frame (105) includes a first horizontal portion (201a) that extends forward from the base surface (101), a vertical portion (201b) that extends perpendicularly downward from the first horizontal portion (201a), and a second horizontal portion (201c) that extends inward from the vertical portion (201b) and towards the base (101). The integration of the first horizontal portion (201a), the second horizontal portion (201c), and the vertical portion (201b) ensures efficient airflow and contributes to the overall structural integrity of the integrated front cover structure (100).
[0045] In terms of dimensions, the first horizontal portion (201a) has a width ‘W1’, the vertical portion (201b) has a width ‘W2’ and the second horizontal portion (201c) has a width ‘W3.’ Further, the width ‘W3’ of the second horizontal portion (201c) surpasses both ‘W1’ and ‘W2’ of the first horizontal portion (201a) and the vertical portion (201b) respectively, with ‘W2’ surpassing ‘W1’, thereby creating a distinctive and purposeful dimensionality wherein W3>W2>W1.
[0046] Referring to Fig. 3, a series of ribs (301a, 301b) are incorporated onto the outer surface of the vertical portion (201b) of the grill frame (105). Further, the vertical portion (201b) has an outer edge (303a) and an inner edge (303b) on its surface and the ribs (301a, 301b) start from the outer edge (303a) of the vertical portion (201b) and end before the inner edge (303b) of the vertical portion (201b).
[0047] The ribs (301a, 301b) not only reinforce the robustness of the grill frame (105) but also add a visually appealing dimension to the design.
[0048] To enable effective air distribution and control, the second horizontal portion (201c) on the grill frame (105) hosts an arrangement of holes (302a, 302b) that are designed for vertical and horizontal louvers (401a, 401b). Notably, the positioning of the holes (302a, 302b) corresponds to their specific louvers. Specifically, the holes (302b) intended for vertical louvers (301a) are situated at a distance 'D1' from the inner edge (303b) of the vertical portion (201b) whereas the holes (302a) designated for horizontal louvers (401a) are placed at a distance 'D2' from the same inner edge (303b) of the of the vertical portion (201b). Importantly, 'D1' is greater than 'D2'.
[0049] Therefore, in an assemble state the horizontal louvers (401a) are connected to the holes (302a), and the vertical louvers (401b) are connected to the holes (302b) forming the integrated front cover structure (100).
[0050] Referring to Fig. 5 and Fig. 6, a method (600) of producing an integrated front cover structure (100) of an air cooler is disclosed. The first step includes blanking (501) a sheet of material that forms a base surface (101) along with forming an opening (102). The opening (102) defines a shape selected from rectangular, circular, oval, and polygonal shapes.
[0051] In an embodiment, a rectangular opening (102) is disclosed and the second step discloses of embossing (502) the blanked sheet. This process imparts a distinct three-dimensional texture to the blanked sheet, resulting in an embossed frame with a predetermined geometry, to serve as the foundation for the integrated front cover structure (100).
[0052] In the third step, the embossed frame undergoes a piercing process (503), where a series of openings are created such as a plurality of switch mountings (103) and a plurality of holes (302a, 302b). These openings serve various functions, from accommodating a plurality of vertical and horizontal louvers (401a, 401b) in the openings (302a, 302b) to accommodating switches in the switch mountings (103). The placement and dimension of these openings are crucial in ensuring optimal performance and functionality of the air cooler.
[0053] In the fourth step, the pierced sheet is further shaped (504) to yield the grill frame (105). The grill frame (105) comprises a set of distinctive components, including a first horizontal portion (201a), a second horizontal portion (201c), and a vertical portion (201b). The first horizontal portion (201a), the second horizontal portion (201c), and the vertical portion (201b) are formed through embossing, resulting in the grill frame (105) that seamlessly integrates into the overall integrated front cover structure (100).
[0054] The last step involves bending (505) the embossed and pierced sheet on at least two lateral sides. The bending gives rise to the formation of flanges (104a, 104b) that project perpendicularly inward from each lateral side of the base surface (101). The flanges (104a, 104b) play a significant role in enhancing the structural stability of the integrated front cover structure (100), allowing for seamless integration with the air cooler.
[0055] Further, the sheet of material utilized in the method (600) may be selected from a versatile group that includes metals, plastics, composites, or combinations thereof. This adaptability ensures that the method (600) can be effectively employed across diverse manufacturing scenarios, catering to varying material preferences and production requirements.
TECHNICAL ADVANTAGES
[0056] The integrated front cover structure streamlines the assembly process and reduces assembly time on the production line, leading to improved overall productivity and efficiency in the manufacturing process.
[0057] With a focus on aesthetics and design, the integrated front cover structure offers a sleek and cohesive appearance. By seamlessly integrating louvers, electrical connections, and knobs, the overall visual appeal of the air cooler is enhanced, contributing to an aesthetically pleasing and modern design.
[0058] The integration of components within the integrated front cover structure contributes to cost savings in air cooler production. The reduction in the number of separate components and assembly steps translates to decreased manufacturing costs without compromising functionality or performance.
[0059] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to disclosures containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. Also, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0060] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the disclosure, and other dimensions or geometries are possible. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
,CLAIMS:We claim:
1. An integrated front cover structure (100) for an air cooler, comprising:
a base surface (101) having an opening (102),
a grill frame (105) defined around outer periphery of the opening (102), the grill frame (105) comprises:
a first horizontal portion (201a) extends in forward direction from the base surface (101);
a vertical portion (201b) extends perpendicularly downward from the first horizontal portion (201a); and
a second horizontal portion (201c) extends perpendicularly inward from the vertical portion (201b) towards the base (101).

2. The integrated front cover structure (100) as claimed in claim 1, wherein the grill frame (105) defines a plurality of ribs (301a, 301b) on outer surface of the vertical portion (201b).

3. The integrated front cover structure (100) as claimed in claim 1, wherein the first horizontal portion (201a) defines a width ‘W1’, the vertical portion (201b) has a width ‘W2’ and the second horizontal portion (201c) has a width ‘W3., wherein the width ‘W3’ is greater than the width ‘W1’ and the width ‘W2’, wherein the width ‘W2’ is greater than the width ‘W1’.

4. The integrated front cover structure (100) as claimed in claim 1, wherein a plurality of switch mountings (103) are provided on the base surface (101).

5. The integrated front cover structure (100) as claimed in claim 1, wherein the opening (102) defines a shape selected from rectangular, circular, oval, polygonal shape.
6. The integrated front cover structure (100) as claimed in claim 5, wherein a plurality of holes (302a, 302b) are provided on the second horizontal portion (201c) of the grill frame (105) to receive a plurality of vertical and horizontal louvers (401b), wherein the plurality of holes (302b) provided for the plurality of vertical louvers (401a) are defined at distance ‘D1’ from lateral edge (303b) of the vertical portion (201b), wherein the plurality of holes (302a) provided for the plurality of horizontal louvers (401b) are defined at distance ‘D2’ from lateral edge (303b) of the vertical portion (201b), wherein the distance ‘D1’ is greater than the distance ‘D2’.

7. The integrated front cover structure (100) as claimed in claim 1, wherein a flange (104a, 104b) extends perpendicularly inward from each of lateral side edges of the base (101).

8. The integrated front cover structure (100) as claimed in claim 1, wherein the plurality of ribs (107a, 107c) a start from outer edge (303a) of the vertical portion (201b) and end before inner edge (303b) of the vertical portion (201a).

9. A method (600) of producing an integrated front cover structure (100) of an air cooler, the method (600) comprising:
blanking (501) a sheet of a material to obtain a base (101) with an opening (102);
embossing (502) the blanked sheet to obtain an embossed frame with a predetermined geometry for the front cover (100);
piercing (503) the embossed frame to create a plurality of openings such as a plurality of switch mountings (103) and a plurality of holes (302a, 302b);
embossing (504) the pierced sheet to obtain a grill frame (105) having a first horizontal portion (301a), a second horizontal portion (301b) and a vertical portion (301c);
bending (505) the embossed and pierced sheet on at least two lateral sides to form flanges (104a, 104b) to obtain the integrated front cover structure (100).

10. The method (600) as claimed in claim 10, wherein the sheet of material is selected from a group consisting of metal, plastic, composite, or a combination thereof.