Abstract: Based on the combination of theoretical analysis and simulation, optimizes the foam structure of an air conditioner pendant. Firstly, according to the theoretical calculation, the theoretical calculation values of foam thickness and contact area are given; Secondly, the load on the foam at the typical moment is extracted by means of drop simulation; Then, with the stress as the constraint condition and the energy absorption of foam as the optimization goal, the optimal optimal material distribution of the original foam structure are analyzed by using the topology optimization method. Finally, by combining the topology results and drop simulation results, the final packaging design scheme is obtained. The scheme was verified to be qualified by the protection test, and the amount of packaging material was reduced by 7% compared with that before optimization, realizing the lightweight design of packaging foam under the condition of ensuring the structural strength.

Key words: Air conditioning foam, Topology optimization, Theoretical analysis, Lightweight structural design