Abstract: Currently, high-end floor-standing air conditioners widely use acrylic for exterior panels. However, traditional solutions require an additional transparent backing plate for assembly, leading to high comprehensive costs in materials, molds, transportation, and labor. By eliminating the transparent backing plate and adopting an integrated assembly process, the manufacturing and transportation costs of exterior components can be significantly reduced. Through validation of acrylic dimensional changes under different temperature and humidity conditions, static suspension tests, various laser engraving techniques, and lamination protection processes, issues such as significant dimensional variations in storage and transportation, double-sided tape adhesion failure, uneven assembly gaps, and stress cracking during lamination—caused by the removal of the backing plate—have been resolved. This successfully achieves a stable first-pass yield rate of over 95% for high-end floor-standing air conditioners with acrylic panels assembled without a backing plate. This solution provides a new technical approach for high-end floor-standing air conditioner acrylic exteriors that is low-cost, highly reliable.

Key words: Acrylic, Hot bending process, Integrated assembly, Temperature and humidity control, Stress cracks