Patent ID: 8113928

Claim:
A method as of forming a molded single piece cover ( 41 ) for a blower wheel compartment ( 10 ) of an air conditioning indoor unit, the cover ( 41 ) comprising a main body section ( 49 ) with an air inlet opening ( 51 ) and a rectangularly shaped nozzle section ( 48 ) for the discharge of conditioned air, the nozzle section ( 48 ) comprising a plurality of complex-shaped vanes ( 56 ) disposed in spaced relationship between a top wall ( 46 ) and a bottom wall ( 41 ) of the nozzle section ( 48 ), said method comprising: forming a pair of mold core elements ( 42 , 43 ) which when brought together in engaging relationship define a cavity which replicates the shape of the cover ( 14 ); injecting a plastic material into said cavity; and withdrawing said pair of mold core elements ( 42 , 43 ) in opposite directions along each of a plane parallel to said top wall ( 46 ) and a plane (a-a) which forms an angle (θ) with an axis (x-x) passing normally through the mold core elements ( 42 , 43 ), said angle (θ) being in the range of 14° to 22°, wherein said to wall ( 46 ) is disposed at an acute angle to a longitudinal axis (B-B) of said cover 41 , wherein each of said mold components comprise teeth ( 57 , 58 ) between which a plurality of said complex-shaped vanes ( 56 ) are formed when the mold components ( 57 , 58 ) are in mating relationship, and wherein each of the complex-shaped vanes ( 56 ) are arcuately formed with a spline that is different for each individual one of the complex-shaped vane ( 56 ).