An electric appliance box assembly, an electric appliance box heat dissipation system, a control method and an air conditioner

Abstract

The application provides an electric appliance box assembly, an electric appliance box heat dissipation system, a control method and an air conditioner, and belongs to the technical field of air conditioning equipment. The electric appliance box assembly provided by the application forms a through air flow channel through double-sided air flow holes arranged on the electric appliance box, and a multi-stage phase change heat absorption unit with gradually increasing phase change temperatures from the heating component to the far end is used to construct a wide-temperature-range heat buffering and conducting chain. The multi-stage phase change heat absorption unit can passively store and buffer the fluctuating heat of the component, can absorb short-time peak heat, reduces the dependence on the continuous high-speed output of the fan, effectively weakens the mechanical noise and wind noise caused by the high-speed operation of the fan, and significantly improves the silent use experience of the air conditioner.

Description

Technical Field

[0001] This application belongs to the field of air conditioning equipment technology, specifically relating to an electrical box assembly, an electrical box heat dissipation system, a control method, and an air conditioner. Background Technology

[0002] The electrical box of the air conditioner's outdoor unit houses core heat-generating components such as the IPM module and motor drive module. The operational stability of these components directly determines the overall reliability and energy efficiency of the air conditioner. During actual operation, the heat generated by the components in the electrical box fluctuates dynamically with the overall load, frequently resulting in short-term high-heat conditions. This places high demands on the heat dissipation and buffering capabilities of the electrical box.

[0003] Currently, the industry standard for air conditioner outdoor unit electrical box cooling generally employs a combination of heat sink heat conduction and forced air cooling by the outdoor unit fan. This results in a simple overall cooling structure with poor adaptability. Existing cooling solutions primarily rely on the outdoor unit's cooling fan operating at high loads to compensate for insufficient cooling capacity. To meet the temperature control requirements of the electrical box components, the fan needs to operate at high speeds continuously for extended periods, leading to significant operating noise and substantial wasted energy. This makes it difficult to simultaneously meet the demands for reliable cooling, low noise, and energy efficiency. Summary of the Invention

[0004] The purpose of this application is to address the shortcomings of the above-mentioned technologies by proposing an electrical box assembly, an electrical box heat dissipation system, a control method, and an air conditioner. The aim is to solve the problems of existing air conditioner outdoor unit electrical boxes relying on forced air cooling by fans, which result in high noise, high energy consumption due to long-term high-load operation of the fans, and difficulty in balancing heat dissipation reliability, low noise, and energy saving.

[0005] This application provides an electrical box assembly, including a box body, a box cover, and a multi-stage phase change heat absorption unit; The box body and the box cover are interlocked to form a cavity for accommodating electronic components; Airflow holes are provided on opposite sides of the box body, which connect the cavity with the outside to form an airflow channel. The multi-stage phase change heat absorption unit is arranged in the cavity. The multi-stage phase change heat absorption unit includes at least two phase change units with different phase change temperatures. Each phase change unit is arranged along the airflow direction from bottom to top in the cavity, and the phase change temperature increases gradually from near to far from the heating element located at the bottom of the cavity, forming a wide temperature range heat buffer conduction chain.

[0006] Furthermore, the multi-stage phase change heat absorption unit is arranged vertically from bottom to top as a low-temperature phase change unit, a medium-temperature phase change unit, and a high-temperature phase change unit, with the phase change temperature range of the three increasing sequentially.

[0007] Furthermore, the cavity is equipped with a detection module, which is used to collect the phase change unit temperature, the ambient temperature inside the cavity, the ambient humidity, and the dust concentration in the airflow and output the collected parameters so that the external main control unit can obtain the status information of the cavity and the phase change unit.

[0008] Accordingly, this application also provides an electrical box heat dissipation system, including the electrical box assembly, cooling fan and main control unit as described above; The cooling fan is used to create a pressure difference on both sides of the cavity of the electrical box assembly, driving the heat exchange airflow through the cavity; The main control unit is connected to the cooling fan and the detection module configured in the electrical box assembly, respectively. The main control unit is configured to: determine the heat storage capacity of the phase change unit based on the temperature parameters of the phase change unit collected by the detection module; When the heat storage margin is determined to be sufficient, the operating power of the cooling fan is reduced; when the heat storage margin is determined to be insufficient, the operating power of the cooling fan is increased to keep the electronic components inside the cavity within the normal operating temperature range.

[0009] Accordingly, this application also provides a heat dissipation control method for an electrical box, applied to the aforementioned electrical box heat dissipation system, the method comprising: Collect real-time operating parameters such as phase change unit temperature, electrical box cavity ambient temperature, cavity humidity, and airflow dust concentration; determine whether each real-time operating parameter exceeds the corresponding preset heat dissipation strategy threshold; If all real-time operating parameters do not exceed the corresponding preset thresholds, the current heat dissipation control strategy will maintain steady-state operation. If any parameter exceeds the corresponding preset threshold, it will be controlled in stages according to the preset priority: temperature abnormality control will be performed first for abnormal temperature parameters, and humidity abnormality control will be performed for abnormal humidity parameters after the cavity temperature recovers to the standard; after both cavity temperature and cavity humidity have recovered to the normal range, dynamic optimization control of heat dissipation power will be performed in combination with the real-time heat storage margin status of the phase change unit; among them, dust concentration abnormality will only output a warning signal and will not participate in the staged control process.

[0010] Accordingly, this application also provides an air conditioner including the aforementioned electrical box heat dissipation system.

[0011] By adopting the above technical solution, this application has the following beneficial effects compared with the prior art: The electrical box assembly provided in this application forms a through-flow channel by setting air vents on both sides of the electrical box, and constructs a wide-temperature-range heat buffer conduction chain by using multi-stage phase change heat absorption units with phase change temperatures gradually increasing from near to far of the heat-generating components. The multi-stage phase change heat absorption units can passively store and buffer fluctuating heat generation from the components, absorb short-term peak heat, reduce dependence on continuous high-speed fan output, effectively reduce mechanical noise and wind noise caused by high-speed fan operation, and significantly improve the quiet user experience of the air conditioner.

[0012] Meanwhile, in conjunction with the detection module and the graded control strategy, this application can realize the monitoring of multiple parameters such as cavity temperature, humidity and dust. On the basis of completing heat dissipation and temperature control, it can achieve dehumidification and dust early warning, further ensuring the working reliability of electronic components inside the electrical box under complex working conditions and improving the overall operational stability of the machine.

[0013] This application utilizes the heat storage and buffering capacity of the phase change unit, so that the short-term heat peak of the components is borne by the phase change material. The cooling fan does not need to maintain high speed for a long time. It only increases power to dissipate heat when the temperature exceeds the threshold. Under most operating conditions, the fan can work in a low-power state, reducing the ineffective heat dissipation power consumption of the fan, reducing the power loss of the whole machine, and achieving a balance between heat dissipation requirements and energy saving goals. Attached Figure Description

[0014] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0015] The following will provide further explanation of this application in conjunction with the accompanying drawings: Figure 1 This is a structural schematic diagram of the electrical box assembly provided in this application; Figure 2 This is a schematic diagram of the heat dissipation system for the electrical box provided in this application; Figure 3 A side view of the electrical box and its connection structure provided in this application; Figure 4 A front view of the electrical box and its connection structure provided in this application; Figure 5 Temperature cloud diagram of the outdoor unit section of the phase-change-free thermal storage structure provided in this application; Figure 6 The vector diagram of airflow velocity at the cross-section of the outdoor unit of the phase-change-free thermal storage structure provided in this application; Figure 7 Temperature cloud diagram of the outdoor unit section of the air conditioner with assembled heat buffer assembly provided in this application; Figure 8 A vector diagram of the airflow velocity of the outdoor unit of an air conditioner with an assembled heat buffer assembly, provided for this application. Figure 9 This is a flowchart illustrating the heat dissipation control method for the electrical box provided in this application.

[0016] In the picture: 1. Box body; 2. Box cover; 3. Multi-stage phase change heat absorption unit; 4. Cavity; 5. Detection module; 6. Cooling fan; 31. Low-temperature phase change unit; 32. Medium-temperature phase change unit; 33. High-temperature phase change unit. Specific Implementation The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0018] Throughout the specification and claims, the following terms will have at least the meaning explicitly associated herein, unless the context otherwise requires. The meanings defined below are not intended to limit the terms, but are merely illustrative examples.

[0019] In the description of this application, the phrase "in one embodiment" does not necessarily refer to the same embodiment, although it may refer to the same embodiment. Similarly, the phrase "in some embodiments," as used herein, does not necessarily refer to the same embodiment when used multiple times, although it may refer to the same embodiment. As used herein, the term "or" is an inclusive "or" operator and is equivalent to the term "and / or," unless the context clearly specifies otherwise. The term "based on" is not exclusive and allows for reliance on additional factors not described, unless the context clearly specifies otherwise. The word "exemplary" herein means "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as superior to or better than other embodiments. The scope of this application is limited only by the scope of the appended claims, and any examples set forth in this specification are not intended to be limiting, but merely to illustrate some of the many possible embodiments of the claimed application. The various embodiments provided in this application should not be construed as limiting the scope of protection of this application.

[0020] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0022] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0023] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0024] like Figure 1 As shown, Figure 1 In the middle path A, the heat exchange airflow direction is defined. This application provides an electrical box assembly applied to an air conditioner outdoor unit for heat dissipation of electronic components inside the electrical box. The electrical box assembly includes a box body 1, a box cover 2, and a multi-stage phase change heat absorption unit 3.

[0025] Box 1 is a box-shaped structure with one open end, made of a metal material with good thermal conductivity, such as aluminum alloy or galvanized steel sheet. The interior of box 1 forms a storage space. A lid 2 is fitted onto the open end of box 1, and the lid 2 and box 1 can be detachably fixed by means of snap-fit ​​connections, screw connections, or sealing strips. When box 1 and lid 2 are interlocked, a cavity 4 is formed between them to house electronic components. The main control PCB board, IPM module, compressor drive module, and other electronic components of the air conditioner outdoor unit are installed inside cavity 4.

[0026] Airflow holes are provided on opposite sides of the housing 1. Specifically, an air inlet is provided on the first side wall of the housing 1, and an air outlet is provided on the second side wall opposite to the first side wall. The airflow holes connect the cavity 4 with the external environment, thereby forming an airflow channel inside the cavity 4. Outside air can flow into the cavity 4 through the air inlet, absorb heat after flowing over the surface of the electronic components, and then flow out through the air outlet, achieving air cooling. Preferably, both the air inlet and the air outlet are multiple small holes arranged in an array to ensure ventilation while preventing external debris from entering the cavity 4. The shape of the airflow holes can be circular, oblong, or elongated.

[0027] In one embodiment, the interior of the outdoor unit of the air conditioner is divided into a fan blade area and a compressor area by a partition. The fan blade area is a low-pressure area when the outdoor fan is running, and the compressor area is a high-pressure area. The electrical box assembly is installed on the partition, and the airflow holes on opposite sides of the box 1 connect to the fan blade area and the compressor area, respectively. When the cooling fan 6 starts running, a significant pressure difference is formed on both sides of the cavity 4. Driven by the pressure difference, the heat exchange airflow automatically flows into the cavity 4 from the high-pressure area side through the airflow holes, flows through the multi-stage phase change heat absorption unit 3 and the surface of electronic components, and then flows out from the airflow holes on the low-pressure area side. The greater the pressure difference, the faster the airflow velocity through the cavity 4, and the higher the convective heat transfer intensity. The main control unit changes the pressure difference on both sides of the cavity 4 by adjusting the speed of the cooling fan 6, thereby precisely controlling the airflow through the cavity 4 and achieving dynamic adjustment of the heat dissipation power. At the same time, by utilizing this pressure difference driving principle, basic airflow self-circulation can still be maintained when the cooling fan 6 is running at low speed, reducing the fan operating load.

[0028] A multi-stage phase change heat absorption unit 3 is arranged inside the cavity 4. The multi-stage phase change heat absorption unit 3 contains at least two phase change units with different phase change temperatures, and each phase change unit is arranged along the upward airflow direction within the cavity 4. Due to the natural rise of hot air, the overall airflow direction within the cavity 4 is upward. The phase change temperature of each phase change unit increases progressively from near to far from the heating element located at the bottom of the cavity 4, thus forming a wide-temperature-range heat buffer conduction chain.

[0029] In one embodiment, the multi-stage phase change heat absorption unit 3 is encapsulated within a separate housing. This housing is a flat, rectangular box-like structure, internally divided into multiple independent cavities, each filled with a material of a different phase change temperature. The housing is fixedly mounted on the side wall inside the cavity 4, or fixedly mounted above the heating element. The housing is made of a thermally conductive metal material, such as aluminum, to ensure efficient heat exchange between the phase change material and the air inside the cavity 4.

[0030] In one embodiment, the multi-stage phase change heat absorption unit 3 is fixed to the inner wall of the cover 2, and the phase change units are arranged vertically from bottom to top. When the cover 2 is closed on the box body 1, the multi-stage phase change heat absorption unit 3 is suspended in the upper space inside the cavity 4, and the phase change units are distributed from bottom to top in order of increasing phase change temperature. In this way, the material closest to the lower heating element is a low-temperature phase change material, which can absorb heat first and undergo phase change, storing the heat in the form of latent heat.

[0031] In one embodiment, the spatial arrangement between each phase change unit and the heating element is as follows: the low-temperature phase change unit is arranged adjacent to the heating element, the medium-temperature phase change unit is arranged above the low-temperature phase change unit and away from the heating element, and the high-temperature phase change unit is arranged in the top region of the cavity 4. Through this gradient arrangement, when the heating element generates heat, the heat is first absorbed by the low-temperature phase change unit, which begins to melt and absorb heat after reaching the phase change temperature; as the heat continues to increase and the low-temperature phase change unit becomes saturated, the excess heat is transferred upwards to the medium-temperature and high-temperature phase change units, forming a progressively buffered heat absorption chain.

[0032] In this embodiment, the box body 1 and the box cover 2 can be sealed at their joint surface using a sealing strip to prevent external dust or moisture from entering the cavity 4. The sealing strip is made of silicone rubber, which has excellent high and low temperature resistance. The outer surface of the box cover 2 can also be coated with a heat radiation coating to enhance the heat dissipation effect from the inside of the cavity 4.

[0033] The electrical box assembly provided in this embodiment, by setting up a multi-stage phase change heat absorption unit 3 with various phase change units of different phase change temperatures, and arranging each phase change unit from bottom to top along the airflow direction according to the phase change temperature from low to high, can adapt to the heat absorption requirements under different heat generation conditions within a wide temperature range. When the heat generation is low, only the low phase change temperature unit works; when the heat generation is high, the medium and high phase change temperature units participate in heat absorption in turn, thereby achieving a multi-stage heat buffer covering the entire temperature range, effectively suppressing drastic temperature fluctuations inside the cavity 4, and avoiding the technical defect that a single phase change material cannot cover a wide temperature range due to its narrow phase change temperature range. At the same time, the inherent pressure difference between the fan blade area and the compressor area drives the heat exchange airflow through the cavity 4, maintaining basic airflow circulation even when the cooling fan 6 is running at low speed, further reducing the fan's operating energy consumption.

[0034] Specifically, in one embodiment, the multi-stage phase change heat absorption unit 3 is arranged vertically from bottom to top as a low-temperature phase change unit 31, a medium-temperature phase change unit 32, and a high-temperature phase change unit 33, with the phase change temperature range of the three increasing sequentially to form a gradient heat storage and heat dissipation structure, which is the preferred three-stage gradient matching scheme of this application.

[0035] It should be noted that this application is not limited to a three-stage phase change unit structure. In other optional embodiments, different combinations of two-stage, five-stage, etc., can be set according to the capacity of the outdoor unit of the air conditioner and the differences in the heating power of the components. As long as the core logic of multi-temperature zone gradient arrangement and gradual increase of phase change temperature is met, they all fall within the protection scope of this application.

[0036] In one embodiment, the low-temperature phase change unit 31, the medium-temperature phase change unit 32, and the high-temperature phase change unit 33 are all flat block structures, stacked vertically from bottom to top, with adjacent phase change units separated by thermally conductive partitions. The thermally conductive partitions are thin aluminum alloy plates, 0.5mm to 1mm thick, ensuring heat conduction between the phase change units while preventing different phase change materials from mixing in the molten state. Each phase change unit is fixed to the thermally conductive partition by bonding or mechanical clamping. This scheme sets three stages of phase change materials corresponding to three operating states of the air conditioner outdoor unit: the low-temperature stage corresponds to standby or light-load conditions, the medium-temperature stage to normal operating conditions, and the high-temperature stage to overload operating conditions. The three phase change materials are arranged sequentially from bottom to top within the cavity 4, forming a gradient heat absorption chain from low temperature to high temperature.

[0037] This solution employs a three-stage phase change unit arrangement from top to bottom, consisting of low, medium, and high temperature phase change units, forming a continuous and interconnected wide-temperature-range heat absorption zone. This precisely addresses three typical heating conditions of the electrical box: light load, normal operation, and overload. It achieves heat storage and buffering across the entire temperature range without any dead zones, effectively avoiding the problems of easy saturation and high-temperature failure of single phase change materials.

[0038] In this preferred embodiment, the phase change temperature range of the low-temperature phase change unit 31 is 30–40°C, and it uses paraffin-based or fatty acid-based phase change materials, which can adapt to the normal light-load low-temperature heating conditions of the components; the phase change temperature range of the medium-temperature phase change unit 32 is 45–55°C, and it uses eutectic chloride salts or modified paraffin composite materials, which match the medium-temperature heating conditions of the components under normal stable operation; the phase change temperature range of the high-temperature phase change unit 33 is 60–75°C, and it uses polyols or high-melting-point salt phase change materials, which can effectively absorb the high-temperature peak heat under high load and overload conditions of the components. The temperature ranges of the three phase change units are interconnected and a small transition temperature range is reserved, covering the entire operating temperature range of the electrical box components, eliminating the defects of narrow heat dissipation temperature range and high-temperature saturation failure of single phase change materials.

[0039] Each phase change unit is precisely matched with the corresponding operating conditions, and the temperature is controlled in zones. The material properties are highly compatible with the operating temperature, which can not only ensure rapid heat absorption and temperature control in low-temperature conditions, but also stably buffer peak heat in high-temperature overload conditions, significantly improving the phase change heat storage utilization rate and heat dissipation response speed.

[0040] In one embodiment, a 5°C transition interval is reserved between the phase change intervals of adjacent phase change units to avoid heat absorption breaks at the temperature junction.

[0041] The three-stage phase change unit precisely corresponds to three typical operating conditions of the components, with low, medium, and high temperatures corresponding to heat absorption respectively. The timing of phase change heat absorption is precise, and the electrical box has the best buffering and heat dissipation effect. The segmented temperature range design makes the selection of phase change materials more targeted, and the heat storage and absorption efficiency of the multi-stage phase change heat absorption unit is further improved.

[0042] In terms of specific structural arrangement, the number of each of the low-temperature phase change unit 31, the medium-temperature phase change unit 32 and the high-temperature phase change unit 33 is at least one. The phase change units of the same type are arranged in a concentrated manner to form an independent heat storage zone, so that the heat absorption capacity of the phase change in the same temperature zone is concentrated and superimposed, thereby improving the heat storage buffer efficiency of the corresponding temperature zone, avoiding heat interference caused by the staggered arrangement of phase change units in different temperature zones, and ensuring the stability of gradient heat dissipation effect.

[0043] As a preferred implementation, a single phase change unit can be configured as a single block to meet the heat dissipation capacity requirements of a conventional 2P outdoor unit. In high-power models, multiple phase change units of the same type can be added, all arranged in a centralized manner without staggered layering, ensuring independent partitioning and orderly heat exchange for each temperature zone's heat storage area. Simultaneously, each phase change unit can be encased in a metal shell made of aluminum or copper alloy, which not only seals and protects the internal phase change material to prevent melting and leakage but also improves heat exchange contact efficiency and enhances heat conduction. Organic phase change materials are preferred due to their advantages of small volume change, long-term operational stability, and no risk of leakage.

[0044] Similar phase change units are arranged in a centralized manner to form an independent heat storage area. The heat absorption capacity is concentrated and the heat exchange interference is small. The number of units can be flexibly increased or decreased according to the power of the model. The structure is highly versatile. At the same time, the metal encapsulation structure improves heat exchange efficiency and eliminates material leakage problems, resulting in higher long-term reliability of the equipment.

[0045] like Figure 1 As shown, in one embodiment, the inner wall of the cavity is integrally formed with an embedded positioning groove. The low-temperature phase change unit 31, the medium-temperature phase change unit 32, and the high-temperature phase change unit 33 are all embedded in the corresponding embedded positioning grooves. The grooves are used to limit and fix the heat storage units, ensuring the fixed arrangement order of the heat storage units.

[0046] In one embodiment, the mounting positioning groove matches the shape of the phase change unit, and elastic buckles are provided on both sides of the groove. After the phase change unit is inserted, the buckles automatically lock in place, and no additional fasteners are required for disassembly and assembly.

[0047] The phase change unit is precisely positioned by the embedded positioning groove to prevent the phase change unit from shifting due to airflow impact, thus ensuring the stability of the phase change unit arrangement sequence; the snap-fit ​​embedded structure is easy to disassemble and assemble, which facilitates the maintenance and replacement of the heat buffer component 12 and reduces the assembly and maintenance cost of the electrical box.

[0048] In one embodiment, a detection module 5 is also provided inside the cavity 4. The detection module 5 is an integrated sensing module, such as an AQ-Mini air quality module, to collect data in real time on the phase change unit temperature, the ambient temperature inside the cavity 4, the ambient humidity, and the dust concentration in the airflow. The collected parameters are then output in real time to the external main control unit to obtain the internal environmental status of the cavity 4 and the heat storage status of each stage of the phase change unit, providing accurate data support for subsequent intelligent hierarchical heat dissipation control. A 5mm to 15mm assembly gap is reserved between the detection module 5 and the heat-generating components and phase change units inside the cavity 4. This gap is only used to avoid assembly bumps and transportation interference, and there are no issues with heat radiation or electromagnetic interference. No additional heat insulation or shielding structures are required, resulting in a simple structure assembly and high reliability.

[0049] By collecting temperature, humidity, dust, and phase change unit status parameters in real time through the detection module, the internal environment and heat storage status of the cavity can be monitored in an all-round way, providing a precise data foundation for subsequent refined and graded intelligent heat dissipation control and avoiding blind heat dissipation control.

[0050] like Figures 2-8 As shown, in one embodiment, this application also discloses an electrical box heat dissipation system, including the above-mentioned electrical box assembly, a cooling fan 6, and a main control unit.

[0051] The cooling fan 6 is installed in the airflow channel position corresponding to the electrical box assembly. The speed range can be set from 1000 RPM to 1800 RPM, with a maximum speed limit set to avoid excessive noise caused by high speed. The speed can be adjusted in stages according to temperature parameters. When the cooling fan 6 is working, it creates an air pressure difference on both sides of the cavity 4 of the electrical box assembly, driving the external heat exchange airflow to flow stably through the cavity 4, and performing forced convection heat exchange on the internal electronic components and the multi-stage phase change heat absorption unit 3.

[0052] The main control unit can use general-purpose main control chips such as GD32F103 and CH32V103. The model can be flexibly replaced according to the production batch and supply chain. The main control unit is connected to the cooling fan 6 and the detection module 5 of the electrical box assembly to realize the linkage between data reception and equipment control.

[0053] This system relies on multi-stage phase change heat storage hardware in conjunction with a controllable speed fan and a main control unit to achieve a combination of passive heat storage buffering and active air cooling regulation. It breaks away from the traditional heat dissipation mode of the fan running at high load throughout the entire process and can dynamically match the heat dissipation power according to the heat storage margin.

[0054] In one embodiment, the main control unit presets phase change temperature ranges corresponding to each phase change unit. The real-time temperature of each phase change unit is compared with its own phase change temperature range. The larger the difference between the real-time temperature and the lower limit of the corresponding phase change temperature range, the more sufficient the heat storage margin is determined; the closer the real-time temperature is to the corresponding phase change temperature range, the more insufficient the heat storage margin is determined.

[0055] In one implementation, the main control unit internally stores the phase change temperature range T1_low to T1_high for the low-temperature phase change unit 31, the phase change temperature range T2_low to T2_high for the medium-temperature phase change unit 32, and the phase change temperature range T3_low to T3_high for the high-temperature phase change unit 33. Taking the low-temperature phase change unit 31 as an example, when the real-time temperature T1_actual of the low-temperature phase change unit 31 collected by the detection module 5 is lower than T1_low, and the temperature difference ΔT1 (ΔT1 = T1_low - T1_actual) is large, it indicates that the low-temperature phase change unit 31 has not yet started to undergo phase change and is still in a solid state, with a very sufficient heat storage margin. When T1_actual approaches T1_low, it indicates that the low-temperature phase change unit 31 is about to enter the phase change range, and the heat storage margin begins to decrease. When T1_actual is between T1_low and T1_high, it indicates that the low-temperature phase change unit 31 is in the process of phase change, absorbing a large amount of latent heat, and the heat storage margin is gradually consumed. When T1_actual exceeds T1_high, it indicates that the low-temperature phase change unit 31 has completed the phase change and the heat storage margin is zero.

[0056] In one implementation, the main control unit comprehensively evaluates the thermal storage margin of each phase change unit to obtain a comprehensive thermal storage margin index. The judgment rules for the comprehensive thermal storage margin index are as follows: if the real-time temperature of each phase change unit is lower than the lower limit of its respective phase change temperature range, the comprehensive thermal storage margin is judged to be "sufficient"; if the real-time temperature of some phase change units is within their respective phase change temperature ranges while that of others is still below the lower limit, the comprehensive thermal storage margin is judged to be "moderate"; if the real-time temperature of at least one phase change unit exceeds the upper limit of its phase change temperature range, the comprehensive thermal storage margin is judged to be "scarce".

[0057] Based on the determination of the heat storage margin, the main control unit performs dynamic fan power regulation: when it is determined that the heat storage margin of the phase change unit is sufficient, the operating power of the cooling fan 6 is reduced, relying on the passive heat storage capacity of the phase change unit to bear the basic heat generation of the components, reducing the ineffective power consumption and operating noise of the fan; when it is determined that the heat storage margin of the phase change unit is insufficient or close to saturation, the operating power of the cooling fan 6 is increased, the convection heat dissipation of the cavity 4 is strengthened, the heat accumulated by the phase change unit is quickly removed, the phase change heat storage capacity is released, and the electronic components in the cavity are always maintained within the normal operating temperature range, realizing the organic combination of passive heat storage buffer and active air cooling.

[0058] The fan power is dynamically adjusted based on the heat storage margin. When the heat storage is sufficient, the fan load is reduced to reduce noise and save energy. When the heat storage is insufficient, the heat dissipation and energy release are actively enhanced, effectively balancing the heat dissipation stability of the electrical box, the quietness of operation, and the energy efficiency of the whole machine.

[0059] Furthermore, in one embodiment, the main control unit also receives the ambient temperature, humidity, and dust concentration parameters of the cavity 4 output by the detection module 5, and performs corresponding heat dissipation strategy adjustments based on these parameters.

[0060] When the ambient temperature of cavity 4 exceeds the preset upper temperature limit, it indicates that the overall heat load inside cavity 4 is too high, exceeding the instantaneous absorption capacity of the multi-stage phase change heat absorption unit 3. At this time, the main control unit increases the power of the cooling fan 6 to enhance heat dissipation. The preset upper temperature limit ranges from 55℃ to 65℃, and can be determined based on the maximum allowable operating temperature of the electronic components inside cavity 4.

[0061] When the humidity inside cavity 4 is too high, for example, when the relative humidity is greater than 75%–80% RH, it indicates a risk of condensation inside cavity 4. High humidity can also lead to oxidation and corrosion of electronic component leads or a decrease in the insulation performance of the circuit board. In this case, the main control unit increases the power of the cooling fan 6 to increase ventilation and achieve dehumidification. Increasing the ventilation volume accelerates the removal of water vapor from inside cavity 4, reducing the relative humidity inside cavity 4. The dehumidification action is accomplished through the coordinated adjustment of actuators such as the compressor, cooling fan 6, and electronic expansion valve.

[0062] When the dust concentration exceeds the threshold, such as PM2.5 concentration greater than 100 μg / m³ or PM10 concentration greater than 200 μg / m³, it indicates poor external air quality. A large amount of dust may enter the cavity 4 with the airflow and adhere to the surface of electronic components or the phase change unit, affecting heat dissipation and electrical safety. At this time, the main control unit outputs a warning signal, which is sent to the air conditioner's central control system via the communication interface and displayed as an indicator light on the indoor unit panel. The outdoor unit itself does not have a buzzer or indicator light to avoid environmental noise interference, complex wiring, and corrosion problems. After the fault is detected by the main control unit, it is reflected on the indoor unit panel as a solid or flashing red light, or a dedicated "Clean" indicator light, reminding the user to clean the heat sink fins or replace the filter.

[0063] In one implementation, the main control unit prioritizes temperature, humidity, and dust concentration as follows: temperature control has the highest priority, humidity control has the second highest priority, and dust concentration only outputs an early warning and does not participate in active control. This is because excessive temperature directly threatens the normal operation and lifespan of electronic components, excessive humidity mainly affects long-term reliability, and dust problems are easier to solve through filtration and cleaning. Therefore, when both temperature and humidity exceed the limits in cavity 4, the main control unit first executes the temperature control strategy, and then executes the humidity control strategy after the temperature returns to the target level.

[0064] This implementation introduces multi-parameter monitoring and control of the cavity environment temperature, humidity, and dust concentration, enabling the heat dissipation system to not only handle pure heat load issues but also adapt to harsh environments such as high humidity and high dust levels. This significantly improves the reliability and environmental adaptability of the air conditioner outdoor unit in complex outdoor environments. The strategy of prioritizing and classifying temperature and humidity control ensures that heat dissipation resources are not diverted by humidity regulation under the most urgent conditions of exceeding temperature limits, thus ensuring the priority achievement of core heat dissipation objectives.

[0065] In one implementation, ANSYS Fluent finite element simulation software was used to compare and verify the heat dissipation performance of the entire system solution. The simulation conditions were uniformly set to the rated overload operation condition of a 2P air conditioner outdoor unit, and the simulation output temperature cloud map was attached. Figure 5 To be continued Figure 8 Through multiple comparisons with and without heat storage structures, and with single / two-stage / three-stage heat storage structures, the cooling effect of the multi-stage phase change heat absorption unit 3 on the mainboard of the electrical box was visually verified: See attached document Figure 5 and attached Figure 6 This is a comparative simulation result without a heat buffer component; (The rest of the text appears to be a mix of unrelated phrases and sentences, possibly from different sources. A coherent translation isn't possible without the full context.) Figure 5 The temperature cloud map shows that the peak temperature at the heat source location of the electrical box is relatively high; combined with Figure 6 As can be seen from the airflow velocity vector diagram, although a pressure difference airflow can be formed on both sides of the partition, the heat dissipation load is entirely borne by the fan cooling.

[0066] See attached document Figure 7 and attached Figure 8 The simulation results are for assembling the thermal buffer assembly; Figure 7 Temperature cloud map shows that the peak temperature of the heat source was significantly suppressed; Figure 8 The airflow vector diagram shows that, under the same fan speed, the airflow in the differential pressure duct flows stably through the ventilation cavity of the electrical box. The heat buffer component shares a large portion of the heat dissipation load, eliminating the need for the fan to operate at full load for extended periods. This verifies the heat dissipation gain effect brought about by the heat buffer component of this invention in conjunction with differential pressure air cooling.

[0067] like Figure 9 As shown, this application also discloses a heat dissipation control method for an electrical box. This method is applied to the aforementioned electrical box heat dissipation system to achieve intelligent heat dissipation regulation with multiple parameters and priority levels. The overall control logic includes: S1: Collect real-time operating parameters such as phase change unit temperature, electrical box cavity ambient temperature, cavity humidity, and airflow dust concentration; Real-time operating parameters are collected. The detection module 5 collects real-time operating parameters including the temperature of the phase change unit, the ambient temperature of the electrical box cavity, the cavity humidity, and the airflow dust concentration. Specifically, the temperature sensor collects the real-time temperature of the surface of each phase change unit and the air temperature inside cavity 4; the humidity sensor collects the real-time relative humidity inside cavity 4; and the dust concentration sensor collects the real-time concentration of PM2.5 and PM10 particles in the airflow inside cavity 4. All real-time operating parameters are transmitted to the main control unit in the form of analog or digital signals.

[0068] S2: Determine whether each real-time operating parameter exceeds the corresponding preset heat dissipation strategy threshold; The main control unit determines whether each real-time operating parameter exceeds the corresponding preset heat dissipation strategy threshold. It compares each received real-time parameter with its internally stored preset threshold to determine if any parameter exceeds the limit. The preset heat dissipation strategy thresholds include the preset upper limit for cavity temperature, the preset upper limit for cavity humidity, and the preset upper limit for dust concentration.

[0069] S3: If all real-time operating parameters do not exceed the corresponding preset thresholds, the current heat dissipation control strategy will be maintained in steady state. If all real-time operating parameters do not exceed the corresponding preset thresholds, the current heat dissipation control strategy will maintain steady-state operation. That is, the cooling fan 6 will maintain its current speed, and the multi-stage phase change heat absorption unit 3 will absorb heat normally according to its own physical characteristics, without the system making any active adjustments.

[0070] S4: If any parameter exceeds the corresponding preset threshold, it will be adjusted according to the preset priority level. If any parameter exceeds its preset threshold, it will be adjusted according to a preset priority level. The specific process of the level adjustment is as follows: temperature anomaly control is performed first for abnormal temperature parameters, and humidity anomaly control is performed after the cavity temperature returns to the standard. After both cavity temperature and cavity humidity have returned to the normal range, dynamic optimization control of heat dissipation power is performed based on the real-time heat storage margin status of the phase change unit. Notably, abnormal dust concentration only outputs a warning signal and does not participate in the level adjustment process.

[0071] In one implementation, the tiered control process is implemented internally by a state machine within the main control unit. The state machine has three states: temperature control, humidity control, and dynamic optimization. After system power-on initialization, it enters the dynamic optimization state. When a temperature exceedance is detected, the state machine unconditionally jumps to the temperature control state and continues control in this state until the temperature returns to the target level. Once the temperature reaches the target level, the state machine jumps to the humidity control state. If the humidity also reaches the target level, it immediately jumps to the humidity control state. If the humidity does not reach the target level, it continues control in the humidity control state until the humidity returns to the target level. Once both humidity and temperature reach the target level, the state machine returns to the dynamic optimization state.

[0072] The electrical box heat dissipation control method provided in this embodiment achieves rational allocation of heat dissipation resources by first determining whether parameters exceed limits and then adjusting them according to priority. The priority logic of temperature over humidity ensures that temperature issues, which have the most direct and urgent impact on the normal operation of electronic components, are addressed first. Dynamic optimization and control of heat dissipation power, performed after both temperature and humidity meet standards, further achieves energy-saving and noise-reduction effects. The method of separately warning for dust concentration without involving active control avoids unnecessary frequent disturbances to the cooling fan speed caused by short-term fluctuations in dust parameters.

[0073] After the cavity temperature and humidity have returned to the normal preset range, the main control unit performs dynamic optimization and control of heat dissipation power based on the real-time heat storage margin status of each phase change unit. The specific control method is as follows: collect the real-time temperature of each phase change unit, match the corresponding phase change temperature range to determine the heat storage margin; when the heat storage margin is insufficient, increase the power of the cooling fan to enhance the pre-heat dissipation of the phase change unit by airflow and release the heat storage capacity in time; when the heat storage margin is sufficient, reduce the fan operating power, rely on the wide temperature range heat storage capacity of the multi-stage phase change units to bear the short-term heat load of the components, significantly reduce the fan operating power consumption and wind noise, and achieve a balance between heat dissipation stability and energy-saving and quiet performance.

[0074] After the operating conditions stabilize, the fan power is dynamically optimized by utilizing the heat storage margin, making full use of the heat storage advantages of phase change materials to share the heat dissipation load, greatly reducing the ineffective high-speed operation of the fan, significantly reducing the overall heat dissipation power consumption and operating noise, and achieving efficient and energy-saving operation.

[0075] To address abnormal dust conditions, this application employs independent early warning logic. When dust concentration exceeds the standard, the main control unit generates an early warning signal and transmits it to the indoor unit via the communication line between the indoor and outdoor units. The user is then alerted through indoor unit indicator lights, on-screen pop-ups, and stored fault codes, prompting timely cleaning of the air ducts to prevent heat dissipation failures caused by long-term blockage. Simultaneously, an excessive humidity warning signal is also triggered by the indoor unit, enabling visualized monitoring of the entire unit's status and improving the ease of equipment maintenance.

[0076] With visual early warning of abnormal dust and humidity, potential problems such as duct blockage and cavity dampness can be predicted in advance, facilitating timely maintenance and preventing secondary high-temperature failures, thus improving the overall safety and ease of operation of the air conditioning unit.

[0077] In one embodiment, abnormal temperature control includes at least one of adjusting the operating power of the cooling fan 6 and adjusting the airflow pressure difference in the cavity 4 to rapidly reduce the ambient temperature of the cavity. Abnormal humidity control includes at least one of increasing the airflow of the cooling fan 6 and increasing the ventilation and air exchange rate of the cavity 4 to achieve ventilation and dehumidification of the cavity 4.

[0078] In one implementation, the specific steps for temperature anomaly control are as follows: First, the main control unit increases the operating power of the cooling fan 6 from its current value to its rated power, causing the cooling fan 6 to run at full speed. The speed of the cooling fan 6 is typically in the range of 1000–1800 RPM, and can be increased to a maximum of 1800 RPM. When the cooling fan 6 is running at full speed, the air pressure difference between the air inlet and outlet of the cavity 4 reaches its maximum value, and the airflow velocity of the heat exchange air flowing through the cavity 4 also reaches its maximum value, thereby removing the heat inside the cavity 4 with the maximum convective heat transfer intensity. Since the fan speed can only serve as an auxiliary cooling solution, it is not increased further once it has reached 1800 RPM to avoid generating excessive noise. At the same time, when the high-speed airflow flows over the surface of each phase change unit, it can also accelerate the heat release process of the phase change unit, causing the molten phase change material to quickly solidify and regenerate, restoring its heat storage capacity.

[0079] In one implementation, abnormal temperature control also includes simultaneously changing the compressor's operating frequency and adjusting the electronic expansion valve opening to enhance heat dissipation. Specifically, the main control unit sends a request for enhanced heat dissipation to the air conditioner's central control system via a communication interface. The central control system then simultaneously executes compressor frequency reduction and electronic expansion valve opening adjustment to reduce the heat generated by heat-generating components from the heat source end, while optimizing the refrigerant circulation state and assisting the heat dissipation system in jointly controlling the temperature of cavity 4. Under the sensor's adjustment strategy, fan speed regulation, compressor frequency regulation, and electronic expansion valve regulation are executed simultaneously to synergistically enhance heat dissipation.

[0080] In one implementation, the specific steps of humidity anomaly control are as follows: when the relative humidity inside cavity 4 exceeds a preset humidity threshold, such as 75%–80% RH, the main control unit increases the speed of the cooling fan 6 to increase ventilation. After increasing ventilation, the air exchange rate inside cavity 4 increases, and hot, humid air containing water vapor is quickly exhausted to the external environment. Simultaneously, relatively dry external air enters cavity 4, thereby gradually reducing the relative humidity of cavity 4. The dehumidification logic is similar to the temperature regulation logic. When the sensor detects an abnormal humidity level, the compressor, cooling fan 6, electronic expansion valve, and other actuators are adjusted to collaboratively perform dehumidification. During humidity anomaly control, the speed increase of the cooling fan 6 can be less than that in temperature anomaly control to avoid generating excessive noise.

[0081] In one embodiment, humidity anomaly control also includes controlling the cooling fan 6 to operate in an intermittent pulse mode when the internal temperature of the cavity 4 is not exceeded but the humidity is too high. The intermittent pulse mode is as follows: the cooling fan 6 runs at its rated speed for a first duration, then stops running for a second duration, and so on in an alternating cycle. The intermittent pulse mode can achieve dehumidification effect while being more energy-efficient than continuous full-speed operation.

[0082] This implementation provides specific control measures for abnormal temperature and humidity. Temperature control focuses on increasing wind speed and pressure difference to enhance convective heat dissipation, while simultaneously adjusting the compressor and electronic expansion valve. Humidity control focuses on increasing ventilation volume to achieve air dehumidification. While there is some overlap between the temperature and humidity control methods, they each have their own emphasis, with temperature control taking precedence over humidity control, ensuring no compromise on the core requirement of temperature control.

[0083] In one implementation, the dynamic optimization and control of heat dissipation power includes the following steps.

[0084] Step 1: Collect the real-time temperature of each phase change unit and determine the heat storage capacity of the phase change unit based on the corresponding phase change temperature range of each phase change unit. The main control unit obtains the real-time temperature of the low-temperature phase change unit 31, the medium-temperature phase change unit 32, and the high-temperature phase change unit 33 through the detection module 5. Then, it compares each real-time temperature with the corresponding phase change temperature range of the phase change unit and determines the heat storage capacity status of each phase change unit according to the above determination logic.

[0085] Step 2: When the heat storage capacity of the phase change unit is insufficient, increase the heat dissipation power of the cooling fan 6, increase the airflow pressure difference in the cavity 4, strengthen the pre-heat dissipation of the phase change unit by the heat exchange airflow, and release the phase change heat storage capacity in time.

[0086] Specifically, when the main control unit determines that the real-time temperature of any phase change unit has exceeded the upper limit of its phase change temperature range, it indicates that the phase change unit has completely melted and its heat storage capacity has been exhausted. At this time, the main control unit increases the speed of the cooling fan 6 to the rated speed, and uses forced convection heat transfer to carry away the latent heat stored inside the phase change unit through airflow, so that the phase change material re-solidifies from a liquid state to a solid state, restoring its ability to absorb latent heat of phase change again.

[0087] Step 3: When the phase change unit has sufficient heat storage capacity, reduce the cooling power of the cooling fan 6. Rely on the phase change heat storage capacity of the phase change unit to handle the short-term heat load, reducing fan power consumption and noise. Specifically, when the main control unit determines that the real-time temperature of each phase change unit is below the lower limit of its respective phase change temperature range and the ambient temperature of the cavity 4 is within the normal range, it indicates that the phase change unit has sufficient heat storage capacity. At this time, the main control unit reduces the speed of the cooling fan 6 to low speed or controls the cooling fan 6 to stop running. The latent heat of phase change of the multi-stage phase change heat absorption unit 3 absorbs the heat generated by the heat-generating components, keeping the temperature of the cavity 4 within the normal operating range, while significantly reducing fan operating energy consumption and noise.

[0088] In one implementation, dynamic optimization and control of heat dissipation power is achieved using a PID closed-loop control algorithm. The main control unit uses the ambient temperature of cavity 4 as the target control variable, the PWM duty cycle of cooling fan 6 as the control output variable, and the real-time temperature of the phase change unit as the feedforward compensation variable. When the heat storage margin of the phase change unit is sufficient, the proportional gain of the PID controller is reduced to make the fan speed response smoother; when the heat storage margin of the phase change unit is insufficient, the proportional gain of the PID controller is increased to make the fan speed response faster.

[0089] This embodiment of dynamic optimization and control of heat dissipation power fully utilizes the heat storage margin information of the phase change unit. It uses the phase change material's heat absorption capacity as the core criterion for fan speed regulation, achieving optimal power distribution between passive phase change heat dissipation and forced fan heat dissipation. When the phase change material can handle the heat load, the fan power is actively reduced, achieving the dual benefits of noise reduction and energy saving. When the phase change material is saturated, the fan power is promptly increased for exothermic regeneration, ensuring the phase change material can be continuously recycled and avoiding the risk of uncontrolled temperature rise caused by a sudden loss of heat dissipation capacity after the phase change material becomes saturated.

[0090] In one embodiment, the preset heat dissipation strategy includes a preset cavity temperature threshold, a preset cavity humidity threshold, and a preset dust concentration threshold. When any one of the cavity ambient temperature, cavity humidity, or dust concentration exceeds the corresponding preset threshold, it is determined that the real-time operating parameters exceed the preset heat dissipation strategy.

[0091] In one implementation, the preset cavity temperature threshold is a maximum temperature value Tmax, the specific value of which is determined based on the maximum allowable operating temperature of the electronic components inside the cavity 4. For example, when the maximum allowable operating temperature of the IPM module on the main control PCB board inside the cavity 4 is 85°C, the preset cavity temperature threshold can be set to 65°C to 70°C to ensure sufficient margin. When the main control unit detects that the cavity ambient temperature is greater than Tmax, it determines that the temperature parameter exceeds the preset heat dissipation strategy.

[0092] In one implementation, the preset humidity threshold for the cavity is a relative humidity upper limit value RHmax. The value of RHmax is determined based on the moisture resistance level of the electronic components inside the cavity 4, and is typically set to 75%–80% RH. When the main control unit detects that the relative humidity inside the cavity 4 is greater than RHmax, it determines that the humidity parameter exceeds the preset heat dissipation strategy. When the humidity exceeds the limit, even if the temperature parameter does not exceed the limit, the main control unit should initiate abnormal humidity control to prevent condensation on the circuit board or a decrease in insulation performance under high humidity conditions.

[0093] In one embodiment, the preset dust concentration thresholds include PM2.5 concentration thresholds and PM10 concentration thresholds. The PM2.5 concentration threshold can be set to different levels of 75 μg / m³, 100 μg / m³, or 150 μg / m³, and the PM10 concentration threshold can be set to different levels of 150 μg / m³, 200 μg / m³, or 300 μg / m³. The main control unit can output different levels of warning signals according to different dust concentration levels. For example, when the PM2.5 concentration exceeds 75 μg / m³ but is less than 150 μg / m³, a level one warning (caution advised) is output; when the PM2.5 concentration exceeds 150 μg / m³, a level two warning (cleaning advised) is output.

[0094] In one implementation, the preset heat dissipation strategy threshold also includes a hysteresis range to prevent frequent switching of the control strategy when parameters fluctuate near the threshold. The width of the hysteresis range is ±5% of the preset threshold. For example, if the preset cavity temperature threshold is 70°C, then abnormal temperature control will be initiated when the temperature parameter exceeds 70°C, and will only be deactivated when the temperature parameter drops below 66.5°C (70°C × 95%). The hysteresis range effectively prevents the cooling fan 6 from frequently starting and stopping near the threshold, improving the stability of system operation.

[0095] In one implementation, the preset heat dissipation strategy threshold is automatically adjusted based on the environmental conditions of the outdoor unit. For example, the preset cavity temperature threshold in high-temperature summer environments can be slightly higher than in spring and autumn, while the preset cavity humidity threshold in humid coastal areas can be appropriately relaxed. The automatic adjustment of the preset threshold is based on the measurement results of external environmental temperature and humidity sensors.

[0096] This implementation provides clear triggering conditions for the graded control method by explicitly setting preset thresholds for three parameters: temperature, humidity, and dust, and defining the criteria for determining when these parameters exceed limits. The establishment of a multi-threshold system enables the heat dissipation control strategy to accurately initiate corresponding control processes under different operating conditions and environmental environments, avoiding blind or delayed control. The introduction of a hysteresis range further enhances the anti-interference capability and operational stability of the control system.

[0097] This application discloses an air conditioner that includes the aforementioned electrical box heat dissipation system.

[0098] In one embodiment, the air conditioner is a split-type air conditioner, including an indoor unit and an outdoor unit. The electrical box assembly of the electrical box cooling system is located inside the outdoor unit, specifically mounted on a partition of the outdoor unit. The interior of the outdoor unit is divided into a fan blade area and a compressor area by a partition, and the electrical box assembly is mounted on the partition and located above or to the side of the compressor area.

[0099] The outdoor unit of an air conditioner also includes a compressor, condenser, outdoor fan, and expansion valve. The compressor is located in the compressor area, the condenser is located in the fan area, and the outdoor fan is located inside the condenser. The main control PCB board in the electrical box assembly is electrically connected to the compressor, outdoor fan motor, and expansion valve via wires, and is used to control each component to operate according to the air conditioner's operating instructions.

[0100] In one implementation, the main control unit of the electrical box heat dissipation system is integrated with the outdoor unit main control board of the air conditioner, meaning the outdoor unit main control board simultaneously performs the dual functions of air conditioner operation control and electrical box heat dissipation control. The outdoor unit main control board integrates a microprocessor for executing heat dissipation control logic and a memory storing preset heat dissipation strategy thresholds. The signal input terminal of the outdoor unit main control board is connected to the detection module 5, and the output terminal is connected to the cooling fan 6.

[0101] In one embodiment, the air conditioner also includes a display panel or a wireless communication module for displaying the operating status of the electrical box and heat dissipation system to the user. When the main control unit outputs a dust concentration warning signal, the display panel displays the message "Please clean the heat dissipation fins," or pushes a cleaning reminder message to the user's mobile app via the wireless communication module. When the main control unit outputs an abnormal temperature or humidity signal, a red light on the indoor unit panel remains on or flashes to alert the user to an operational malfunction.

[0102] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a feature, structure, material, or characteristic described in connection with that embodiment is included in at least one embodiment of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments described in this specification.

[0103] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary, and those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application, all of which fall within the protection scope of this application.

Claims

1. An electrical box assembly, characterized in that, It includes a box body (1), a box cover (2), and a multi-stage phase change heat absorption unit (3); The box body (1) and the box cover (2) are fastened together to form a cavity (4) for accommodating electronic components; air flow holes are provided on opposite sides of the box body (1), and the air flow holes connect the cavity (4) with the outside to form an air flow channel; The multi-stage phase change heat absorption unit (3) is arranged in the cavity (4). The multi-stage phase change heat absorption unit (3) includes at least two phase change units with different phase change temperatures. Each phase change unit is arranged along the airflow direction from bottom to top in the cavity (4), and the phase change temperature increases gradually from near to far from the heating element located at the bottom of the cavity (4), forming a wide temperature range heat buffer conduction chain.

2. The electrical box assembly according to claim 1, characterized in that, The multi-stage phase change heat absorption unit (3) is arranged in the vertical direction from bottom to top as a low-temperature phase change unit (31), a medium-temperature phase change unit (32), and a high-temperature phase change unit (33), with the phase change temperature range of the three increasing sequentially.

3. The electrical box assembly according to claim 2, characterized in that, The phase change temperature range of the low-temperature phase change unit (31) is 30-40℃, and it uses paraffin-based or fatty acid-based phase change materials. The phase change temperature range of the intermediate temperature stage phase change unit (32) is 45-55℃, and it adopts eutectic chloride salt or modified paraffin composite material. The phase change temperature range of the high-temperature phase change unit (33) is 60-75°C, and it uses polyols or high-melting-point salt phase change materials.

4. The electrical box assembly according to claim 1, characterized in that, The cavity (4) is equipped with a detection module (5). The detection module (5) is used to collect the phase change unit temperature, the ambient temperature inside the cavity (4), the ambient humidity, and the airflow dust concentration and output the collected parameters so that the external main control unit can obtain the status information of the cavity (4) and the phase change unit.

5. The electrical box assembly according to claim 2, characterized in that, The number of each of the low-temperature phase change unit (31), the medium-temperature phase change unit (32) and the high-temperature phase change unit (33) is at least one, and the phase change units of the same type are arranged in a concentrated manner to form an independent heat storage zone.

6. A heat dissipation system for an electrical box, characterized in that, Includes the electrical box assembly, cooling fan (6), and main control unit as described in any one of claims 1-5; The cooling fan (6) is used to create a pressure difference on both sides of the cavity (4) of the electrical box assembly, and drive the heat exchange airflow through the cavity (4). The main control unit is connected to the cooling fan (6) and the detection module (5) configured in the electrical box assembly, respectively. The main control unit is configured to: determine the heat storage margin of the phase change unit based on the temperature parameters of the phase change unit collected by the detection module (5); when the heat storage margin is determined to be sufficient, control to reduce the operating power of the cooling fan (6); when the heat storage margin is determined to be insufficient, control to increase the operating power of the cooling fan (6) so that the electronic components in the cavity (4) are maintained in the normal operating temperature range.

7. The heat dissipation system for the electrical box according to claim 6, characterized in that, The main control unit is preset with phase change temperature ranges corresponding to each phase change unit; The real-time temperature of each phase change unit is compared with its own phase change temperature range. The greater the difference between the real-time temperature and the lower limit of the corresponding phase change temperature range, the more sufficient the thermal storage margin is determined. The closer the real-time temperature is to the corresponding phase change temperature range, the more scarce the thermal storage margin is determined.

8. The heat dissipation system for the electrical box according to claim 6, characterized in that, The main control unit also receives the ambient temperature, humidity and dust concentration parameters of the cavity (4) output by the detection module (5); When the ambient temperature of the cavity (4) exceeds the preset upper limit, the main control unit increases the power of the cooling fan (6) to enhance heat dissipation; when the humidity of the cavity (4) is too high, the main control unit increases the power of the cooling fan (6) to increase ventilation and achieve dehumidification; when the dust concentration exceeds the threshold, the main control unit outputs a warning signal.

9. A method for controlling heat dissipation in an electrical box, characterized in that, The method, applied to the heat dissipation system of the electrical box according to any one of claims 6-8, comprises: Real-time operating parameters such as phase change unit temperature, electrical box cavity ambient temperature, cavity humidity, and airflow dust concentration are collected. Determine whether each real-time operating parameter exceeds the corresponding preset heat dissipation strategy threshold; If all real-time operating parameters do not exceed the corresponding preset thresholds, the current heat dissipation control strategy will maintain steady-state operation. If any parameter exceeds the corresponding preset threshold, it will be controlled in stages according to the preset priority: temperature abnormality control will be performed first for abnormal temperature parameters, and humidity abnormality control will be performed for abnormal humidity parameters after the cavity temperature recovers to the standard; after both cavity temperature and cavity humidity have recovered to the normal range, dynamic optimization control of heat dissipation power will be performed in combination with the real-time heat storage margin status of the phase change unit; among them, dust concentration abnormality will only output a warning signal and will not participate in the staged control process.

10. The heat dissipation control method for an electrical box according to claim 9, characterized in that: The abnormal temperature control includes at least one of adjusting the operating power of the cooling fan and adjusting the airflow pressure difference in the cavity to quickly reduce the ambient temperature of the cavity; the abnormal humidity control includes at least one of increasing the airflow of the cooling fan and increasing the ventilation and air exchange volume in the cavity to achieve ventilation and dehumidification of the cavity.

11. The heat dissipation control method for an electrical box according to claim 9, characterized in that, The dynamic optimization and control of heat dissipation power includes: The system collects the real-time temperature of each phase change unit and, based on the corresponding phase change temperature range, determines the heat storage margin of the phase change unit. When the heat storage margin of the phase change unit is insufficient, the cooling fan power is increased, the airflow pressure difference in the cavity is increased, and the pre-heat dissipation of the heat exchange airflow on the phase change unit is strengthened to release the phase change heat storage capacity in a timely manner. When the heat storage margin of the phase change unit is sufficient, the cooling fan power is reduced, and the phase change heat storage capacity of the phase change unit is used to bear the short-term heat load, thereby reducing the fan's operating power consumption and noise.

12. The heat dissipation control method for an electrical box according to claim 9, characterized in that, The preset heat dissipation strategy includes a preset cavity temperature threshold, a preset cavity humidity threshold, and a preset dust concentration threshold. When any one of the cavity ambient temperature, cavity humidity, or dust concentration exceeds the corresponding preset threshold, it is determined that the real-time operating parameters exceed the preset heat dissipation strategy.

13. An air conditioner, characterized in that, Includes the heat dissipation system for the electrical box as described in any one of claims 6-8.

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