Contactor Refrigerant Blocking Structure to Prevent A2L Ignition
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Solution Overview
Problem
Existing air conditioning systems using A2L refrigerants face safety risks due to potential ignition sources, as traditional contactors can generate electric arcs that ignite the refrigerant, leading to explosions.
Innovation Solution
A contactor design with a refrigerant blocking structure surrounding the contact support, limiting the effective opening size to prevent ignition and incorporating a guide stopper for smooth movement, made from self-lubricating and wear-resistant materials to facilitate maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional contactors are used, then electrical connection function is achieved, but electric arc is generated which can ignite A2L refrigerant
Solution Approach 1:
The patent extracts and removes the harmful electric arc generation by replacing traditional contactor components with a magnetic drive mechanism. The movable contact member is driven by a magnetic drive assembly that actuates through a drive shaft, eliminating the need for direct electrical contact and arc generation while maintaining the switching function.
Solution Approach 2:
The patent replaces the traditional mechanical contact-based switching system with a magnetic field-based drive system. The magnetic drive assembly uses magnetic attraction and repulsion forces to actuate the movable contact member, substituting mechanical direct contact with magnetic field interaction, thereby preventing electric arc generation.
2Reliability
If refrigerant blocking structure is added to prevent ignition, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges the refrigerant blocking function with the existing contactor housing structure. The housing is designed to enclose the movable contact member and magnetic drive components, simultaneously serving as both the structural framework and the refrigerant barrier, thus preventing ignition without adding separate blocking components.
Solution Approach 2:
The contactor housing performs multiple functions: it provides structural support, houses the magnetic drive mechanism, and acts as a refrigerant blocking structure. This multi-functionality eliminates the need for additional components, maintaining simplicity while ensuring safety.
3Reliability
If effective opening size is limited to prevent flame spread, then safety is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The patent applies local quality by providing targeted cooling channels in specific areas of the housing where heat generation occurs, rather than requiring large overall openings. The cooling channels are strategically positioned to remove heat from critical components while maintaining the housing's integrity as a refrigerant barrier.
Solution Approach 2:
The patent introduces cooling channels as an intermediary heat transfer path that allows heat to be conducted away from internal components through the housing material itself, rather than requiring direct openings to the external environment. This mediator approach enables heat dissipation while maintaining the sealing function.
Data Source
AI summary
The disclosure provides a contactor and an air conditioning system. The contactor includes a main body, a first electrical terminal, a second electrical terminal, a contact support, and a refrigerant blocking structure. The contact support is at least partially arranged in the main body and arranged between the first electrical terminal and the second electrical terminal. The contact support is configured such that a power received by the first electrical terminal from a power grid is at least partially transmitted to a load through the second electrical terminal when activated. The refrigerant blocking structure is arranged on a side of the main body toward the contact support, and the refrigerant blocking structure, the contact support, and the opening are arranged correspondingly, and the refrigerant blocking structure at least partially surrounds an outside of the contact support for blocking a flame generated by igniting of a refrigerant.