Control Box Dual Cooling Design for Air Conditioner Heat Dissipation
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Solution Overview
Problem
Air conditioners face challenges in efficiently dissipating heat from electrical components in a sealed space, leading to potential malfunctions and shortened lifetimes due to self-heating, especially in water-cooled systems where heat dissipation is difficult and requires continuous cooling water supply.
Innovation Solution
A control box equipped with both a refrigerant cooling device and an air cooling device, where the refrigerant cooling device uses a heat dissipating plate to absorb heat from electrical components and a refrigerant pipe to dissipate it, and the air cooling device includes a circulation fan to forcibly circulate internal air, optimizing heat dissipation by combining refrigerant and air cooling methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are installed in a sealed space, then the structure is compact and protected, but heat dissipation becomes difficult leading to self-heating and reduced reliability
Solution Approach 1:
The control box is divided into a sealed outer housing for protection and an internal ventilation structure with inlet/outlet openings. Electrical components are positioned within this segmented structure, allowing the housing to remain sealed for protection while the ventilation pathway enables heat dissipation, thus resolving the contradiction between sealed structure reliability and temperature control.
Solution Approach 2:
A heat dissipation plate is introduced as an intermediary component between the electrical components and the external environment. This plate conducts heat from the electrical components and transfers it to the circulating air, enabling effective heat transfer while maintaining the sealed protective housing structure, thereby improving reliability without compromising temperature management.
2Loss of energy
If a water-cooled heat exchanger is used, then heat exchange efficiency is high and heat dissipation is effective, but the system requires continuous cooling water supply and complex piping
Solution Approach 1:
The cooling water system is extracted and replaced with an air cooling system. The invention removes the complex water piping and continuous water supply requirements by using ambient air as the cooling medium, achieving effective heat dissipation through a simpler air-based heat exchanger and circulation fan system.
Solution Approach 2:
The air cooling system utilizes ambient air from the environment as the cooling medium, eliminating the need for external water supply infrastructure. The circulation fan draws in ambient air, which absorbs heat from the electrical components and is then discharged, allowing the system to self-regulate using freely available atmospheric air.
3Device complexity
If air cooling is used instead of water cooling, then the system is simpler and no water supply is needed, but heat exchange efficiency is lower requiring larger components
Solution Approach 1:
The heat dissipation approach transitions from surface-level air flow to three-dimensional air circulation throughout the control box. The circulation fan creates comprehensive air movement that flows around and through the electrical components and heat dissipation plate, maximizing heat exchange efficiency in the available space without requiring increased box volume.
Solution Approach 2:
The heat dissipation plate serves as a composite thermal interface, combining high thermal conductivity material properties to efficiently transfer heat from electrical components to the circulating air. This composite approach optimizes heat transfer within the constrained volume, achieving water-cooling-like efficiency with air cooling.
4Reliability
If the control box is completely sealed, then environmental protection is maximized, but electrical components overheat due to lack of air circulation
Solution Approach 1:
The housing structure implements local quality differentiation: the outer housing remains sealed for environmental protection, while specific localized openings (inlet and outlet) are provided for air circulation. This allows different regions of the housing to serve different functions - protection versus heat dissipation - resolving the contradiction between sealed structure reliability and temperature control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively dissipates heat from electrical components, ensuring reliable operation and extending their lifespan by suitably adjusting refrigerant and air cooling, while optimizing the space for cooling devices.
Implementation Method 1
a refrigerant cooling device which is attached to one side of the case, contacts the electrical component, and dissipates heat to the outside
Implementation Method 2
a heat dissipating plate which penetrates the case to directly contact the electrical component
Implementation Method 3
an air cooling device attached to one side of the case and including a circulation fan which forcibly circulates internal air of the case
Implementation Method 4
the air cooling device includes a circulation fan to forcibly circulate internal air
Data Source
AI summary
The present invention relates to a control box and to an outdoor unit of an air conditioner comprising the same; the control box using a refrigerant cooling device and an air cooling device so as to radiate heat efficiently. The control box comprises: a case; a heat-radiating electronic component located inside the case; a refrigerant cooling device which is attached to one side of the case and makes contact with the electronic component so as to radiate heat to the outside; and an air cooling device which is attached to one side of the case and has a circulation fan for forcible circulating the air inside the case. Because the present invention is provided both with the refrigerant cooling device and the air cooling device, the electronic component inside the control box can radiate heat efficiently.