Air Conditioner Control Module Layout for Cooler-Supported PCB Access
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Solution Overview
Problem
The outdoor unit of an air conditioner has a cooler disposed on the front side of the printed circuit board, making maintenance difficult and the mechanical strength of the supporting structure low, as the cooler is supported by the printed circuit board.
Innovation Solution
An electrical component module with a fixed plate, upper and lower frames, and a cooler that bridges between these frames, allowing the printed circuit board to be maintained without detaching the cooler and enhancing the mechanical strength of the supporting structure with a simple configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooler is disposed on the front side of the printed circuit board to cool power devices, then the cooling function is improved, but the maintenance difficulty increases and mechanical strength decreases
Solution Approach 1:
The support structure is segmented into multiple components: a support plate attached to the rear surface of the printed circuit board, and a support bracket attached to the case. This segmentation allows the cooler to be mounted on the front side while the support structures are distributed on both rear and front surfaces, enabling maintenance access without removing the cooler.
Solution Approach 2:
The support structure transitions from a single-plane support to a three-dimensional distributed support system. The support plate extends on the rear surface while the support bracket extends on the front surface, creating a spatial distribution that resolves the conflict between front-side cooling and maintenance accessibility.
2Device complexity
If the cooler is supported by the printed circuit board, then the structure is simplified, but the mechanical strength of the supporting structure becomes low
Solution Approach 1:
The support function is merged with the cooler mounting structure. The support bracket is integrally formed with the cooler mounting portion, combining the support function with the cooler attachment function into a single structural element that provides both structural strength and cooler mounting capability.
Solution Approach 2:
The support bracket serves multiple functions: it supports the printed circuit board, provides mounting points for the cooler, and reinforces the overall structure. This multi-functionality reduces the need for separate support components while increasing structural strength.
3Volume of moving object
If the cooler is disposed on the front side of the printed circuit board, then the space utilization is improved, but the maintenance operation becomes difficult
Solution Approach 1:
The support function is extracted from the printed circuit board and assigned to separate support structures (support plate and support bracket). This extraction allows the printed circuit board to be maintained independently by removing only the support plate, while the cooler remains mounted on the front side through the support bracket.
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
Enables easy maintenance of the printed circuit board without removing the cooler and increases the mechanical strength of the supporting structure, improving operational reliability and ease of maintenance.
Implementation Method 1
the heat sink is arranged to be thermally coupled with the printed circuit board 41 to receive the heat produced by the power device 41B1... In the liquid side refrigerant pipe 30L, the refrigerant condensed in the outdoor heat exchanger 11 flows during the cooling operation, and the refrigerant condensed in the indoor heat exchanger 21 and decompressed in the expansion valve 14 flows during the heating operation. Thus, the heat sink of the cooler 50 is cooled on the basis of the temperature of the refrigerant
Data Source
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AI summary
An electrical component module (200) includes: a control unit that controls an air conditioner; a fixed plate (210) on which the control unit is mounted, the fixed plate (210) being arranged to have a front surface (211a) facing a direction toward a service panel; a cooler (300) that is attached to a part of a refrigerant pipe (30L) with the refrigerant pipe (30L) arranged between the cooler (300) and a back surface (211b) of the fixed plate (210); a first frame (220) attached to one end portion of the fixed plate (210); and a second frame (230) attached to another end portion of the fixed plate (210). The control unit includes a printed circuit board (360) on which a power device (274) is mounted. The power device (274) is thermally coupled with the cooler (300). The cooler (300) is attached to bridge between the first frame (230) and the second frame (230).