L-Shaped Drain Pan Structure for Heat Exchanger Insulation Bonding
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Solution Overview
Problem
The existing air-conditioning apparatuses face a challenge in improving the work efficiency of bonding heat insulating materials while maintaining the strength of the drain pan, as the addition of ribs on the rear surface to enhance strength leads to fragmented insulation and reduced bonding efficiency.
Innovation Solution
A heat exchange unit is designed with a first drain pan facing the heat exchanger and a second drain pan forming an L shape, where the second drain pan has a rib on its facing surface to enhance bonding efficiency and strength without increasing the number of rear ribs, thus avoiding the fragmentation of insulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ribs are added on the rear surface of the drain pan to improve strength, then the strength of the drain pan is improved, but the bonding area for heat insulating material is reduced and work efficiency deteriorates
Solution Approach 1:
The drain pan is divided into two separate panes (first drain pan and second drain pan) that are coupled together. The rib structure is placed only on the second drain pan, which does not contact the heat insulating material, while the first drain pan provides a smooth bonding surface. This segmentation allows the rib structure to reinforce strength without interfering with the bonding area.
Solution Approach 2:
The first drain pan acts as an intermediary between the heat insulating material and the second drain pan with ribs. The heat insulating material bonds to the smooth surface of the first drain pan, while the second drain pan with ribs provides structural support. This intermediary structure allows both the rib reinforcement and full bonding area to coexist.
2Strength
If the number of ribs is increased to further improve strength, then the strength of the drain pan is further improved, but the number of divided pieces of insulating material increases and work efficiency further deteriorates
Solution Approach 1:
By separating the drain pan into two panes with different functions, the design allows multiple ribs to be added on the second drain pan without affecting the bonding surface on the first drain pan. The first drain pan maintains a smooth, uninterrupted surface that allows heat insulating material to be bonded in single large pieces, preserving high work efficiency even as the second drain pan gains strength through additional ribs.
3Strength
If ribs are provided on the facing surface of the second drain pan, then the strength is improved and bonding efficiency is improved, but the water drainage performance may be affected
Solution Approach 1:
The rib structure on the second drain pan is designed with specific local characteristics: ribs are provided only on the facing surface that contacts the heat exchanger, while the rear surface and bottom surface remain smooth to facilitate water drainage. This local differentiation allows the ribs to provide strength and bonding efficiency on the facing surface without interfering with water drainage performance on other surfaces.
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
This configuration improves the work efficiency of bonding heat insulating materials while maintaining the strength of the second drain pan, ensuring effective heat exchange and water drainage performance across various installation forms.
Implementation Method 1
a heat exchanger 10 that allows heat to be exchanged between air and refrigerant
Implementation Method 2
a heat exchanger 10 that allows heat to be exchanged between air and refrigerant
Implementation Method 3
bonding of the heat insulating material to the rear surface of the drain pan to prevent condensation
Data Source
AI summary
A heat exchange unit includes a heat exchanger, a first drain pan, and a second drain pan. The heat exchanger is configured to cause heat to be exchanged between air and refrigerant. The first drain pan is provided so as to face the heat exchanger and has an opening through which the air flows. The second drain pan is provided so as to face the heat exchanger and is attached to the first drain pan so as to form an L shape in side view together with the first drain pan. The heat exchange unit is installed in an installation state in which the first drain pan is located below the heat exchanger or in an installation state in which the second drain pan is located below the heat exchanger. The second drain pan includes a rib on a facing surface facing the heat exchanger.