Electrical component module
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Solution Overview
Problem
The existing electrical component modules for air conditioners have a large size in the upward and downward direction due to the arrangement of low voltage and high voltage electronic components, making them unsuitable for outdoor units with limited space and requiring complex attachment and detachment procedures.
Innovation Solution
The electrical component module is divided into a main board and a power board, mounted on a fixed plate with the main board facing the service panel and the power board facing the back, allowing for vertical arrangement of power devices on the power board for thermal coupling with a cooler, reducing the overall size and facilitating easy attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate mounting of electrical components is used, then individual component replacement is possible, but assembly time and labor costs increase
Solution Approach 1:
The patent combines multiple electrical components (battery, capacitor, relay, fuse) with their mounting structure into a single integrated module. The components are electrically and mechanically connected to a circuit board that is firmly attached to the housing, creating one replaceable unit that reduces assembly time while maintaining replacement capability.
Solution Approach 2:
The electrical component module is designed as a separate, self-contained unit that can be easily removed and replaced as a whole. This segmentation allows the entire assembly to be treated as a single modular component, facilitating quick replacement without affecting other parts of the device.
2Ease of manufacture
If separate mounting of electrical components is used, then individual component access is possible, but the number of parts and assembly complexity increase
Solution Approach 1:
Multiple electrical components are merged into a single integrated module with a unified housing and circuit board. This reduces the total number of separate parts while maintaining access to all components through the module's standardized interface, simplifying the overall assembly structure.
3Ease of repair
If separate mounting of electrical components is used, then individual component servicing is possible, but servicing time and costs increase
Solution Approach 1:
The electrical components are combined into an integrated module that can be serviced as a complete unit. The module's design with standardized mounting and electrical connections allows for quick removal and replacement, reducing servicing time while maintaining the ability to service the electrical components.
Solution Approach 2:
The integrated electrical module is designed as a separate, self-contained unit that can be easily removed from the device housing. This segmentation enables quick servicing by replacing the entire module rather than individually accessing and servicing each component, significantly reducing servicing time and costs.
4Ease of manufacture
If separate mounting of electrical components is used, then individual component installation is possible, but installation time and labor costs increase
Solution Approach 1:
Multiple electrical components are merged into a single integrated module with pre-established electrical connections and mounting structure. This allows the entire assembly to be installed as one unit, dramatically reducing installation time and labor costs while maintaining the capability to install electrical components.
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 significantly reduces the size of the electrical component module in the upward and downward direction, enabling its application in outdoor units with limited space and allows for effective cooling of power devices, simplifying the attachment and maintenance process.
Implementation Method 1
the plurality of power devices is vertically arranged on the front surface of the power board and is thermally couplable with the cooler
Data Source
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AI summary
An electrical component module (200) includes a main board (260) having a front surface on which an electronic component forming a part of a control circuit is mounted, a power board (270) having a front surface on which a plurality of power devices (274) forming a remaining part of the control circuit is mounted, and a fixed plate (210) on which the main board (260) and the power board (270) are mounted, with a back surface of the main board (260) facing a front surface of the fixed plate (210), and with a back surface of the power board (270) facing a back surface of the fixed plate (210). The fixed plate (210) is attached to a machine section. The plurality of power devices (274) is vertically arranged on the front surface of the power board (270) and face a cooler (300) for thermal coupling. The power board (270) has a size in an upward and downward direction set to correspond to a size of the plurality of power devices (274) vertically arranged in the upward and downward direction, and the main board (260) has a size in the upward and downward direction set to correspond to the size of the power board (270) in the upward and downward direction.