Electrically conductive and air-tight layer for heat pump systems

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Solution Overview

Problem

Traditional heat pump systems face challenges in achieving both air-tightness and electromagnetic compatibility (EMC) due to the use of non-conductive sealing solutions, which can lead to refrigerant leaks and electromagnetic interference.

Innovation Solution

A heat pump system with an electrically conductive housing and a sealing layer that is both air-tight and electrically conductive, using materials like closed-cell foams, elastomers, and conductive materials such as copper braiding to ensure effective sealing and EMC compliance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-conductive sealing solution is used, then air-tightness is achieved, but electromagnetic compatibility is compromised

Engineering Contradiction:

Improveair-tightnessVSAvoidelectromagnetic interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sealing layer is constructed as a composite material combining non-conductive elastomer foam (providing air-tightness) with conductive elements such as carbon black, metal particles, or conductive fabric (providing electromagnetic shielding). This composite structure simultaneously achieves both air-tightness and electromagnetic compatibility without requiring additional separate components.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If multiple metal panels are assembled, then manufacturing flexibility is improved, but sealing complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidsealing complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The sealing function and electromagnetic shielding function are merged into a single integrated sealing layer component. This eliminates the need for separate sealing materials and shielding materials, simplifying the assembly process despite the use of multiple metal panels.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The composite sealing layer with embedded conductive elements provides both sealing and electromagnetic shielding in a single component, reducing the overall number of parts and assembly steps required when working with multiple metal panels.

Inventive Principle:

Principle #40Composite materials

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

The solution provides an air-tight and refrigerant-tight assembly while ensuring electromagnetic compatibility, preventing refrigerant leaks, and shielding electronic components from electromagnetic interference.

Implementation Method 1

a sealing layer, designated with the reference numeral 3, which is both electrically conductive and air-tight

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

the sealing layer is both electrically conductive and air-tight... ensure that the systems components do not interfere with the external environment

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentEP4538609A1Electrically conductive and air-tight layer for heat pump systems

Publication Date: 2025.04.16 BDR THERMEA GRP

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Figure 3A

AI summary

The present invention relates to a heat pump system with a seal that is both electrically conductive and air-tight. The sealing material comprises a closed-cell foam with a conductive material woven into it. Such a heat pump system meets the Electromagnetic Compatibility (EMC) requirements and also efficiently prevents refrigerant leakages from potentially reaching ignition sources.