External Sensor Box for Refrigerant Leak Detection
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Solution Overview
Problem
Existing refrigeration cycle apparatuses using flammable or slightly flammable refrigerants face challenges in detecting leaks without modifying the unit device design, as the sensors require space and are prone to failure due to water condensation.
Innovation Solution
A storage box is attached to the outer wall of the unit body, allowing the sensor to be placed outside without modifying the unit design, with a communication passage that directs refrigerant leaks to the sensor for accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor is attached inside the unit body to detect refrigerant leakage, then the detection function is achieved, but the unit body requires additional space and design modification
Solution Approach 1:
The sensor is extracted from the unit body and relocated to the storage box (drain pan), which is a separate component. This allows the sensor to be installed without modifying the unit body design, while still achieving refrigerant leakage detection through the communication passage that connects the unit body to the storage box.
2Measurement precision
If the sensor is placed below the refrigerant pipe to detect refrigerant leakage, then the detection sensitivity is improved, but water condensation droplets may adhere to the sensor causing failure
Solution Approach 1:
The storage box (drain pan) acts as an intermediary between the unit body and the sensor. Refrigerant that leaks into the storage box is detected by the sensor, while water condensation is directed away from the sensor through the drain hole, preventing direct contact between water droplets and the sensor.
Solution Approach 2:
The storage box creates a localized environment where refrigerant can accumulate near the sensor for detection, while water condensation is channeled through a separate path (drain hole) away from the sensor. This spatial separation of refrigerant and water paths protects the sensor from water damage while maintaining detection sensitivity.
3Ease of manufacture
If the unit device is modified to provide space for the sensor, then the sensor can be installed, but the design and manufacturing complexity increases
Solution Approach 1:
The sensor is combined with the storage box (drain pan) as an integrated assembly, rather than being a separate component in the unit body. This merging allows the sensor to be installed in the storage box without requiring any modifications to the unit body design, simplifying both manufacturing and assembly processes.
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 leak detection without requiring space within the unit body for the sensor, preventing sensor failures from water condensation and allowing for easy maintenance, while effectively utilizing existing drain outlets for refrigerant collection.
Implementation Method 1
a sensor that detects leakage of the refrigerant
Implementation Method 2
The flammable or slightly flammable refrigerant has a specific gravity greater than air. The refrigerant sensor, therefore, needs to be provided below a refrigerant pipe from which the refrigerant may leak.
Data Source
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AI summary
A unit device of a refrigeration cycle apparatus forms part of a refrigerant circuit using flammable or slightly flammable refrigerant. The unit device includes a unit body and a storage box. The storage box is provided with a sensor that detects leakage of the refrigerant and a communicating portion that communicates with the unit body. The storage box is attached to an outer wall portion of the unit body.