Foamed Insert Element for Heat Pump Base Module Thermal Insulation
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Solution Overview
Problem
Current base module assemblies for heat pumps are inflexible and costly to adapt to different heat exchanger variants, and they have a low thermal insulation effect, leading to inefficiencies in energy transfer and increased manufacturing costs.
Innovation Solution
A base module assembly with a foamed material insert element that can be adapted to various evaporator dimensions and drainage structures, allowing for improved condensate collection and thermal insulation, reducing manufacturing costs and enhancing energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional base module assembly is used, then the structure is simple and manufacturing is straightforward, but it is inflexible and costly to adapt to different heat exchanger variants
Solution Approach 1:
The base module is divided into two functional parts: a removable insert element and a stationary base module body. The insert element contains the condensate collection basin and can be easily removed or replaced, while the base module body remains fixed. This segmentation allows different insert elements to be used with different heat exchanger variants without redesigning the entire base module structure.
Solution Approach 2:
The base module body is designed as a universal platform that can accommodate multiple types of heat exchangers through the use of different insert elements. The standardized interface and mounting structure allow the same base module body to work with various evaporator dimensions and drainage configurations, reducing the need for multiple specialized base module designs.
2Loss of energy
If conventional materials are used in the base module, then manufacturing costs are low, but thermal insulation effect is insufficient leading to energy losses
Solution Approach 1:
The insert element is constructed using composite materials, specifically a thermally insulating foam core surrounded by a metallic outer shell. The foam material provides excellent thermal insulation properties to minimize heat losses from the condensate collection basin, while the metallic shell provides structural integrity and condensation resistance. This composite structure achieves superior thermal performance without significantly complicating the manufacturing process.
3Adaptability or versatility
If the condensate collection basin is made as a single integrated piece, then manufacturing is simpler, but adaptability to different evaporator dimensions is reduced
Solution Approach 1:
The condensate collection system is segmented into the removable insert element that can be tailored to specific evaporator dimensions, while the base module body remains standardized. This allows the condensate collection basin to be optimized for different evaporator sizes and drainage requirements without redesigning the entire base module.
Solution Approach 2:
The insert element is designed to be dynamically removable and replaceable, allowing the system to adapt to different operational requirements and heat exchanger variants. The insert element can be easily taken out and replaced with another insert element of different dimensions or drainage configuration, providing flexibility without permanent modifications to the base module structure.
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 use of a foamed material insert element allows for flexible adaptation to different heat exchangers, reduces production costs, and enhances thermal insulation, leading to improved energy efficiency and reduced heat losses in heat pump dryers.
Implementation Method 1
The use of a foamed material insert element allows for flexible adaptation to different heat exchangers, reduces production costs, and enhances thermal insulation, leading to improved energy efficiency and reduced heat losses in heat pump dryers.
Implementation Method 2
Inside the heat pump, the moisture extracted from the laundry is condensed from the process air in the evaporator and discharged to the outside in liquid form.
Data Source
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AI summary
The invention relates to a base module assembly (2, 3) for a heat pump (12), preferably a heat pump dryer (1), comprising a base module (2) configured to form at least a section of a process air space (15) for accommodating at least one evaporator (17) of the heat pump (12), wherein the base module (2) has at least one condensate collection basin (21) configured to collect condensate from the evaporator (17), and an insert element (3) arranged and configured within the condensate collection basin (21) to accommodate at least the evaporator (17) from above. The base module assembly (2, 3) is characterized in that the insert element (3) is made of a foamed material.