Outdoor Heat Exchanger Cap Drainage for Header Manifold Corrosion
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Solution Overview
Problem
Outdoor units of refrigeration apparatuses are susceptible to metal corrosion due to water infiltration, which can lead to electrical corrosion of the header manifold, especially when water accumulates in the cap or drain pan and enters the reticulated portion of the cage-shaped corrosion-preventing body.
Innovation Solution
A cap made of rubber with drainage structures such as openings, cutouts, or gutters is placed on the lower end of the header manifold to allow dew and condensation to drain out, preventing heat exchanger corrosion and refrigerant leakage. The cap is designed with a side face drainage structure, an inclined bottom face, and a projection to ensure efficient water routing and prevent water infiltration, using materials like natural rubber or fluorine rubber for waterproofness and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cap or cage-shaped electrical-corrosion-preventing body is provided to the lower end of the header manifold, then electrical corrosion prevention is improved, but water infiltration and accumulation in the cap causes header manifold corrosion
Solution Approach 1:
The patent extracts the harmful function of the cap by providing drainage holes that allow water to escape. The cap retains its protective function against electrical corrosion while the drainage holes remove the harmful water accumulation effect, transforming the cap from a potential water trap into an effective protective component.
Solution Approach 2:
The patent converts the harmful effect of water accumulation into a beneficial drainage function. By adding drainage holes, the cap's ability to protect against electrical corrosion is enhanced while simultaneously providing a controlled path for water to escape, turning the potential harm of water trapping into a beneficial active drainage system.
2Reliability
If the cap is made of rubber for waterproofness and vibration resistance, then sealing performance is improved, but water can still infiltrate through gaps between the header manifold and cap
Solution Approach 1:
The drainage holes act as an intermediary element that mediates between the sealing function of the rubber cap and the water infiltration problem. They provide a controlled passage that allows water to escape while maintaining the overall sealing integrity of the cap-header manifold assembly.
Solution Approach 2:
The rubber cap utilizes the flexible properties of rubber material to maintain tight sealing against the header manifold while the drainage holes provide controlled water escape paths. The flexibility allows the cap to conform to the header manifold surface, reducing gaps while the drainage holes manage water infiltration.
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 effectively prevents heat exchanger corrosion and refrigerant leakage by ensuring efficient drainage of condensation and dew, raising the lower end of the header manifold to prevent water contact, and guiding condensation away from the header manifold, thus reducing the risk of corrosion and leakage.
Implementation Method 1
having the cap placed on the lower end of the header manifold and an opening part for draining water provided to the cap, it is possible for dew from the heat exchanger that has entered via a gap between the header manifold and the cap to drain out
Implementation Method 2
the bottom face of the opening is set to incline downward from the inside toward the outside
Data Source
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AI summary
An outdoor unit (20) of an air-conditioning apparatus (1) according to the present embodiment comprises a heat exchanger (25), a floor frame (8), and a cap (14). The heat exchanger (25) is made of aluminum or aluminum alloy. The heat exchanger (25) has a plurality of flat pipes (2) arranged in rows so as to face a side face, a header manifold (6) to which each of the flat pipes (2) is connected, and a plurality of fins (4) joined to the flat pipes (2). In the heat exchanger (25), exchange of heat occurs between a fluid flowing inside the flat pipes (2) and air flowing outside the flat pipes (2). The heat exchanger (25) is mounted on the floor frame (8). The cap (14) covers a lower end part (6a) of the header manifold (6) from below. The cap (14) has a drainage opening (17) through which water that has entered via a gap between the header manifold (6) and the cap (14) drains out.