Outdoor Unit Heat Exchanger Support for Load and Corrosion Control
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Solution Overview
Problem
Existing outdoor units for air-conditioning apparatuses face issues with heat exchanger deformation due to perpendicular downward loads and electrolytic corrosion from metal powders like iron and copper, which are not effectively addressed by current designs.
Innovation Solution
The design incorporates a metal bottom plate with a heat exchanger of a different metal, featuring an L-shaped configuration and an upper support that continuously covers the heat exchanger, including a groove to reduce water contact and distribute loads evenly, preventing deformation and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat exchangers are stacked up to increase capacity, then the productivity of the air-conditioning apparatus is improved, but the heat exchanger may be locally deformed by the perpendicular downward load
Solution Approach 1:
A support plate is introduced as an intermediary component between stacked heat exchangers. The support plate receives perpendicular downward loads from upper heat exchangers and distributes them to the bottom plate, preventing direct transmission of concentrated loads to the heat exchanger fins and tubes. This mediator structure enables safe stacking while maintaining heat exchanger integrity.
Solution Approach 2:
The support plate provides localized structural reinforcement at critical load-bearing positions beneath the heat exchanger. By strengthening specific areas where loads are transmitted to the bottom plate, the system can support stacked configurations without compromising the overall shape stability of the heat exchanger components.
2Strength
If metal powders like iron powder or copper powder cling to the heat exchanger, then the heat exchanger efficiency may be improved through better thermal contact, but electrolytic corrosion occurs due to rainwater and drain water
Solution Approach 1:
The patent applies anti-corrosion coating materials (such as plastic coatings or corrosion-resistant metal coatings) on the heat exchanger surfaces where metal powders accumulate. This composite structure combines the thermal conductivity benefits of metal powder accumulation with the corrosion protection of the coating layer, allowing the system to maintain thermal efficiency while preventing electrolytic corrosion from rainwater and drain water.
Solution Approach 2:
The patent converts the potentially harmful effect of metal powder accumulation (which could cause corrosion) into a beneficial thermal contact enhancement by applying anti-corrosion coatings. The coatings allow metal powders to remain in place for improved thermal contact while protecting against the corrosive effects of water, thus transforming a harmful situation into a beneficial one.
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 local deformation of the heat exchanger under stacked loads and reduces electrolytic corrosion by minimizing water contact and distributing loads across the upper support, ensuring the heat exchanger remains intact and corrosion-free.
Implementation Method 1
even if the heat exchangers are stacked up and thereby the perpendicular downward load generated by the stacked heat exchangers on the upper support, is applied on the upper support, the load can be distributed on the whole upper support
Implementation Method 2
since the upper support which continuously covers the front surface portion, the corner portion and the side surface portion when viewed from above, the upper support functions as the cover which is formed to cover the top of the heat exchanger. As such, even if the rainwater and/or the drain water flows into the heat exchanger, it is possible to reduce the opportunities to bring the rainwater and/or the drain water into contact with the heat exchanger
Data Source
AI summary
The present invention discloses an outdoor unit 100 for an air-conditioning apparatus, comprising: a bottom plate made of metal; a heat exchanger made of metal that is different from metal of the bottom plate, which includes a front surface portion, a corner portion and a side surface portion, and which is formed in an L-shape when viewed from; and an upper support which continuously covers the front surface portion, the corner portion and the side surface portion when viewed from above.