Heat Pump Control Box Layout for Airtight Sensor Connections
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Solution Overview
Problem
Heat pump devices using flammable refrigerants with low global warming potential (GWP) face challenges in ensuring airtightness of electrical component boxes while simplifying assembly, as existing solutions require extensive wiring connections through connection terminals, increasing man-hours and potential ignition risks.
Innovation Solution
A heat pump device design featuring a sealed refrigerant circuit with sensors and a control board housed in an electrical component box, where the control board is positioned to close the opening and connectors for sensors are mounted on an exposed portion, allowing for easy airtightness and assembly, with wiring connections that do not ignite even when exposed to flammable refrigerants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminals are used to connect wirings through the electrical component box, then electrical components can be connected to sensors, but the assembly process becomes complex and time-consuming with extensive wiring connections
Solution Approach 1:
The control board is integrated directly into the electrical component box, merging two previously separate components. This integration eliminates the need for extensive wiring connections through connection terminals, significantly reducing assembly time while maintaining reliable electrical connections through direct mounting of sensors and components on the control board
2Object-affected harmful factors
If electrical components are placed away from the heat exchanger to prevent ignition, then safety is improved, but the electrical component box requires complex sealing to maintain airtightness
Solution Approach 1:
The control board with electrical components is extracted from the heat exchanger area and housed in a separate electrical component box. This spatial separation prevents ignition risks by keeping electrical components away from flammable refrigerant, while the box itself provides the necessary sealing functionality through its housing structure rather than complex internal sealing mechanisms
3Reliability
If the control board is positioned inside the electrical component box, then airtightness is improved, but access for wiring connections becomes difficult
Solution Approach 1:
The control board serves multiple functions: it maintains the airtight seal by closing the opening of the electrical component box, provides mounting surfaces for sensors and connectors, and enables wiring connections through its exposed portions. This multi-functionality resolves the contradiction by making the control board both a sealing element and an accessible connection point
Data Source
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AI summary
The present disclosure provides a heat pump device that easily ensures airtightness of an electrical equipment box, and allows easy assembling of the electrical equipment box. The heat pump device of the present disclosure includes: a refrigerant circuit inside which a flammable refrigerant is sealed and circulated, and to which a compressor and a heat exchanger are connected; a sensor attached to each portion of the refrigerant circuit; a control board that is connected to the sensor, and controls driving of the compressor; and an electrical component box storing the control board, wherein the control board is disposed at a location for closing an opening portion provided on the electrical component box, and a connector for connecting the sensor and the control board is mounted on an exposed portion of the control board that is a portion exposed from the electrical component box through the opening portion.