Outdoor Unit Heat Exchanger Support for Condensate Drainage
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Solution Overview
Problem
Existing outdoor units for air-conditioning apparatuses face issues with dew condensation water freezing and corroding heat-transfer pipes, leading to reduced air flow rates and potential breakage, due to inadequate drainage and structural weaknesses in current designs.
Innovation Solution
The outdoor unit incorporates a support member with a first support portion engaged with the frame and a perpendicularly extending support piece that holds the heat-transfer pipes, keeping the heat exchanger away from the bottom plate, thereby preventing dew condensation water from accumulating and maintaining air flow rates without increasing costs or structural weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heat exchangers are stacked vertically to increase the number of rows of heat-transfer pipes, then the heat exchange capacity is improved, but dew condensation water accumulates on the bottom plate causing freezing and corrosion of heat-transfer pipes
Solution Approach 1:
The patent introduces a third dimension (vertical height) by suspending heat exchangers from the upper frame, creating a three-dimensional heat exchange structure. This allows multiple rows of heat-transfer pipes to be arranged vertically without stacking on the bottom plate, enabling dew condensation water to drain freely while maintaining high heat exchange capacity.
Solution Approach 2:
The patent uses suspension members as intermediaries to connect the heat exchangers between the upper frame and bottom plate. These suspension members hold the heat exchangers at an appropriate height, preventing direct contact with accumulated dew condensation water on the bottom plate, thereby eliminating freezing and corrosion issues.
2Object-affected harmful factors
If multiple drain water outlets are provided in the bottom plate to drain dew condensation water, then freezing and corrosion are prevented, but the strength of the bottom plate is reduced
Solution Approach 1:
The patent extracts the drainage function from the bottom plate by allowing dew condensation water to drain through the lower surface of the bottom plate without requiring multiple outlets. The bottom plate maintains its structural integrity while still achieving effective drainage through its inherent permeability or single outlet design.
3Object-affected harmful factors
If a slope is provided to the bottom plate to drain dew condensation water, then drainage efficiency is improved, but the structural complexity and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by providing drainage holes or permeable regions at specific locations on the bottom plate where dew condensation water accumulates, rather than creating a global slope throughout the entire bottom plate structure. This maintains overall structural simplicity while achieving effective local drainage.
4Object-affected harmful factors
If heat pipes are disposed at the lowermost stage to heat dew condensation water and prevent freezing, then freezing is avoided, but manufacturing cost increases
Solution Approach 1:
The patent converts the harmful effect of dew condensation water accumulation into a beneficial drainage mechanism by utilizing gravity and the natural flow of condensate through the bottom plate. This eliminates the need for additional heating components like heat pipes, preventing freezing through passive drainage rather than active heating, thereby reducing manufacturing costs.
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
This configuration effectively prevents dew condensation water from freezing and corroding the heat-transfer pipes, ensuring stable operation and maintaining air flow rates through the heat exchanger while avoiding structural weaknesses and cost increases.
Implementation Method 1
dew condensation water (drain water) generated from the heat exchangers remains on the bottom plate
Implementation Method 2
heat is exchanged between the air and refrigerant in the heat exchangers
Implementation Method 3
heat is exchanged between the air and refrigerant in the heat exchangers
Implementation Method 4
heat-transfer pipes penetrate fins... the fins reject heat transmitted from the circular pipe by the refrigerant moving in the circular pipe
Implementation Method 5
A negative pressure is produced in the outdoor unit by driving the fan, so that the ambient air around the outdoor unit is sucked into the outdoor unit
Data Source
AI summary
An outdoor unit for an air-conditioning apparatus prevents dew condensation water from remaining at a lower portion of a heat exchanger and prevents the flow rate of air passing through the heat exchanger from being decreased, and a method of producing the outdoor unit for an air-conditioning apparatus. The outdoor unit includes a housing including a bottom plate, and a frame at an upper end portion of the housing, a heat exchanger including a plurality of fins arranged in parallel at intervals and heat-transfer pipes penetrating the plurality of fins, and a support member including a first support portion engaged with the frame, a fourth support piece perpendicularly extending from the first support portion, and an engagement piece erected on the fourth support piece and holding the heat-transfer pipes, and the support member supports the heat exchanger such that the heat exchanger is away from the bottom plate.