Power Device Cooling Structure for Air Conditioner Vibration Loads
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Solution Overview
Problem
In air conditioners with refrigerant jackets, vibrations from the compressor can cause excessive loads on lead wires of power devices, leading to loose connections and potential damage due to the direct attachment of the refrigerant jacket to the power device.
Innovation Solution
A common support member, such as a switch box, connects the printed circuit board and refrigerant jacket, allowing them to vibrate together and indirectly fixing the refrigerant jacket through a heat transfer plate, thereby reducing the load on lead wires and ensuring effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the refrigerant jacket is directly attached to the power device to cool it, then the cooling efficiency is improved, but the lead wires of the power device are subjected to excessive load due to vibration from the compressor
Solution Approach 1:
The support structure is segmented into multiple components: the refrigerant jacket, the heat transfer plate, and the switch box. The refrigerant jacket is separated from direct attachment to the power device, instead being mounted on the switch box which also supports the printed circuit board. This segmentation isolates the vibration-prone refrigerant jacket from the sensitive power device connections.
Solution Approach 2:
The switch box serves as an intermediary structure between the refrigerant jacket and the power device. Both the refrigerant jacket and the printed circuit board are mounted on this common support structure, allowing them to move together during vibration while maintaining proper thermal contact through the heat transfer plate, thus preventing excessive load on lead wires.
2Loss of energy
If the refrigerant jacket is fixed rigidly to ensure stable cooling, then the heat transfer efficiency is improved, but the excessive vibration load damages the power device
Solution Approach 1:
The support functions are merged into a common structure - the switch box serves as the mounting base for both the refrigerant jacket and the printed circuit board. This unified support structure ensures that both components experience the same vibrations and maintain their relative positions, preserving heat transfer efficiency while protecting against differential movement damage.
Solution Approach 2:
The heat transfer plate acts as an intermediary thermal interface between the power device and the refrigerant jacket, while the switch box serves as an intermediary mechanical support. This intermediary structure decouples the rigid mechanical connection from the thermal connection, allowing vibration isolation while maintaining heat transfer efficiency.
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 prevents damage to the power device by minimizing the excessive load on lead wires during vibrations and ensures efficient heat transfer and dissipation, even at low refrigerant flow rates.
Implementation Method 1
Refrigerant flowing through the refrigerant jacket (20) cools the power device (33)
Implementation Method 2
the heat transfer plate (50) ensures a predetermined thermal capacity
Data Source
AI summary
An air conditioner includes a printed circuit board (31) to which a power device (33) is attached; and a refrigerant jacket (20) which is connected to the power device (33), and through which refrigerant used for a refrigeration cycle flows. The printed circuit board (31) is accommodated in a switch box (40). The refrigerant jacket (20) is fixed to the switch box (40) through a heat transfer plate (50), and the refrigerant jacket (20) and the printed circuit board (31) are connected together by the switch box (40).