Outdoor Unit Terminal Block Cover for Water-Safe Cable Routing
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Solution Overview
Problem
In multi-split air-conditioning systems, the arrangement of refrigerant pipes below a terminal block in outdoor units creates a risk of water ingress through gaps in the conduit plate, leading to potential operational issues and difficulty in connecting electric wires to the terminal block, especially under adverse weather conditions.
Innovation Solution
The outdoor unit design includes a conduit plate with a terminal block cover, an outer casing cover, and a cable connection cover featuring attachment holes, which prevents water entry and facilitates easy connection of conduit cables to the terminal block, even when positioned beside the terminal block cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the conduit plate is positioned beside the terminal block cover to allow cable connection, then the connection accessibility is improved, but water drops can enter through gaps in the conduit plate and stick to the terminal block
Solution Approach 1:
The conduit plate is divided into multiple functional components: a terminal block cover portion that covers the terminal block, an outer casing cover portion that provides structural support and positioning, and a cable connection cover portion that enables cable access. This segmentation allows each portion to perform its specific function while collectively preventing water ingress and ensuring cable accessibility.
Solution Approach 2:
The cable connection cover portion acts as an intermediary element that provides a protected pathway for cables to connect to the terminal block. It includes through holes that allow cable passage while maintaining the waterproof seal of the overall conduit plate structure, thus mediating between the need for cable access and water protection.
2Device complexity
If a common conduit plate is used below the terminal block, then the structure is simplified, but refrigerant pipes arranged in the up-down direction prevent conduit cables from being connected
Solution Approach 1:
The cable connection functionality is moved from the vertical dimension (below the terminal block) to the lateral dimension (beside the terminal block cover). The conduit plate extends in the lateral direction with the cable connection cover portion positioned beside the terminal block, allowing cables to connect horizontally rather than vertically, thus avoiding interference with refrigerant pipes.
Solution Approach 2:
The conduit plate is segmented into distinct functional portions: the terminal block cover portion for electrical connection, the outer casing cover portion for structural integrity, and the cable connection cover portion for cable access. This segmentation allows the cable connection function to be positioned independently beside the terminal block rather than below it, resolving the spatial conflict with refrigerant pipes.
3Object-affected harmful factors
If the conduit plate is positioned below the terminal block, then water protection is improved, but cable connection becomes difficult when positioned side by side with the terminal block
Solution Approach 1:
The conduit plate is segmented so that the terminal block cover portion remains below the terminal block for optimal water protection, while the cable connection cover portion extends laterally beside the terminal block for easy cable access. This segmentation allows both water protection and cable connection ease to be optimized in their respective positions.
Solution Approach 2:
The conduit plate is designed as a multi-functional integrated structure that simultaneously provides water protection (through the terminal block cover portion positioned below), structural support (through the outer casing cover portion), and cable connection capability (through the laterally positioned cable connection cover portion with through holes).
4Ease of manufacture
If the terminal block and conduit plate are covered by a single cover structure, then manufacturing is simplified, but water drops can still enter through gaps and reach the terminal block
Solution Approach 1:
The cover structure is segmented into the terminal block cover portion, outer casing cover portion, and cable connection cover portion, each with specific waterproof sealing functions. While this increases manufacturing complexity compared to a single cover, it provides comprehensive water protection by eliminating gaps between the conduit plate and housing through coordinated sealing at each segment interface.
Data Source
AI summary
An outdoor unit of an air-conditioning apparatus in which indoor units are connected, includes: a housing forming an outer casing of the outdoor unit; a terminal block located at a side of the housing; and a conduit plate to be attached to the terminal block. The conduit plate includes: a terminal block cover to be attached to the housing to cover the terminal block, and having an opening portion formed at a lower portion of the terminal block cover; an outer casing cover to be attached to the terminal block cover to cover the opening portion of the terminal block cover, and having an opening portion at a side of the outer casing cover; and a cable connection cover to be attached to the side of the outer casing cover, and having attachment holes for connection of a conduit cable to be connected to the terminal block.