Abstract:
An air conditioner includes a compressor, a condenser, an expansion device, and an evaporator. The air conditioner further includes an electric unit including electric components to operate the air conditioner. A cooling module is disposed at least on a side of the electric unit to dissipate heat generated from the electric unit, and at least a portion of the refrigerant tube supply refrigerant discharged from the evaporator to the cooling module. The refrigerant supplied to the cooling module exchanges heat with the electric unit and then flows to the compressor.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2011-0054678 filed on Jun. 7, 2011, which is hereby incorporated by reference in its entirety. 
       BACKGROUND 
       [0002]    The present disclosure relates to an air conditioner, and in particular with an air conditioner with a cooling module. 
         [0003]    Air conditioners are used to maintain indoor air at predetermined states according to desired purposes and preferences. For example, air conditioners are used to keep indoor air cool in summer and warm in winter. In addition, air conditioners are used to adjust the humidity of indoor air for providing pleasant and clean environments. In the refrigeration cycle of an air conditioner, refrigerant may be compressed, condensed, expanded, and evaporated for operation in cooling or heating mode. 
         [0004]    Air conditioners can be classified into split air conditioners in which indoor and outdoor units are separated; and one-boy air conditioners in which indoor and outdoor units are integrated. An outdoor unit includes an outdoor heat exchanger for heat exchanging with outdoor air, and an indoor unit includes an indoor heat exchanger for heat exchanging with indoor air. 
         [0005]    When an air conditioner operates in cooling mode, an outdoor heat exchanger functions as a condenser, and an indoor heat exchanger functions as an evaporator. When an air conditioner operates in heating mode, an indoor heat exchanger functions as a condenser, and an outdoor heat exchanger functions as an evaporator. 
         [0006]    An electric unit is disposed in an indoor unit of an air conditioner for operating the air conditioner. Such an electric unit includes a plurality of control components. 
         [0007]    While an air conditioner operates, the electric unit of the air conditioner may generate a lot of heat. The temperature of the electric unit may increase to about 70° C. to 80° C. 
         [0008]    If the electric unit of an air conditioner is not sufficiently cooled, control components of the electric unit may operate abnormally. Then, the air conditioner may improperly operate. For example, exchange operations of the air conditioner may be insufficiently carried out, or the air conditioner may be out of order. 
         [0009]    Therefore, in an air conditioner of the related art, a substrate having high thermal conductivity is disposed at a side of an electric unit for cooling the electric unit by heat exchanging with outdoor air (heat sink structure). 
         [0010]    However, such a heat sink structure is not effective in hot areas (for example, in areas where the outdoor temperature reaches about 50° C.). 
       SUMMARY 
       [0011]    Embodiments provide an air conditioner in which an electric unit can be efficiently cooled. 
         [0012]    In one embodiment, there is provided an air conditioner comprising a compressor, a condenser, an expansion device, and an evaporator, the air conditioner further comprising an electric unit including electric components to operate the air conditioner; a cooling module disposed at least on a side of the electric unit to dissipate heat generated from the electric unit; and at least a portion of a refrigerant tube supply refrigerant discharged from the evaporator to the cooling module, wherein the refrigerant supplied to the cooling module exchanges heat with the electric unit and then flows to the compressor. 
         [0013]    In another embodiment, there is provided an air conditioner configured comprising a compressor, a condenser, an expansion device, and an evaporator, the air conditioner further comprising an electric unit including electric components to operate the air conditioner; and a cooling module disposed on a side of the electric unit to dissipate heat generated from the electric unit; and at least a portion of a refrigerant tube to supply refrigerant discharged from the condenser to the cooling module, wherein the refrigerant supplied to the cooling module exchanges heat with the electric unit and then flows to the evaporator. 
         [0014]    The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a view illustrating an air conditioner according to a first embodiment. 
           [0016]      FIG. 2  is a perspective view illustrating an inner structure of an outdoor unit according to the first embodiment. 
           [0017]      FIG. 3  is a schematic view illustrating the air conditioner according to the first embodiment. 
           [0018]      FIG. 4  is a perspective view illustrating an assembly of an electric unit and a cooling module according to the first embodiment. 
           [0019]      FIG. 5  is a perspective view illustrating the cooling module according to the first embodiment. 
           [0020]      FIG. 6  is a sectional view taken along line II-II′ of  FIG. 5 . 
           [0021]      FIG. 7  is a sectional view taken along line I-I′ of  FIG. 4 . 
           [0022]      FIG. 8  is a sectional view illustrating an assembly of an electric unit and a cooling module according to a second embodiment. 
           [0023]      FIG. 9  is a perspective view illustrating a cooling module according to a third embodiment. 
           [0024]      FIG. 10  is a schematic view illustrating a refrigerant cycle according to a fourth embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0025]    Hereinafter, embodiments will now be described with reference to the accompanying drawings. However, the spirit and scope set forth in the present disclosure are not limited to the embodiments. Those of ordinary skill in the art will easily propose other embodiments within the spirit and scope. 
         [0026]      FIG. 1  is a perspective view illustrating an air conditioner according to a first embodiment, and  FIG. 2  is a perspective view illustrating an inner structure of an outdoor unit  10  according to the first embodiment. 
         [0027]    Referring to  FIGS. 1 and 2 , the air conditioner  1  of the first embodiment includes the outdoor unit  10  configured to exchange heat with outdoor air, an indoor unit  20  disposed in an indoor area to exchange heat with indoor air, and a pipe  30  connecting the outdoor unit  10  and the indoor unit  20 . 
         [0028]    The outdoor unit  10  includes a case  100  that forms the exterior of the outdoor unit  10  and accommodates a plurality of components. The case  100  includes an intake grill (not shown) and a discharge grill  105 . Indoor air is sucked into the case  100  through the intake grill, and after heat exchange, the air is discharged through the discharge grill  105 . The discharge grill  105  may be provided in plurality. In this case, the discharge grills  105  may be vertically arranged. 
         [0029]    The case  100  accommodates a compressor  110  configured to compress refrigerant, a gas-liquid separator  115  configured to separate a liquid portion from the refrigerant before the refrigerant is introduced into the compressor  110 , an outdoor heat exchanger ( 121 ,  122 ), and a blower fan  130  configured to blow outdoor air to the outdoor heat exchanger ( 121 ,  122 ). 
         [0030]    The case  100  includes a blower chamber  101  in which the outdoor heat exchanger ( 121 ,  122 ) is disposed; and a machinery chamber  102  in which the compressor  110  and the gas-liquid separator  115  are disposed. The blower chamber  101  and the machinery chamber  102  may be divided by a barrier  103 . 
         [0031]    The heat exchanger ( 121 ,  122 ) includes a refrigerant tube  121  and heat-exchange fins  122 . The refrigerant flows through the refrigerant tube  121 , and the heat-exchange fins  122  facilitate heat exchange between the refrigerant and outdoor air. The refrigerant tube  121  may be disposed through the heat-exchange fins  122 . The outdoor heat exchanger ( 121 ,  122 ) may extend in the length direction of the case  100  from an upper side to a lower side of the case  100 . In addition, the outdoor heat exchanger ( 121 ,  122 ) may be bent in a reverse L shape from a rear surface to lateral surfaces of the case  100 . 
         [0032]    The blower fan  130  may be disposed at a rear side of the discharge grill  105 . The blower fan  130  may be provided in plurality. In this case, the blower fans  130  may be disposed at upper and lower portions of the case  100 . The number of the blower fans  130  and the number of the discharge grills  105  are not limited. For example, one blower fan  130  and one discharge grill  105  may be provided according to the lengths or arrangement of the outdoor heat exchanger ( 121 ,  122 ). 
         [0033]    An electric unit  200  including a plurality of control components is disposed in the machinery chamber  102 . For example, the electric unit  200  may be disposed at an upper side of the compressor  110 . 
         [0034]      FIG. 3  is a schematic view illustrating the air conditioner  1  of the first embodiment. 
         [0035]    Referring to  FIG. 3 , the air conditioner  1  of the first embodiment includes the compressor  110  configured to compress the refrigerant; and a four-way valve  113  configured to guide the refrigerant from the compressor  110  to the outdoor heat exchanger ( 121 ,  122 ) or to an indoor heat exchanger ( 151 ,  152 ). 
         [0036]    If the air conditioner  1  is operating in cooling mode, the outdoor heat exchanger ( 121 ,  122 ) functions as a condenser. In this case, the refrigerant discharged from the compressor  110  is introduced into the outdoor heat exchanger ( 121 ,  122 ) through the four-way valve  113 . If the air conditioner  1  is operating in heating mode, the indoor heat exchanger ( 151 ,  152 ) functions as a condenser. In this case, the refrigerant discharged from the compressor  110  is introduced into the indoor heat exchanger ( 151 ,  152 ) through the four-way valve  113 . 
         [0037]    An explanation will now be given on an exemplary case where the air conditioner  1  is operating in cooling mode.  FIG. 3  shows flows of the refrigerant in cooling mode. 
         [0038]    The outdoor unit  10  includes the blower fan  130  configured to blow outdoor air to the outdoor heat exchanger ( 121 ,  122 ); and a fan motor  132  configured to drive the blower fan  130 . In addition, the outdoor unit  10  includes an expansion device  140  in which the refrigerant is decompressed after passing through the outdoor heat exchanger ( 121 ,  122 ). 
         [0039]    The indoor unit  20  includes the indoor heat exchanger ( 151 ,  152 ). After passing through the expansion device  140 , the refrigerant is introduced into the indoor heat exchanger ( 151 ,  152 ) and is evaporated in the indoor heat exchanger ( 151 ,  152 ). The indoor heat exchanger ( 151 ,  152 ) includes a refrigerant tube  151  and heat-exchange fins  152 . The refrigerant flows in the refrigerant tube  151 , and the heat-exchange fins  152  facilitate heat exchange between the refrigerant and indoor air. An indoor blower fan  160  and a fan motor  162  are disposed at a side of the indoor heat exchanger ( 151 ,  152 ). 
         [0040]    A refrigerant tube  50  and a branch tube  32  branching off from the refrigerant tube  50  are disposed between an outlet side of the indoor heat exchanger ( 151 ,  152 ) and an inlet side of the compressor  110 . The refrigerant tube  50  may be referred to as a main tube, and the branch tube  32  may be referred to as a branch tube or pipe. 
         [0041]    A flow controller  170  is provided on the refrigerant tube  50  at a position from which the branch tube  32  branches off, so as to control the flow rate of the refrigerant flowing to the branch tube  32 . The flow controller  170  includes a valve device. At least a portion of the refrigerant flowing in the refrigerant tube  50  may be guided to the branch tube  32  by adjusting the opening degree of the flow controller  170 . 
         [0042]    The electric unit  200  is disposed at a side of the branch tube  32 . The refrigerant flowing through branch tube  32  may exchange heat with the electric unit  200 . For example, the temperature of the refrigerant flowing in the branch tube  32  may be about 10° C. because the refrigerant has passed through the indoor heat exchanger ( 151 ,  152 ), and the temperature of the electric unit  200  may be about 70° C. to 80° C. Thus, owing to the temperature difference between the refrigerant and the electric unit  200 , the electric unit  200  may be cooled. That is, heat may be dissipated from the electric unit  200 . 
         [0043]    After exchanging heat with the electric unit  200 , the refrigerant flowing in the branch tube  32  is mixed with the refrigerant flowing in the refrigerant tube  50  at a joint part  55 . Then, the refrigerant flows to the compressor  110  through the four-way valve  113 . 
         [0044]    In this way, since the refrigerant flows from the indoor heat exchanger (evaporator) ( 151 ,  152 ) to the compressor  110  through the electric unit  200 , heat can be dissipated from the electric unit  200 . Therefore, the electric unit  200  can be kept at a predetermined temperature for stable operation. 
         [0045]    On the other hand, if the air conditioner  1  is operated in heating mode, the electric unit  200  may be disposed between an inlet side of the compressor  110  and an outlet side of the outdoor heat exchanger ( 121 ,  122 ) functioning as an evaporator. If the air conditioner  1  is operated in normal heating mode, since the temperature of outdoor air may be low, the electric unit  200  may be naturally cooled by the outdoor air. Therefore, the electric unit  200  may be less cooled by the refrigerant in heating mode as compared with in cooling mode. 
         [0046]    Referring to  FIG. 3  again, although the flow controller  170 , electric unit  200 , branch tube  32 , and joint part  55  are shown to be in the outdoor unit  10 , these parts can be installed in the indoor unit  20  in an alternative embodiment. Thus, the above-mentioned parts may be installed in an outdoor unit  10  or in an indoor unit  20  or in both the outdoor unit  10  and the indoor unit  20  as the need arises. 
         [0047]      FIG. 4  is a perspective view illustrating an assembly of the electric unit  200  and a cooling module  250  according to the first embodiment;  FIG. 5  is a perspective view illustrating the cooling module  250  according to the first embodiment;  FIG. 6  is a sectional view taken along line II-II′ of  FIG. 5 ; and  FIG. 7  is a sectional view taken along line I-I′ of  FIG. 4 . 
         [0048]    Referring to  FIGS. 4 to 7 , the electric unit  200  of the first embodiment includes an electric board  210  and a plurality of electric components  220  disposed on the electric board  210 . The electric board  210  may be a main body of the electric unit  200 . The electric components  220  include a first heating component  261  and a second heating component  262 . 
         [0049]    The cooling module  250  is disposed at a side of the electric unit  200  to cool the electric unit  200 . The first heating component  261  and the second heating component  262  may be disposed on the bottom side of the electric board  210  facing the topside of the cooling module  250 . In other words, the first heating component  261  and the second heating component  262  may be disposed between the electric board  210  and the cooling module  250 . 
         [0050]    The first and second heating components  261  and  262  are parts that generate heat more than other electric components  220 . For example, parts generating heat equal to or more than a reference amount may be the first and second heating components  261  and  262 . Examples of the first and second heating components  261  and  262  may include a micro computer, an inverter, a converter, an electrically erasable programmable read only memory (EEPROM), a rectification diode, and a condenser. 
         [0051]    The first and second heating components  261  and  262  may make contact with a side of the cooling module  250 . A heat transfer member having a high thermal conductivity may be disposed between the cooling module  250  and the first and second heating components  261  and  262 . The number of the first and second heating components  261  and  262  is not limited. For example, the number of the first and second heating components  261  and  262  may be one, three, or more. 
         [0052]    The cooling module  250  includes a module main body  251 ; a module inlet part  252  disposed on a side of the module main body  251  to introduce the refrigerant; and a module outlet part  253  disposed on the other side of the module main body  251  to discharge the refrigerant. The module inlet part  252  or the module outlet part  253  may be a part of a refrigerant tube for introducing the refrigerant into the cooling module  250  or discharging the refrigerant from the cooling module  250 . 
         [0053]    Refrigerant passages  255 ,  256 , and  258  are formed in the module main body  251  so that the refrigerant introduced through the module inlet part  252  can flow in the module main body  251 . The refrigerant passages  255 ,  256 , and  258  may be refrigerant flow channels formed in the module main body  251 . After passing through an evaporator, the refrigerant may be introduced into the module main body  251  through the module inlet part  252 . 
         [0054]    The refrigerant passages  255 ,  256 , and  258  include an inlet passage  255  connected to the module inlet part  252 ; an outlet passage  256  connected to the module outlet part  253 ; and a branch passage  258  branching off from at least a position of the inlet passage  255  to the outlet passage  256 . The branch passage  258  may include a plurality of flow passages. The refrigerant may flow from the inlet passage  255  to the outlet passage  256  through the branch passage  258 . 
         [0055]    While flowing in the refrigerant passages  255 ,  256 , and  258 , the refrigerant may exchange heat with the first and second heating components  261  and  262 . Thus, the first and second heating components  261  and  262  may be cooled. Thereafter, the refrigerant may be discharged through the module outlet part  253  and flow to the compressor  110 . 
         [0056]    Hereinafter, second to fourth embodiments will be described. In the following descriptions of the second to fourth embodiments, the same elements as those of the first embodiment will be denoted by the same reference numerals, and differences from those of the first embodiment will be mainly explained. 
         [0057]      FIG. 8  is a sectional view illustrating an assembly of an electric unit and a cooling module according to a second embodiment. 
         [0058]    Referring to  FIG. 8 , the electric unit  200  of the second embodiment includes a first unit  201 , a second unit  202 , and a connection member  270  through which the first and second units  201  and  202  are electrically connected. 
         [0059]    The first unit  201  includes a first electric board  215  and a plurality of electric components  220 . The second unit  202  includes a second electric board  216  and a heating component  260 . One of the electric components  220  that generates a relatively large amount of heat may be separated from the first electric board  215  as the heating component  260 . One or more of the electric components  220  may be separated from the first electric board  215  as the heating component(s)  260 . Of course, the second electric board  216  may also include electric components  220 . 
         [0060]    The connection member  270  may connect the heating component  260  to the first electric board  215  or the electric components  220 . The connection member  270  may include an electric wire. 
         [0061]    As described above, since the electric unit  200  is divided into the first and second units  201  and  202  (two units), the electric unit  200  may freely be disposed even in a small outdoor unit with satisfactory space efficiency. In addition, since one or more of the electric components  220  of the electric unit  200  that generate heat more than the other electric components  220  can be separately cooled, the electric unit  200  can be cooled with improved heat exchange efficiency (cooling efficiency) as compared with the case where all the electric components  220  are cooled. 
         [0062]      FIG. 9  is a perspective view illustrating a cooling module  250  according to a third embodiment. 
         [0063]    Referring to  FIG. 9 , the cooling module  250  of the third embodiment includes a module main body  251 , a refrigerant tube  50  disposed on a side of the module main body  251 , and first and second heating components  261  and  262  disposed on the other side of the module main body  251 . Refrigerant flowing in the refrigerant tube  50  may exchange heat with the first and second heating components  261  and  262  through the module main body  251 . 
         [0064]    The module main body  251  includes an insertion groove  251   a  for inserting the refrigerant tube  50  therein. The refrigerant tube  50  may be inserted in the insertion groove  251   a  formed in the bottom side of the module main body  251 , and the first and second heating components  261  and  262  may be disposed on the topside of the module main body  251 . 
         [0065]    The refrigerant tube  50  is inserted in the insertion groove  251   a  and bent two or more times in a U shape. Since the refrigerant tube  50  is bent two more times, the refrigerant flowing in the refrigerant tube  50  can exchange heat with the first and second heating components  261  and  262  at a larger area. 
         [0066]    In addition, since the refrigerant tube  50  can extend from a refrigerant cycle component to the electric unit  200 , the electric unit  200  can be cooled with a simply cooling structure (cooling device). 
         [0067]      FIG. 10  is a schematic view illustrating a refrigerant cycle according to a fourth embodiment. 
         [0068]    Referring to  FIG. 10 , an outdoor unit  10  of the fourth embodiment includes a flow controller  180 . The flow controller  180  is used to control a flow of refrigerant from outdoor heat exchanger ( 121 ,  122 ) to a branch tube  32 . In cooling mode, the outdoor heat exchanger ( 121 ,  122 ) functions as a condenser. 
         [0069]    The flow controller  180  may be disposed at the branch tube  32 . Although not shown, the flow controller  180  may be disposed at a position where the branch tube  32  branches off from a refrigerant tube  50 . 
         [0070]    An electric unit  200  may be disposed at the branch tube  32 . The electric unit  200  and an expansion device  140  are arranged in parallel. That is, the expansion device  140  may be disposed at the refrigerant tube  50 , and the electric unit  200  may be disposed at the branch tube  32 . 
         [0071]    At least a portion of refrigerant flowing in the refrigerant tube  50  can be guided to the electric unit  200  through the branch tube  32  by controlling the opening degree of the flow controller  180 . The portion of the refrigerant flowing in the branch tube  32  may be mixed with other portion of the refrigerant flowing in the refrigerant tube  50  at a joint part  55 . 
         [0072]    The other portion of the refrigerant flowing in the refrigerant tube  50  is expanded at the expansion device  140  and is then mixed with the portion of the refrigerant flowing in the branch tube  32  at the joint part  55 . 
         [0073]    The refrigerant flowing in the branch tube  32  may be expanded at the expansion device  140 . Or as illustrated in  FIG. 10 , a branch-tube expansion device  185  may be disposed at the branch tube  32 . After exchanging heat with the electric unit  200 , the portion of the refrigerant may be decompressed a low temperature while passing through the branch-tube expansion device  185 . 
         [0074]    Unlike the structure shown in  FIG. 10 , the branch-tube expansion device  185  may be disposed at an inlet side of the electric unit  200 . In this case, the refrigerant decompressed by the branch-tube expansion device  185  may be used to cool the electric unit  200 . Alternatively, the portion of the refrigerant passing through the electric unit  200  through the branch tube  32  may connect with the refrigerant tube  50  at the joint part before the expansion device  140 . 
         [0075]    In the above-described structure, after passing through the outdoor heat exchanger (condenser) ( 121 ,  122 ), the refrigerant may flow to the electric unit  200  to exchange heat with the electric unit  200 . For example, the temperature of the refrigerant may be about 40° C. after passing through the condenser ( 121 ,  122 ), and thus the electric unit  200  having a temperature of about 70° C. to 80° C. may be effectively cooled by the refrigerant. 
         [0076]    Channels formed in a cooling module  250  for cooling the electric unit  200 , and a portion of the refrigerant tube  50  passing through the cooling module  250  may be referred to as cooling passages because they are used to cool the electric unit  200 . 
         [0077]    The refrigerant mixed at the joint part  55  flows to a compressor  110  through an indoor heat exchanger ( 151 ,  152 ). This cycle of the refrigerant is repeated. 
         [0078]    Referring to  FIG. 10  again, although the flow controller  180 , electric unit  200 , branch tube  32 , the expansion device  140 , the branch-tube expansion device  185 , and joint part  55  are shown to be in the outdoor unit  10 , these parts can be installed in the indoor unit  20  in an alternative embodiment. Thus, the above-mentioned parts may be installed in an outdoor unit  10  or in an indoor unit  20  or in both the outdoor unit  10  and the indoor unit  20  (the expansion device and/or branch-tube expansion device  185  may be installed in one of the indoor unit or outdoor unit) as the need arises. 
         [0079]    In another embodiment, electric units such as the electric units  200  described with reference to  FIGS. 3 and 10  may be used in one refrigerant cycle system. That is, one of the electric units may be disposed at an outlet side of an evaporator, and the other of the electric units may be disposed at an outlet side of a condenser. 
         [0080]    In this case, the electric unit or one of the electric units may be cooled by a first flow of refrigerant from the evaporator, and the electric unit or the other of the electric units may be cooled by a second flow of the refrigerant from the condenser. Thus, the electric units may be cooled more effectively. 
         [0081]    As described above, according to the embodiments, the electric unit can be cooled using refrigerant of a refrigeration cycle so as to prevent errors of the control components of the electric unit and abnormal behaviors of the air conditioner. 
         [0082]    In addition, since low-temperature refrigerant is guided to the electric unit before the low-temperature refrigerant is guided to the compressor, heat exchange between the electric unit and the refrigerant can be more efficient. Particularly, the electric unit can be effectively cooled even when the air conditioner is used in a hot area. 
         [0083]    In addition, since the electric unit can be cooled by extending the coolant tube to the electric unit or forming refrigerant channels, a cooling device (cooling module) having a simple structure can be provided without using additional parts for cooling the electric unit. 
         [0084]    Furthermore, a cooling device separable from the electric unit can be provided. That is, the cooling device can be disposed even in a small outdoor unit, and thus the inner space of the outdoor unit can be efficiently used. 
         [0085]    As described above, since the electric unit can be cooled using refrigerant of a refrigeration cycle to prevent errors of the control components of the electric unit and abnormal behaviors of the air conditioner, the air conditioner can be used in various industrial fields. 
         [0086]    Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.