Patent Description:
In general, an air conditioner is an apparatus that processes suctioned air and supplies the processed air into a building or a room to keep indoor air fresh. The air conditioner is mainly classified as a window type air conditioner or a separate type (or split type) air conditioner.

The window type air conditioner, which has an integrated cooling and radiating function, is directly mounted in a window of a building or a house or in a hole formed through the wall of the building or the house with the aid of a support frame.

The separate type air conditioner includes an indoor unit including an indoor heat exchanger and an indoor blower, an outdoor unit including a compressor, an outdoor heat exchanger, and an outdoor blower, and a refrigerant pipe connected between the indoor unit and the outdoor unit.

An outdoor unit of an air conditioner may include a printed circuit board for controlling various components such as a compressor and an outdoor blower. The printed circuit board may be installed in an electric component box.

An outdoor unit of an air conditioner may introduce outdoor air into an electric component box and then discharge the outdoor air. At this time, the outdoor air may dissipate heat in the electric component box, thus enhancing operation reliability of the electric component box. However, when the interior of the electric component box is air-cooled, efficient temperature management according to temperature variation of outdoor air may not be facilitated.

An outdoor unit of an air conditioner may cool an interior of an electric component box using refrigerant, and may cool an interior of an electric component box using a heat exchanger installed at the electric component box, through which refrigerant passes.

Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide an outdoor unit of an air conditioner capable of minimizing material costs of a refrigerant tube for cooling a heat generating element in an electric component box.

In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of an outdoor unit of an air conditioner, including a printed circuit board on which a heat generating element is mounted, a radiating block which contacts the heat generating element and includes a refrigerant path through which refrigerant passes, and a refrigerant tube connected to the radiating block to communicate with the refrigerant path.

The refrigerant path is formed between the opposite sides of the radiating block.

The refrigerant path may be longitudinally formed in the radiating block.

The refrigerant tube may include a plurality of tube parts which are spaced apart from each other with the refrigerant path being disposed therebetween.

Each tube part may be partially fitted in the refrigerant path.

The refrigerant path may include a plurality of refrigerant paths formed in the radiating block.

The plurality of tube parts may include a return tube part for guiding refrigerant introduced through one of the plurality of refrigerant paths into another one of the plurality of refrigerant paths.

The return tube part may be made of the same material as that of the radiating block.

The plurality of tube parts may include a hybrid coupling tube part composed of a first tube section made of the same material as that of the radiating block and a second tube section made of a different material than the radiating block, and the first tube section may be joined to the radiating block.

The refrigerant path may include a plurality of refrigerant paths formed in the radiating block, and wherein the hybrid coupling tube part may include a plurality of hybrid coupling tube parts joined to the radiating block, wherein one of the plurality of hybrid coupling tube parts may be connected to one of the plurality of refrigerant paths and another one of the plurality of hybrid coupling tube parts may be connected to another one of the plurality of refrigerant paths.

An outdoor unit of an air conditioner according to the present invention includes a printed circuit board on which a heat generating element is mounted, an electric component box in which the printed circuit board is installed, a radiating block made of aluminum-based material, which contacts the heat generating element and includes a refrigerant path through which refrigerant passes, and a plurality of tube parts connected to the radiating block to communicate with the refrigerant path and spaced apart from each other with the refrigerant path being disposed therebetween, wherein the plurality of tube parts include a hybrid coupling tube part composed of a first tube section made of aluminum-based material and communicating with the refrigerant path and a second tube section made of copper-based material and connected to the first tube section.

Each of the plurality of tube parts may be partially fitted in the refrigerant path.

The plurality of tube parts may include a return tube part made of aluminum-based material for guiding refrigerant introduced through one of the plurality of refrigerant paths into another one of the plurality of refrigerant paths.

The hybrid coupling tube part may include a plurality of hybrid coupling tube parts joined to the radiating block, wherein one of the plurality of hybrid coupling tube parts may be connected to one of the plurality of refrigerant paths and another one of the plurality of hybrid coupling tube parts may be connected to another one of the plurality of refrigerant paths.

According to the present invention, material costs of a refrigerant tube can be reduced, and radiation performance can be improved by utilization of the whole surface of the refrigerant path as a surface for heat exchange.

Furthermore, since a radiating block and part of a refrigeration tube are made of aluminum-based material, weight of an outdoor unit can be reduced. In this case, when a copper connecting tube is directly joined to the radiating block, product reliability is enhanced.

Hereinafter, embodiments of the present invention will be described in detail with respect to the accompanying drawings.

<FIG> is a perspective view illustrating an embodiment of an outdoor unit of an air conditioner according to the present invention. <FIG> is an exploded perspective view illustrating the embodiment of the outdoor unit of an air conditioner according to the present invention. <FIG> is an enlarged front view of a radiating module of the embodiment of the outdoor unit of an air conditioner according to the present invention. <FIG> is an exploded front view of the radiating module of the embodiment of the outdoor unit of an air conditioner according to the present invention. <FIG> is a transverse cross-sectional view illustrating the radiating module and an electric component box of the embodiment of the outdoor unit of an air conditioner according to the present invention. <FIG> is a longitudinal cross-sectional view illustrating the radiating module and the electric component box of the embodiment of the outdoor unit of an air conditioner according to the present invention.

The outdoor unit of the air conditioner may include an outdoor body <NUM>, a compressor <NUM>, an outdoor heat exchanger <NUM>, and an outdoor blower <NUM>. The outdoor unit of the air conditioner may be connected to an indoor unit via a liquid pipe and an air pipe. Refrigerant may pass through an indoor heat exchanger provided in the indoor unit while exchanging heat with indoor air. The air conditioner may include an expansion device for expanding the refrigerant in one of the outdoor unit and the indoor unit. The expansion device may include an electronic expansion valve.

The outdoor body <NUM> may be provided with air suction ports I through which indoor air is introduced into the outdoor body <NUM>. The outdoor body <NUM> may further be provided with air discharge ports O through which heat exchanged air is discharged to the outside of the outdoor body <NUM>. The outdoor body <NUM> may define an appearance of the outdoor unit.

The outdoor body <NUM> may further include a base, cabinet bodies <NUM>, <NUM> and <NUM> installed at the base <NUM>, and a top cover <NUM> mounted on the cabinet bodies <NUM>, <NUM> and <NUM>. The outdoor body <NUM> may further include outdoor unit covers <NUM> and <NUM> for opening and closing the outdoor unit. The outdoor body <NUM> may further include a frame <NUM>.

The cabinet bodies <NUM>, <NUM> and <NUM> may be formed with the air suction ports I, and thus may serve as air suction bodies through which outdoor air passes for introduction into the outdoor unit. The air suction ports I may be formed at a plurality of surfaces of the outdoor unit body <NUM>. The cabinet bodies <NUM>, <NUM> and <NUM> may be composed of a plurality of bodies. The cabinet bodies <NUM>, <NUM> and <NUM> may include the left cabinet body <NUM> including a left outdoor air suction port formed thereat, the rear cabinet body <NUM> including a rear outdoor air suction port formed thereat, and the right cabinet body <NUM> including a right outdoor air suction port formed thereat. The rear cabinet body <NUM> may be integrally formed with at least one of the left cabinet body <NUM> and the right cabinet body <NUM>, or may be coupled to at least one of the left cabinet body <NUM> and the right cabinet body <NUM> by means of fastening elements such as screws. The cabinet bodies <NUM>, <NUM> and <NUM> may be provided at areas facing the outdoor heat exchanger <NUM> with suction grills at which the air suction ports I are formed. Furthermore, the cabinet bodies <NUM>, <NUM> and <NUM> may be made of plates at areas facing the outdoor blower <NUM>.

The top cover <NUM> may be provided with the air discharge port O. The top cover <NUM> may serve as a discharge body through which outdoor air passes for discharge to the outside of the outdoor unit. The top cover <NUM> may be horizontally installed on the cabinet bodies <NUM>, <NUM> and <NUM>. The top cover <NUM> may define an upper appearance of the outdoor unit. The outdoor blower <NUM> may be installed at the top cover <NUM>.

The outdoor unit covers <NUM> and <NUM> may be coupled to at least one of the base <NUM>, the cabinet bodies <NUM>, <NUM> and <NUM>, and the frame <NUM>. The outdoor unit covers <NUM> and <NUM> may be coupled or dismantled by a worker when the outdoor unit needs to be serviced. The outdoor unit covers <NUM> and <NUM> may be coupled by means of fastening elements such as screws. The outdoor unit covers <NUM> and <NUM> may be integrated into one member or may be composed of a plurality of members. The outdoor unit covers <NUM> and <NUM> may be installed in such a way as to shield an opening between the left cabinet body <NUM> and the right cabinet body <NUM> by means of a single cover or a plurality of covers. The outdoor unit covers <NUM> and <NUM> may define a front appearance of the outdoor unit. At least one of the outdoor unit covers <NUM> and <NUM> may be disposed to shield the front of the electric component box <NUM>. At least one of the outdoor unit covers <NUM> and <NUM> may serve as a service cover <NUM> for shielding the front of the electric component box <NUM>. When the electric component box <NUM> needs to be serviced, a worker may take the electric component box <NUM> out of the outdoor unit after removal of the service cover <NUM>. The electric component box <NUM> may be taken out of the outdoor unit through an opening between the left cabinet body <NUM> and the right cabinet body <NUM> after removal of the service cover <NUM>.

The frame <NUM> may support the outdoor unit body <NUM>. At least one of components of the outdoor unit may be mounted on the frame <NUM>. The frame <NUM> may include a vertical frame which is vertically disposed in the outdoor unit. The frame <NUM> may include a horizontal frame which is horizontally disposed in the outdoor unit. The frame <NUM> may include a plurality of frames, at least one of which may be disposed between a lower part of the outdoor blower <NUM> and back surfaces of the outdoor unit covers <NUM> and <NUM>. The frame <NUM> may include a transverse frame 18A which extends in a lateral direction. The transverse frame 18A may be disposed between the left cabinet body <NUM> and the right cabinet body <NUM>. The transverse frame 18A may include a plurality of frames which are disposed between the rear cabinet body <NUM> and the outdoor unit covers <NUM> and <NUM>. The frame <NUM> may include an anteroposterior frame 18B which extends in a front-back direction. The anteroposterior frame 18B may be connected to the transverse frame 18A. The anteroposterior frame 18B may be connected to the plurality of transverse frames. The anteroposterior frame 18B may include a plurality of flames which are disposed between the plurality of transverse frames 18A.

The compressor <NUM> may compress refrigerant.

The air conditioner may be an air conditioner exclusively for cooling. In this case, refrigerant compressed in the compressor <NUM> may sequentially pass through the outdoor heat exchanger <NUM>, the expansion device, and an indoor heat exchanger (not shown), and then may be introduced into the compressor <NUM>.

The air conditioner may be a heat pump type air conditioner. In this case, refrigerant compressed in the compressor <NUM> may sequentially pass through the outdoor heat exchanger <NUM>, the expansion device (not shown), and the indoor heat exchanger (not shown), and may be introduced into the compressor <NUM>, during a cooling operation. Meanwhile, the refrigerant may sequentially pass through the indoor heat exchanger, the expansion device (not shown), and the outdoor heat exchanger <NUM>, and may be introduced into the compressor <NUM>, during a heating operation.

The compressor <NUM> may be installed at the outdoor unit body <NUM>. The compressor <NUM> may be installed at the base <NUM> of the outdoor unit body <NUM>. The compressor <NUM> may be installed so as to be disposed at a lower position in the outdoor unit. When the outdoor unit covers <NUM> and <NUM> are removed, the compressor <NUM> may be exposed to the outside. When the outdoor unit cover <NUM>, which is disposed at a lower position than the outdoor unit cover <NUM>, is removed, the compressor <NUM> may be exposed through an opening between the left cabinet body <NUM> and the right cabinet body <NUM>. The compressor <NUM> may include a plurality of compressors installed at the outdoor unit body <NUM>. At least one of the plurality of compressors <NUM> may be a variable capacity compressor or an inverter compressor.

The outdoor heat exchanger <NUM> may exchange heat between outdoor air and refrigerant. The outdoor heat exchanger <NUM> may be installed at the outdoor unit body <NUM>. The outdoor heat exchanger <NUM> may be installed on the base <NUM> of the outdoor unit body <NUM>. The outdoor heat exchanger <NUM> may be configured to have a shape which is bent at at least one position. The outdoor heat exchanger <NUM> may be installed so as to be disposed in a space defined by the cabinet bodies <NUM>, <NUM> and <NUM>. The outdoor heat exchanger may include a left heat exchanger part facing the left cabinet body <NUM>, a right heat exchanger part facing the right cabinet body <NUM>, and a rear heat exchanger part facing the rear cabinet body <NUM>, wherein the left heat exchanger part and the right heat exchanger part may be connected to each other via the rear heat exchanger part.

The outdoor heat exchanger <NUM> may include a plurality of outdoor heat exchangers which are spaced apart from one another. The outdoor heat exchanger <NUM> may include a first heat exchanger at which the left heat exchanger part facing the left cabinet body <NUM> is bent with respect to the rear heat exchanger part facing the rear cabinet body <NUM>, and a second heat exchanger at which the right heat exchanger part facing the right cabinet body <NUM> is bent with respect to the rear heat exchanger part facing the rear cabinet body <NUM>.

The outdoor blower <NUM> may cause outdoor air to flow. The outdoor blower <NUM> may be installed at the outdoor unit body <NUM> to introduce outdoor air into the outdoor heat exchanger <NUM> and to discharge the outdoor air. The outdoor blower <NUM> may be installed at an upper position in the outdoor unit body <NUM>. The outdoor blower <NUM> may be installed at the top cover <NUM> of the outdoor unit body <NUM>. The outdoor blower <NUM> may draw in air present thereunder and discharge the air upward. The outdoor blower <NUM> may include a shroud 8A for guiding discharge of outdoor air, a motor 8C, and a fan 8D fitted over a rotating shaft of the motor 8C and rotating therewith. The motor 8C of the outdoor blower <NUM> may be mounted on the frame <NUM>, or may be mounted on the frame <NUM> by means of an additional motor mount 8B. The motor 8C may be installed at the motor mount 8B. The motor mount 8B may be coupled to at least one of the shroud 8A, the top cover <NUM>, and the frame <NUM>. The shroud 8A may be coupled to at least one of the top cover <NUM> and the frame <NUM>. The outdoor blower <NUM> may include a plurality of outdoor blowers installed at the outdoor unit body <NUM>. The outdoor blower <NUM> may be disposed such that a portion thereof protrudes upward from the top cover <NUM>. The outdoor unit of the air conditioner may further include a discharge grill <NUM>. The discharge grill <NUM> is installed at the outdoor blower <NUM> or the top cover <NUM> to protect the outdoor blower <NUM>.

The outdoor unit of the air conditioner may include a controller C for controlling the air conditioner. The controller C may be composed of a single controller or a plurality of controllers installed at the outdoor unit of the air conditioner. The controller C may be installed at the outdoor unit of the air conditioner to control various electric components such as the compressor <NUM> or the outdoor blower <NUM>. The controller C may communicate with the indoor unit of the air conditioner to control various electric components such as an indoor blower (not shown) installed at the indoor unit of the air conditioner. The controller C may include at least one electric component for controlling various electric components installed at the air conditioner. The at least one electric component may include at least one printed circuit board on which at least one electric element is mounted. The at least one electric element may include a heat generating element which generates heat during operation of the air conditioner.

The outdoor unit of the air conditioner may include a printed circuit board <NUM> on which a heat generating element <NUM> is mounted, and a radiating module <NUM> through which refrigerant passes and which is in contact with the heat generating element <NUM>. The radiating module <NUM> may include a radiating block <NUM>, and a refrigerant tube <NUM> which is connected to the radiating block <NUM> and through which refrigerant passes.

The outdoor unit of the air conditioner further includes the electric component box <NUM> in which the printed circuit board <NUM> is installed. The heat generating element <NUM> may be mounted on the printed circuit board <NUM> to be isolated from a back plate <NUM> of the electric component box <NUM>. The heat generating element <NUM> may be mounted on the printed circuit board <NUM> such that all or a part thereof protrudes rearward.

The printed circuit board <NUM> may include an invert driving printed circuit board for varying an operating frequency of an electric motor for driving the compressor <NUM>. The printed circuit board <NUM> may be an inverter driver for controlling an inverter compressor. The inverter driving printed circuit board may be provided with the heat generating element <NUM> such as an intelligent power module (IPM) which generates a large amount of heat. The printed circuit board <NUM> may be configured to have a larger size than that of the heat generating element <NUM>.

The electric component box <NUM> protects various electric components including the heat generating element <NUM> and the printed circuit board <NUM>. The electric component box <NUM> is mounted on the outdoor unit body <NUM>. The electric component box <NUM> is mounted on the outdoor unit body <NUM> by means of fastening elements such as screws, and may be removed from the outdoor unit body <NUM> at the time of service. The electric component box <NUM> may be coupled to at least one of the left cabinet body <NUM>, the right cabinet body <NUM>, the service covers <NUM> and <NUM>, the frame <NUM>, and the outdoor blower <NUM> by means of fastening elements such as screws. The electric component box <NUM> may be installed such that at least a portion thereof is positioned in front of the outdoor blower <NUM>. The electric component box <NUM> may be open at one side thereof. The electric component box <NUM> may be configured to have a box shape having one open side. The electric component box <NUM> has an internal space in which the printed circuit board <NUM> may be provided. The electric component box <NUM> may be open at a side thereof facing the outdoor unit covers <NUM> and <NUM>. The electric component box <NUM> may include the back plate <NUM>, and a peripheral wall <NUM> formed at a peripheral edge of the back plate <NUM>. The electric component box <NUM> may have an internal space defined therein. The printed circuit board <NUM> may be positioned in the internal space defined by the peripheral wall <NUM>. The printed circuit board <NUM> may be installed at the back plate <NUM> of the electric component box <NUM>. Disposed between the printed circuit board <NUM> and the electric component box <NUM> may be a spacer <NUM> for isolating the printed circuit board <NUM> from the back surface <NUM> of the electric component box <NUM>. The electric component box <NUM> may have an opening <NUM> in which one of the radiating block <NUM> and the heat generating element <NUM> is disposed. One of the radiating block <NUM> and the heat generating element <NUM> may be disposed to pass through the opening <NUM>.

The radiating module <NUM> may be connected to a refrigeration cycle circuit including the compressor <NUM>, the outdoor heat exchanger <NUM>, the expansion device, and the indoor heat exchanger. The radiating module <NUM> may be connected to a lower temperature part of the refrigeration cycle circuit which further includes a higher temperature part in addition to the lower temperature part. Refrigerant in the lower temperature part of the refrigeration cycle circuit may flow into the radiating module <NUM> and may pass through the radiating module <NUM>. The refrigerant may pass through the radiating module <NUM> while absorbing heat from the heat generating element <NUM>.

The radiating module <NUM> may be a refrigerant type cooling module in which at least a portion of the radiating module <NUM> contacts the heat generating element <NUM> to absorb heat from the heat generating element <NUM> in a heat transfer manner while refrigerant cools the heat generating element <NUM>. The refrigerant tube <NUM> may be connected to a refrigerant pipe between the outdoor heat exchanger <NUM> and the expansion device, or may be connected to a refrigerant pipe between the expansion device and the indoor heat exchanger.

The radiating block <NUM> may be provided with refrigerant paths <NUM> and <NUM> through which refrigerant passes. When refrigerant passes through the refrigerant paths <NUM> and <NUM>, the radiating block <NUM> may directly exchange heat with refrigerant in the refrigerant paths <NUM> and <NUM> without an additional heat transfer member or tube. The radiating block <NUM> may absorb heat from the heat generating element <NUM> through a contact area contacting the heat generating element <NUM> and may transfer the heat to refrigerant passing through the refrigerant paths <NUM> and <NUM>. In other words, the refrigerant and the heat generating element <NUM> may exchange heat through the radiating block <NUM>. The radiating block <NUM> may be a single heat exchanger member which exchanges heat between the refrigerant and the heat generation element <NUM>.

The radiating block <NUM> may be configured to have a plate shape, and may be a radiating plate contacting the heat generating element <NUM>. The refrigerant paths <NUM> and <NUM> may be longitudinally formed between one side <NUM> and the other side <NUM> of the radiating block <NUM>. The radiating block <NUM> may be formed with a surface contact area which contacts the heat generating element <NUM>. The radiating block <NUM> may face the heat generating element <NUM> at one side <NUM> thereof. The one side of the radiating block <NUM>, which faces the heat generating element <NUM>, includes the surface contact area which contacts the heat generating element <NUM>. The radiating block <NUM> may be partially positioned outside the electric component box <NUM>. The radiating block <NUM> may include the other side <NUM> positioned outside the electric component box <NUM>. The other side <NUM> positioned outside the electric component box <NUM> may be positioned opposite the one side <NUM> including the surface contact area contacting the heat generating element. The one side <NUM> and the other side <NUM> of the radiating block <NUM> may be composed of respective flat surfaces. The refrigerant paths <NUM> and <NUM> may be longitudinally formed in the radiating block <NUM> between the one side <NUM> contacting the heat generating element <NUM> and the other side <NUM> positioned outside the electric component box <NUM>. The refrigerant paths <NUM> and <NUM> may be spaced apart from the one side <NUM> contacting the heat generating element <NUM> and the other side <NUM> positioned outside the electric component box <NUM>. The refrigerant paths <NUM> and <NUM> may be longitudinally formed to be parallel to the one side <NUM> contacting the heat generating element <NUM> and the other side <NUM> positioned outside the electric component box <NUM>. The refrigerant paths <NUM> and <NUM> may have a smaller diameter than a thickness of the radiating plate <NUM> as viewed in cross-section perpendicular to a flow direction of refrigerant.

The radiating block <NUM> may be configured to have a rectangular shape, and may be extended in a lateral or vertical direction. The refrigerant paths <NUM> and <NUM> may be longitudinally formed in the radiating block <NUM>. One-side ends 55A and 56A and the other-side ends 55B and 56B of the refrigerant paths <NUM> and <NUM> may be open. The radiating block <NUM> may extend in the lateral direction. The refrigerant paths <NUM> and <NUM> may be connected between a left end and a right end of the radiating block <NUM>. The radiating paths <NUM> and <NUM> may be elongated holes which are longitudinally formed in the radiating block <NUM> between the left end and the right end.

The refrigerant paths <NUM> and <NUM> may include a plurality of refrigerant paths formed in the radiating block <NUM>. The plurality of refrigerant paths <NUM> and <NUM> may be spaced apart from each other. The plurality of refrigerant paths <NUM> and <NUM> may be independently formed in the radiating block <NUM> without merging with each other. The plurality of refrigerant paths <NUM> and <NUM> may be formed to be parallel to each other. One refrigerant path <NUM> of the plurality of refrigerant paths <NUM> and <NUM> may be positioned over the other <NUM>. One refrigerant path <NUM> of the plurality of refrigerant paths <NUM> and <NUM> may be disposed close to an upper surface 59A of the radiating block <NUM>, and the other refrigerant path <NUM> of the plurality of refrigerant paths <NUM> and <NUM> may be disposed closer to a lower surface 59B of the radiating block <NUM>. The plurality of refrigerant paths <NUM> and <NUM> may be spaced apart from each other between the upper surface 59A and the lower surface 59B of the radiating block <NUM>.

The radiating block <NUM> may be made of aluminum-based material. In the specification, the aluminum-based material may refer to a single aluminum-based material or an aluminum alloy material. The radiating block may be an aluminum radiating plate which is produced from aluminum through extrusion processing. The aluminum radiating block <NUM> may be produced at lower cost and may have a lighter weight, compared to a copper radiating block. The radiating module <NUM> may be partially made of an aluminum-based material at a portion thereof through which refrigerant exchanges heat with the heat generating element <NUM>, and, as such, the radiating module <NUM> may be produced at lower cost, compared to the case in which the radiating block <NUM> is made of a copper-based material.

The radiating block <NUM> may be fixedly positioned at the outdoor unit body <NUM> by means of fastening elements such as screws or hanging elements such as hooks. The radiating block <NUM> is fixedly positioned at the outdoor unit body <NUM> by means of an additional radiating block mount <NUM>. The radiating block mount <NUM> is fixedly installed at the outdoor unit body <NUM>. The radiating block mount <NUM> may be installed at the frame <NUM> of the outdoor unit body <NUM>. Specifically, the radiating block mount <NUM> may be installed at the horizontal frame 18A of the outdoor unit body <NUM> by means of fastening elements such as screws or hanging elements such as hooks.

The radiating block <NUM> may be formed with fastening holes 61B through which fastening elements 61A such as screws pass. The radiating block <NUM> is provided at an upper side thereof with an upper protrusion 61C, and is provided at a lower side thereof with a lower protrusion 61D. The radiating block <NUM> may have the fastening holes 61B formed at at least one of the upper protrusion 61C and the lower protrusion 61D of the radiating block <NUM>. The radiating block <NUM> is coupled to the radiating block mount <NUM> by attaching the upper protrusion 61C and the lower protrusion 61D of the radiating block <NUM> to the radiating block mount <NUM> by screws.

The radiating block <NUM> is coupled to the heat generating element <NUM> by means of a fastening element 64A such as a screw. The radiating block <NUM> may be formed with a fastening hole 62B into which the fastening element 64A such as a screw is screwed. The fastening hole 62B of the radiating block <NUM> may be formed at a region excluding the refrigerant paths <NUM> and <NUM>. The fastening hole 62B of the radiating block <NUM> may include a plurality of fastening holes which are formed between the refrigerant paths <NUM> and <NUM>. The heat generating element <NUM> may be formed with a fastening hole <NUM> through which the fastening element 64A such as a screw passes. Therefore, the fastening element 64A such as a screw may pass through the fastening hole <NUM> of the heat generating element <NUM> and then may be screwed into the fastening hole 62B of the radiating block <NUM>.

The refrigerant tube <NUM> may be connected to the refrigeration cycle circuit in such a manner that one end of the refrigerant tube <NUM> at which refrigerant is introduced is connected to the lower temperature part of the refrigerant cycle circuit and the other end of the refrigerant tube <NUM> at which the refrigerant is discharged is connected to the lower temperature part of the refrigerant cycle circuit. The refrigerant tube <NUM> may be connected to the refrigerant pipe between the outdoor heat exchanger <NUM> and the expansion device, or may be connected to the refrigerant pipe between the expansion device and the indoor heat exchanger. The refrigerant tube <NUM> may be connected to the radiating block <NUM> at a position outside the electric component box <NUM>.

The refrigerant tube <NUM> may be connected to the radiating block <NUM> so as to communicate with the refrigerant paths <NUM> and <NUM>. The refrigerant tube <NUM> may be partially fitted in the refrigerant paths <NUM> and <NUM>.

The refrigerant tube <NUM> includes a plurality of tube parts <NUM>, <NUM> and <NUM> which are separated from one another. The plurality of tube parts <NUM>, <NUM> and <NUM> each may be partially fitted in the refrigerant paths <NUM> and <NUM>. The plurality of tube parts <NUM>, <NUM> and <NUM> may be disposed spaced apart from one another with the refrigerant paths <NUM> and <NUM> being disposed therebetween. The refrigerant paths <NUM> and <NUM> may have relatively long non-fitting sections in which the plurality of tube parts <NUM>, <NUM> and <NUM> are not fitted, and, as such, material costs of the refrigerant tube may be reduced by portions corresponding to the non-fitting sections in which the plurality of tubes <NUM>, <NUM> and <NUM> are not fitted. The refrigerant paths <NUM> and <NUM> are preferably sectioned such that a length of the non-fitting section of each refrigerant path <NUM> or <NUM> is longer than the total length of the fitting sections in which the plurality of tube parts <NUM>, <NUM> and <NUM> are fitted. As the total length of the fitting sections in which the plurality of tube parts <NUM>, <NUM> and <NUM> are fitted is increased, material costs may be increased. The total length of the fitting sections of the refrigerant paths <NUM> and <NUM> in which the plurality of tube parts <NUM>, <NUM> and <NUM> are fitted is preferably less than <NUM>% the total length of the refrigerant paths <NUM> and <NUM>, and most preferably less than <NUM>% the total length of the refrigerant paths <NUM> and <NUM>.

The plurality of tube parts <NUM>, <NUM> and <NUM> may include heterojunction tube parts <NUM> and <NUM>. Each of the heterojunction tube parts <NUM> and <NUM> may include a first tube section <NUM> communicating with the corresponding one of the refrigerant paths <NUM> and <NUM> and made of the same material as that of the radiating block <NUM>, and a second tube section <NUM> made of a different material than the radiating block <NUM>. The hybrid coupling tube parts <NUM> and <NUM> may be disposed spaced apart from a return tube section <NUM> (described later) with the refrigerant paths <NUM> and <NUM> being disposed therebetween.

The first tube section <NUM> may be joined to the radiation block <NUM>. The first tube section <NUM> may be of the same material as that of the radiation block <NUM>. The second tube section <NUM> may be made of a different material than the radiation block <NUM>. The first tube section <NUM> may be made of aluminum-based material. The second tube section <NUM> may be made of copper-based material. In the description, the copper-based material may refer to a single copper-based material and a copper alloy material. The first tube section <NUM> and the second tube section <NUM> may be joined to the radiation module <NUM> after integral conjunction of the first tube section <NUM> and the second tube section <NUM>. The first tube section <NUM> made of the same material as that of the radiation block <NUM> may be joined to the radiation block <NUM>. The first tube section <NUM> may be joined at one end 66A thereof to the second tube section <NUM> through welding. The first tube section <NUM> may be fitted at the other end 66B thereof in the refrigerant paths <NUM> and <NUM> to contact the radiation block <NUM>. Since the radiation block <NUM> and the first tube section <NUM> are made of the same material, the radiation block <NUM> and the first tube section <NUM> may be joined to each other through welding while minimizing corrosion at the contact area therebetween.

The hybrid coupling tube parts <NUM> and <NUM> may include a plurality of tube sections joined to the radiation block <NUM>. One hybrid coupling tube part <NUM> of the plurality of hybrid coupling tube parts <NUM> and <NUM> may be connected to one refrigerant path <NUM> of the plurality of refrigerant paths <NUM> and <NUM>, and the other hybrid coupling part <NUM> of the plurality of hybrid coupling tube parts <NUM> and <NUM> may be connected to the other refrigerant path <NUM> of the plurality of refrigerant paths <NUM> and <NUM>.

The radiation block <NUM> may be joined to the pair of hybrid coupling tube parts <NUM> and <NUM>. One of the pair of hybrid coupling tube parts <NUM> and <NUM> may be an inlet tube section <NUM> for guiding refrigerant into one refrigerant path <NUM> of the radiation block <NUM>, and the other of the pair of hybrid coupling tube parts <NUM> and <NUM> may be an outlet tube section <NUM> for guiding refrigerant flowing from the other refrigerant path <NUM> of the radiation block <NUM>.

The plurality of tube parts <NUM>, <NUM> and <NUM> may include the return tube section <NUM> for guiding refrigerant introduced through one of the plurality of refrigerant paths <NUM> and <NUM> into the other of the plurality of refrigerant paths <NUM> and <NUM>.

The return tube part <NUM> may be joined to the radiation block <NUM>. The return tube part <NUM> may be configured such that an inlet end 65A at which refrigerant is introduced and an outlet end 65B from which the refrigerant flows out are disposed parallel to each other and the section between the inlet end 65A and the outlet end 65B is bent into a U shape. The inlet end 65A of the return tube part <NUM> may be fitted in one <NUM> of the refrigerant paths of the radiation block <NUM>, and the outlet end 65B of the return tube part <NUM> may be fitted in the other refrigerant path <NUM> of the refrigerant paths. The return tube part <NUM> may be spaced apart from the heteroconjuction tube parts <NUM> and <NUM> with the refrigerant paths <NUM> and <NUM> being disposed therebetween. The inlet end 65A of the return tube part <NUM> may be spaced apart from the inlet side tube part <NUM> with one refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> being disposed therebetween, and the outlet end 65B of the return tube part <NUM> may be spaced apart from the outlet side tube part <NUM> with the other refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> being disposed therebetween.

The refrigerant tube <NUM> may be configured such that the inlet side tube part <NUM> and the return tube part <NUM> are connected to each other via the radiation block <NUM> with a spacing being defined therebetween. Furthermore, the refrigerant tube <NUM> may be configured such that the outlet side tube part <NUM> and the return tube part <NUM> are connected to each other via the radiation block <NUM> with a spacing being defined therebetween. Accordingly, material costs of the refrigerant tube <NUM> may be reduced by a portion corresponding to the length between the inlet side tube part <NUM> and the return tube part <NUM>. Furthermore, material costs of the refrigerant tube <NUM> may be reduced by a portion corresponding to the length between the outlet side tube part <NUM> and the return tube part <NUM>.

The return tube part <NUM> may be welded to the radiation block <NUM> after the inlet side end 65A and the outlet side end 65B are fitted in the radiation block <NUM>. The return tube part <NUM> may be made of the same material as that of the radiating block <NUM>. When the radiating block <NUM> is made of aluminum-based material, the return tube part <NUM> may also be made of aluminum-based material. Since the radiating block <NUM> and the return tube <NUM> are made of the same material, the radiation block <NUM> and the return tube part <NUM> may be joined to each other through welding while minimizing corrosion at the contact area therebetween.

When the pair of refrigerant paths <NUM> and <NUM> are formed in the radiating block <NUM>, the return tube part <NUM> may connect the pair of refrigerant paths <NUM> and <NUM> to each other. The radiating block <NUM> may be provided with an even number of refrigerant paths, and one return tube part <NUM> may be provided for every two refrigerant paths.

The refrigerant tube <NUM> may further include connecting tube sections <NUM> and <NUM> connected to the hybrid coupling tube parts <NUM> and <NUM>. The connecting tube sections <NUM> and <NUM> may be connected to the lower temperature part of the refrigeration cycle circuit. The connecting tube sections <NUM> and <NUM> may be connected to a refrigerant pipe between the outdoor heat exchanger <NUM> and the expansion device, or may be connected to a refrigerant pipe between the expansion device and the indoor heat exchanger. The connecting tube sections may be made of the same material as that of the refrigerant pipe between the outdoor heat exchanger <NUM> and the expansion device or that of the refrigerant pipe between the expansion device and the indoor heat exchanger. The refrigerant pipe between the outdoor heat exchanger <NUM> and the expansion device or the refrigerant pipe between the expansion device and the indoor heat exchanger may be made of copper-based material, and the connecting tube sections <NUM> and <NUM> may be made of copper-based material. The connecting tube sections <NUM> and <NUM> may include a pair of connecting tube sections. One connecting tube section <NUM> of the pair of connecting tube sections may serve as an inlet side connecting tube section connected to the inlet side tube part <NUM>, and the other connecting tube section <NUM> of the pair of connecting tube sections may serve as an outlet side connecting tube section connected to the outlet side tube part <NUM>.

Since the second tube section <NUM> of the inlet side tube part <NUM> may be joined to the inlet side connecting tube section <NUM> through welding and may be made of the same copper-based material as that of the inlet side connecting tube section <NUM>, the second tube section <NUM> may be joined to the inlet side connecting tube section <NUM> through welding while minimizing corrosion at a contact area therebetween.

Furthermore, since the second tube section <NUM> of the outlet side tube part <NUM> may be joined to the outlet side connecting tube section <NUM> through welding and may be made of the same copper-based material as that of the outlet side connecting tube section <NUM>, the second tube section <NUM> may be joined to the outlet side connecting tube section <NUM> through welding while minimizing corrosion at a contact area therebetween.

Operations of the present invention will now be described.

During operation of the air conditioner, the heat generating element <NUM> and the printed circuit board <NUM> may control the air conditioner, and the heat generating element <NUM> generates heat.

Refrigerant passing through the lower temperature part of the refrigeration cycle circuit may be introduced into the refrigerant tube <NUM>. The refrigerant passing through the lower temperature part of the refrigeration cycle circuit may be introduced into the inlet side tube part <NUM> through the inlet side connecting tube section <NUM> and then may pass through the inlet side tube part <NUM>. Subsequently, the refrigerant may be introduced into one refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> of the radiating block <NUM>. The refrigerant may exchange heat with the radiating block <NUM> to primarily absorb heat from the radiating block <NUM> while passing through the one refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM>. The refrigerant passed through the one refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> may be introduced into the return tube part <NUM>, and then may be introduced into the other refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> through the return tube part <NUM>. The refrigerant may exchange heat with the radiating block <NUM> to secondarily absorb heat from the radiating block <NUM> while passing through the other <NUM> of the refrigerant paths <NUM> and <NUM>. The refrigerant passed through the other refrigerant path <NUM> of the refrigerant paths <NUM> and <NUM> and having an increased temperature may be introduced into the outlet side tube part <NUM>, and then may flow to the lower temperature part of the refrigeration cycle circuit through the outlet side connecting tube section <NUM>.

<FIG> is a flowchart illustrating an embodiment of a method of manufacturing the outdoor unit of the air conditioner according to the present invention.

The method of manufacturing the outdoor unit of the air conditioner according to the present invention may include operations of manufacturing the radiating module <NUM> for dissipating heat from the heat generating element <NUM> and connecting the radiating module <NUM> to the refrigerant pipe of the outdoor unit of the air conditioner. Hereinafter, the operations of manufacturing the radiating module <NUM> and connecting the radiating module <NUM> to the refrigerant pipe of the outdoor unit of the air conditioner will be described.

The method of manufacturing the outdoor unit of the air conditioner includes an operation of extruding the radiating block <NUM> having the plurality of refrigerant paths <NUM> and <NUM> from aluminum (S1: Extrusion of radiating block).

In the extrusion of the radiating block <NUM>, the refrigerant paths <NUM> and <NUM> may be longitudinally formed in the radiating block <NUM>. The radiating block <NUM> may include a pair of refrigerant paths <NUM> and <NUM> disposed parallel to each other. The radiating block <NUM> may be configured into a plate shape having one side <NUM> and the other side <NUM> both of which are flat. The radiating block <NUM> may be configured to have an approximately rectangular shape.

In the method of manufacturing the outdoor unit of the air conditioner, the radiating block <NUM>, which has been prepared through extrusion, may be connected to the return tube part <NUM> and the hybrid coupling tube parts <NUM> and <NUM>.

Here, the return tube part <NUM>, which serves as a connecting tube for connecting the plurality of refrigerant paths <NUM> and <NUM>, may be formed so as to guide refrigerant introduced through one of the pair of refrigerant paths <NUM> and <NUM> to the other of the pair of refrigerant paths <NUM> and <NUM>. The return tube part <NUM> is preferably made of aluminum-based material for the sake of compatibility with the radiating tube <NUM> made of aluminum-based material.

The pair of hybrid coupling tube parts <NUM> and <NUM> may be welded to the single radiating block <NUM>. One <NUM> of the pair of hybrid coupling tube parts <NUM> and <NUM> may be welded to the radiating block <NUM> to communicate with one refrigerant path <NUM>, and the other <NUM> of the pair of hybrid coupling tube parts <NUM> and <NUM> may be welded to the radiating block <NUM> to communicate with the other refrigerant path <NUM>.

The method of manufacturing the outdoor unit of the air conditioner includes an operation of welding the return tube part <NUM> made of aluminum-based material to the radiating block <NUM> such that the return tube part <NUM> communicates with the refrigerant paths <NUM> and <NUM> (S2), and an operation of welding the first tube sections <NUM> of the hybrid coupling tube parts <NUM> and <NUM>, which are made of aluminum-based material and coupled to the second tube sections <NUM> made of copper-based material, to the radiating block <NUM> such that the first tube sections <NUM> communicate with the refrigerant paths <NUM> and <NUM>, respectively (S3).

Briefly, the method of manufacturing the outdoor unit of the air conditioner may include the operation S2 of welding the return tube part <NUM> to the radiating block <NUM>, and the operation S3 of welding the heterojunction tube parts <NUM> and <NUM> to the radiating block <NUM>. The method of manufacturing the outdoor unit of the air conditioner may be implemented in such a way that the operation S2 of welding the return tube part <NUM> to the radiating block <NUM> is first performed and then the operation S3 of welding the hybrid coupling tube parts <NUM> and <NUM> to the radiating block <NUM> is performed. Conversely, the method of manufacturing the outdoor unit of the air conditioner may be implemented in such a way that the operation S3 of welding the hybrid coupling tube parts <NUM> and <NUM> to the radiating block <NUM> is first performed and then the operation S2 of welding the return tube part <NUM> to the radiating block <NUM> is performed. The method of manufacturing the outdoor unit of the air conditioner may, of course, be implemented in such a way that the operation S2 of welding the return tube part <NUM> to the radiating block <NUM> and the operation S3 of welding the hybrid coupling tube parts <NUM> and <NUM> to the radiating block <NUM> are concurrently performed. Therefore, the sequence of the operations may be variously selected depending on worker's needs without limitation.

For the purpose of illustration, the operation S2 of welding the return tube part <NUM> to the radiating block <NUM> will first be described.

The aluminum return tube part <NUM> may be fitted in the pair of refrigerant paths <NUM> and <NUM> in such a manner that the inlet end 65A of the return tube part <NUM>, at which refrigerant is introduced, is fitted in one refrigerant path <NUM> of the pair of refrigerant paths <NUM> and <NUM> and the outlet end 65B of the return tube part <NUM>, at which the refrigerant flows out, is fitted in the other refrigerant path <NUM> of the pair of refrigerant paths <NUM> and <NUM>. After fitting of the return tube part <NUM> in the refrigerant paths <NUM> and <NUM>, the return tube part <NUM> may be welded to the radiating block <NUM>.

Next, the operation S3 of welding the hybrid coupling tube parts <NUM> and <NUM> to the radiating block <NUM> will be described.

One hybrid coupling tube part <NUM> of the pair of hybrid coupling tube parts <NUM> and <NUM> may be welded to the radiating block <NUM> after being fitted in the one refrigerant path <NUM>, and the other hybrid coupling tube part <NUM> of the pair of hybrid coupling tube parts <NUM> and <NUM> may be welded to the radiating block <NUM> after being fitted in the other refrigerant path <NUM>.

The method of manufacturing the outdoor unit of the air conditioner may also be implemented in such a manner that the return tube part <NUM> and the pair of hybrid coupling tube parts <NUM> and <NUM> are concurrently welded to the radiating block <NUM> after the return tube part <NUM> and the pair of hybrid coupling tube parts <NUM> and <NUM> are partially fitted in the radiating block <NUM>.

By joining the return tube part <NUM> and the hybrid coupling tube parts <NUM> and <NUM> to the radiating block <NUM> in the above-described manner, the return tube part <NUM>, the hybrid coupling tube parts <NUM> and <NUM>, and the radiating block <NUM> may be integrated, thus providing the single radiating module <NUM>. The radiating module <NUM> in which the return tube part <NUM>, the hybrid coupling tube parts <NUM> and <NUM>, and the radiating block <NUM> have been incorporated may be installed at the outdoor unit of the air conditioner.

The method of manufacturing the outdoor unit of the air conditioner includes an operation of connecting the second tube sections <NUM> to the refrigerant pipes of the outdoor unit of the air conditioner (S4). The second tube sections <NUM> may be connected to the refrigerant pipes of the outdoor unit after being joined to the radiating block <NUM> via the first tube sections <NUM>. A worker may connect the second tube sections <NUM> to the refrigerant pipes positioned at the outdoor unit of the refrigeration cycle circuit. The worker may connect the second tube sections <NUM> to the refrigerant pipes of the lower temperature part of the refrigeration cycle circuit. The worker may connect the second tube sections <NUM> to the refrigerant pipes between the outdoor heat exchanger <NUM> and the expansion device or the refrigerant pipes between the expansion device and the indoor heat exchanger. The radiating block <NUM> may be connected to the refrigerant pipes of the outdoor unit of the air conditioner via the heterojunction tube parts <NUM> and <NUM>. The refrigerant in the refrigeration cycle circuit may partially flow into and out of the radiating block <NUM> through the hybrid coupling tube parts <NUM> and <NUM>.

The worker may mount the electric component box <NUM> on the outdoor unit of the air conditioner after the radiating block <NUM> is connected to the refrigeration cycle circuit in the above-described manner. At this time, the worker may mount the electric component box <NUM> in such a manner that the heat generating element <NUM> of the printed circuit board <NUM> installed in the electric component box <NUM> comes into contact with one side <NUM> of the radiating block <NUM>. When the electric component box <NUM> is mounted in this manner, the radiating block <NUM> may absorb heat from the heat generating element <NUM> and may transfer the heat to the refrigerant paths <NUM> and <NUM>.

It will be appreciated that the present invention is not limited to the above embodiments and may adopt a construction in which the refrigerant tube part <NUM> is connected to a plurality aluminum radiating plates and the refrigerant tube part <NUM> may further include an aluminum connecting pipe connected to the plurality of radiating plates. The present invention may, of course, be implemented in various ways within the technical scope thereof as defined in the claims.

Various embodiments have been described in the best mode for carrying out the invention.

Claim 1:
An outdoor unit of an air conditioner, comprising:
a printed circuit board (<NUM>) on which a heat generating element (<NUM>) is mounted;
an electric component box (<NUM>) in which the printed circuit board (<NUM>) is mounted;
a radiating block (<NUM>) contacting the heat generating element (<NUM>) and including a refrigerant path (<NUM>, <NUM>) through which refrigerant passes, wherein the radiating block is provided at an upper side thereof with an upper protrusion (61C) and at a lower side thereof with a lower protrusion (61D); and
a refrigerant tube part joined to the radiating block (<NUM>) to communicate with the refrigerant path (<NUM>, <NUM>);
wherein a radiating block mount (<NUM>) is fixedly installed at an outdoor unit body (<NUM>), wherein the radiating block (<NUM>) is coupled to the radiating block mount (<NUM>) by attaching the upper protrusion (61C) and the lower protrusion (61D) to the radiating block mount (<NUM>) by screws (61A), and the electric component box (<NUM>) is mounted on the outdoor unit body (<NUM>) by means of fastening elements such as screws in such a manner that the heat generating element (<NUM>) comes into contact with one side (<NUM>) of the radiating block (<NUM>).