EP1041349B1

EP1041349B1 - Replacing gas apparatus for an air conditioner

Info

Publication number: EP1041349B1
Application number: EP00106829A
Authority: EP
Inventors: Shigehiro Sato; Hironao Numoto; Hitoshi Motegi; Yukio Rm1108 Co-op Nomura Kyoto Minami Watanabe; Eiji Nakatsuno; Hiroyuki Takeuchi
Original assignee: Matsushita Electric Industrial Co Ltd
Current assignee: Panasonic Holdings Corp
Priority date: 1999-04-01
Filing date: 2000-03-30
Publication date: 2006-02-15
Anticipated expiration: 2020-03-30
Also published as: DE60025966T2; EP1041349A3; MY128696A; EP1041349A2; ES2255908T3; EP1469262A2; EP1469262A3; DE60025966D1

Description

Background of the Invention

(1) Field of the Invention

The present invention relates to a method for installing an air conditioner used for connecting an indoor unit and an outdoor unit using connecting pipes, and to a collecting trap apparatus of replacing gas used for this method.

(2) Description of the Prior Art

A refrigeration cycle used for an air conditioner comprises a mechanical portion in which a compressor, a heat exchanger and a refrigerant flow rate controller having an expanding mechanism such as a capillary tube or an expanding valve, are connected by pipes such as copper pipes, and fluid charged in the refrigeration cycle such as refrigerant and lubricant oil composition.
A separate-type air conditioner comprises an outdoor unit having a compressor and a heat exchanger, and an indoor unit having another heat exchanger installed at a place where refrigeration air conditioning is performed. The outdoor unit and the indoor unit are connected through connection pipes such as copper pipes. In this type of refrigeration cycle, it is common to establish a the refrigeration cycle in the following way: first, a part or all of the refrigerant and lubricant oil composition is previously charged into the outdoor unit and the valves of the outdoor unit are closed; and then the outdoor unit is connected to the indoor unit by the connection pipes at the time of installing.
However, if the pipes are merely connected in this way, air remains in the indoor unit and the connection pipes. In order to remove the air, a conventional method employs a vacuum pump connected to a refrigerant charge port provided at the valve of the outdoor unit. And, after the air is removed by the vacuum pump, the valve is opened to connect the indoor unit and the outdoor unit, thereby forming the refrigeration cycle.
There is another simple installing method in which a valve of the outdoor unit is opened at the time of the installing so that the refrigerant in the outdoor unit is allowed to flow into the one of connection pipes, the indoor unit and then the other connection pipe and is released together with the air remained in the system from a gap created by moderating the connection of a connection port or a refrigerant charge port provided at the other valve of the outdoor unit; thereby replacing the gas in the indoor unit and the connection pipes.
In view of these conventional methods, Japanese Patent Application Laid-open No.H3-70953 discloses a method to establish a refrigeration cycle without using a vacuum pump in which, after replacing the gas in the refrigeration cycle by oxygen, the refrigerant is charged and the oxygen is solidified by oxygen fixing agent disposed in the refrigeration cycle.
Further, Japanese Patent Application Laid-open No.H7-159004 discloses a method for charging, into a portion of a refrigeration cycle, material capable of absorbing two or more of water, oxygen, nitrogen, carbon dioxide and the like in the air in such a separate type air conditioner in which among a freezing compressor, a condenser, an expanding mechanism such as a capillary tube and an expanding valve, and an evaporator, one of the condenser and the evaporator, or one of the condenser and the evaporator is separated from the expanding mechanism and connected by the pipes.
Further, Japanese Patent Application Laid-open No.H7-269994 discloses a refrigeration cycle in which oxygen absorbing agent is disposed in a refrigerant circulating system.
Further, Japanese Patent Application Laid-open No.H9-292168 discloses a method in which air absorbing agent is disposed for removing air in a pipe and an indoor unit, and a method in which after carbon dioxide is charged in the pipe and the indoor unit, the carbon dioxide in the pipe and the indoor unit is absorbed by carbon dioxide absorbing agent to establish vacuum.
Since air remaining in the refrigeration cycle deteriorates freezing ability as non-condensation gas, and oxygen and water facilitate degradation of freezer oil, iron and the like in the refrigeration cycle, it is inevitably necessary to remove the air.
JP 11014203 A discloses a method and an apparatus for installing a refrigeration cycle. In particular, the conventional problem is solved that a power supply is required for a vacuum pump removing the detrimental residual air in the refrigeration cycle. Detrimental residual air in the refrigeration cycle lowers the refrigeration capacity since it constitutes a non-condensable gas. Moreover, the problem of ozone layer destruction and global warm-up due to atmospheric discharge of Freon gas is addressed. This problem arises due to the substitution of a coolant.
US 4,793,717 discloses an apparatus for preventing excessive pressure from acting on packages or palettes. When excessive pressure acts on a dome, the dome will be deformed and discolored. US 5,719,119 shows a similar state of the art.
It is the object of the present invention to improve the performance of the replace gas collecting trap apparatus and develop a respective method. The object is solved by the features of claims 1, 9 or 10, respectively.
Among the above-described conventional techniques, the method for removing the air using the vacuum pump is common. However, in order to operate the vacuum pump in the installing site, it is necessary that an electric power supply is available; further, it is difficult to use the pump on a roof and the like, and therefore, this method cannot be called a simple method.
Further, in the case of the replacing method of air using refrigerant, it is not possible to avoid emissions of chlorofluorocarbon, which is the refrigerant, into the atmosphere, and this is not preferable because of global-warming problem in view of global environment concerns.
Further, concerning a method for collecting a replacing gas after the air in the indoor heat exchanger and the connection pipes is once replaced by the replacing gas, no simple apparatus for collecting the replacing gas has not been proposed.
Thereupon, it is an object of the present invention to provide a method for installing an air conditioner capable of easily and reliably collecting a replacing gas after the air in an indoor heat exchanger and a connection pipe is once replaced by the replacing gas, and to provide a collecting trap apparatus of replacing gas used for this method.

Disclosure of the Invention

According to the present invention, there is provided a replacing gas collecting trap apparatus as claimed in claim 1.
With this mode, if the gas collecting trap agent causes the physical absorbing reaction or chemical reaction at a dash, high reaction heat is generated. If this is detected by the temperature indicating portion, sufficient gas absorbing function is exhibited when the installing operation is completed, and it is possible to confirm that the interior is in the negative pressure state.
According to the present invention, in the replacing gas collecting trap apparatus, the temperature indicating portion is a color change label depending on temperature. By using the color change label depending on temperature, it is possible to sufficiently meet a large variation in the operational environment such as winter and summer. Further, the color change label depending on temperature is small as a member, if this is handled separately, it is possible to adhere the color change label depending on temperature on the outer side of the container immediately before the installing operation.
Further, according to the present invention, in the replacing gas collecting trap apparatus, a structure body made of material having excellent thermal conductivity is disposed so as to come into contact with an inner wall of the container. With this mode, by providing the material having excellent thermal conductivity inside, when the gas collecting trap agent reacts with gas, the generated heat can swiftly be transmitted outside the container.
Further, according to the present invention, in the replacing gas collecting trap apparatus, the structure body has a fin shape or a rod shape. With this mode, with a simple structure such as the fin shape and the rod shape, when the gas collecting trap agent reacts with gas, the generated heat can swiftly be transmitted outside the container.
Further, according to the present invention, in the replacing gas collecting trap apparatus, there is provided a structure body in which a coating layer mainly made of the gas collecting trap agent is formed on a carrier constituting the structure body and having excellent thermal conductivity. With this mode, since structure body in which a coating layer mainly made of the gas collecting trap agent is formed on the carriers having excellent thermal conductivity, when the gas collecting trap agent reacts with gas, the generated heat can swiftly be transmitted outside the container.
Further, according to the present invention, in the replacing gas collecting trap apparatus, the structure body is a honeycomb structure body or a corrugated structure body. With this mode, by using the honeycomb structure body or the corrugated structure body, a sufficient heat transmitting speed can be obtained, and by using the integral structure body, the body can easily be accommodated in the container, and an adverse possibility that the gas collecting trap agent is damaged when it is stored or transported is reduced.
Further, according to the present invention, in the replacing gas collecting trap apparatus, the structure body or the carriers are made of the material having excellent thermal conductivity such as aluminum, copper, graphite or compound thereof. With this mode, sufficient thermal conductivity can be obtained.
According to the present invention, in the replacing gas collecting trap apparatus, the gas collecting trap agents collects gas by physical absorbing reaction, chemical reaction or combination thereof. The sufficient reaction heat may not be obtained only by the physical absorbing reaction, and the operability is slightly inferior if only the chemical reaction is used because the reaction heat is too high. Therefore, by using combination of the physical absorbing reaction and the chemical reaction, an appropriate reaction heat can be generated such that proper temperature detection is made possible.
Further, according to the present invention, in the replacing gas collecting trap apparatus, the replacing gas is carbon dioxide, the gas collecting trap agent is mainly made of zeolite and calcium hydroxide, and the gas collecting trap agent traps the carbon dioxide. With this mode, it is possible to control the amount of temperature increase of the container even under various environment by selecting suitable amount of the zeolite and the calcium hydroxide as the trap agent for the carbon dioxide. Thereby, it is possible to confirm whether sufficient gas collecting trap function has been exhibited without error by the temperature indicating portion when the installing operation is completed.
Further, according to the present invention, in the replacing gas collecting trap apparatus, the gas collecting trap agent comprises 100 parts by weight zeolite and 0.5 to 5 parts by weight calcium hydroxide. With this mode, by optimizing the calcium hydroxide with respect to the zeolite when the replacing gas is carbon dioxide, it is possible to increase the temperature by about 20°C, and it is possible to confirm whether sufficient gas collecting trap function has been exhibited without error by the temperature indicating portion when the installing operation is completed.
Further, according to the present invention, there is provided a method for installing an air conditioner for connecting an indoor unit and an outdoor unit by a connecting pipe as claimed in claim 9. With this mode, the gas collecting trap agent in the replacing gas collecting trap apparatus traps the gas at a dash by the physical absorbing reaction or chemical reaction without the need of using a power supply and thus, the installing operation can be completed within a short time. At that time, since high reaction heat is generated, by detecting the resultant temperature increase by the temperature indicating portion, it is possible to confirm whether the sufficient gas collecting trap function has been exhibited when the installing operation is completed, and whether the interior is in the negative pressure state.
Further, according to the present invention, there is provided a method for installing an air conditioner for connecting an indoor uni t and an outdoor unit by a connecting pipe, as claimed in claim 10. With this mode, the temperature indicating portion can be prepared separately with respect to various operational environments such as winter and summer, and when the installing operation is carried out, appropriate temperature indicating portion can be selected and used at site, thus, it is possible to confirm the amount of temperature increase without error.

Brief Description of the Drawings

Fig.1 is a block diagram of a refrigeration cycle for an air conditioner used for an embodiment of the present invention to which a replacing gas charging container is connected;
Fig.2 is a block diagram of a refrigeration cycle for an air conditioner used for an embodiment of the present invention to which a replacing gas collecting trap apparatus is connected;
Fig. 3 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.4 is an enlarged sectional view of an essential portion of the replacing gas collecting trap apparatus;
Fig.5 is a plan view of a baffle used for the replacing gas collecting trap apparatus;
Fig.6 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.7 is a side view of a baffle used for the replacing gas collecting trap apparatus;
Fig.8 is a side view of a baffle used;
Fig.9 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus;
Fig.10 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus;
Fig.11 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.12 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.13 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus of another embodiment of the present invention;
Fig.14 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus;
Fig.15 is a perspective view of an outward appearance of a replacing gas collecting trap apparatus;
Fig.16 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.17 is a view of an outward appearance of the replacing gas collecting trap apparatus as viewed from an inlet thereof;
Fig.18 is an enlarged sectional view of an essential portion of an internal pressure indicating portion;
Fig.19 is a schematic sectional side view of a replacing gas collecting trap apparatus;
Fig.20 is a view of an outward appearance of the replacing gas collecting trap apparatus as viewed from an inlet thereof;
Fig. 21 is an enlarged sectional view of an essential portion of an internal pressure indicating portion;
Fig.22 is a schematic sectional side view of a replacing gas collecting trap apparatus of an embodiment of the present invention as claimed;
Fig.23 is a view of an outward appearance of the replacing gas collecting trap apparatus;
Fig.24 is a schematic sectional side view of a replacing gas collecting trap apparatus of another embodiment of the present invention;
Fig.25 is a sectional view taken along the line A-A in Fig.24;
Fig.26 is a schematic sectional side view of a replacing gas collecting trap apparatus of another embodiment of the present invention;
Fig.27 is a sectional view taken along the line B-B in Fig.26;
Fig.28 is a schematic sectional side view of a replacing gas collecting trap apparatus of another embodiment of the present invention;
Fig.29 is a sectional view taken along the line C-C in Fig.28;
Fig.30 is an enlarged sectional view of an essential portion of an internal structure in Fig.28;
Fig.31 is a schematic sectional side view of a replacing gas collecting trap apparatus of another embodiment of the present invention;
Fig.32 is a sectional view taken along the line D-D in Fig.31; and
Fig.33 is a graph showing characteristics of temperature increase of a replacing gas collecting trap apparatus.

Description of the Preferred Embodiments

Embodiments of the present invention will be explained with reference to the drawings below.
Figs.1 and 2 are block diagrams of refrigeration cycles used in the embodiment. Fig.1 shows the refrigeration cycle to which a replacing gas charging container is connected, and Fig.2 shows the refrigeration cycle to which a replacing gas collecting trap apparatus is connected.
First, the entire structure of the refrigeration cycle constituting the air conditioner will be explained using Figs.1 and 2.
The refrigeration cycle comprises a compressor 1, a four-way valve 2, an outdoor unit heat exchanger 3, an expansion device 4, a dryer 5 and an indoor unit heat exchanger 6. The compressor 1, the four-way valve 2, the outdoor unit heat exchanger 3, the expansion device 4 and the dryer 5 are disposed in an outdoor unit A, and the indoor unit heat exchanger 6 is disposed in an indoor unit B.
The outdoor unit A is provided with a liquid-side two-way valve 7 and a gas-side three-way valve 8. The outdoor unit A and the indoor unit Bare connected to each other through connection pipes 9 and 10 using the liquid-side two-way valve 7 and the gas-side three-way valve 8. The liquid-side two-way valve 7 is provided with a screw portion 7a, and a pipe on the side of the outdoor unit A and a connecting pipe 9 are brought into communication with each other by opening the screw portion 7a. The gas-side three-way valve 8 is provided with a screw portion 8a and a service port 8b, and a pipe on the side of the outdoor unit A and a connecting pipe 10 are brought into communication with each other by opening this screw portion 8a.
As shown in Fig.1, a replacing gas charging container 20 can be connected to the service port 8b using a connecting apparatus 30, and as shown in Fig.2, a replacing gas collecting trap apparatus 40 can be connected to the refrigerant charge port 8b using a connecting apparatus 50.
These replacing gas charging container 20 or the replacing gas collecting trap apparatus 40 can be brought into communication with the connecting pipe 10 by connecting the container to the connecting apparatus 30 or 50, respectively.
A replacing gas comprising one kind or a plurality of kinds of gas mixture which is inert toward the refrigerant in the refrigeration cycle and which is gas state at room temperature and atmospheric pressure is charged into the replacing gas charge container 20. More specifically, it is preferable that the replacing gas has a global warming coefficient smaller than that of a refrigerant. For example, when R410A is used as the refrigerant, the global warming coefficient (GWP) is 1730, it is preferable that the replacing gas has a global warming coefficient smaller than this value and the replacing gas is inert toward the refrigeration cycle. Examples of the replacing gas are carbon dioxide (GWP=1), propane (GWP<3), butane (GWP<3) and the like.
On the other hand, a material which absorbs the replacing gas (adsorbent) is charged in the replacing gas collecting trap apparatus 40. More specifically, when carbon dioxide is charged as the replacing gas, zeolite, epoxy compound, calcium hydroxide, calcium chloride and the like can be used as the material which absorbs the replacing gas. Among them, zeolite is preferable because the absorbing speed is high. Zeolite having hole diameter of 1.0 nm is most suitable because the absorbing speed of the carbon dioxide is high. Although any shape of zeolite can be used, but spherical shape is preferable because the zeolite of such shape is less prone to be crushed.
Next, various embodiments of the replacing gas collecting trap apparatus 40 shown in Fig.2 will be explained below using Figs.3 to 11.
Figs.3 to 5 shows a schematic structure of the replacing gas collecting trap apparatus, wherein Fig.3 is a sectional side view of the replacing gas collecting trap apparatus, Fig.4 is an enlarged sectional view of an essential portion of the replacing gas collecting trap apparatus, and Fig. 5 is a plain view of a baffle used for the replacing gas collecting trap apparatus.
The replacing gas collecting trap apparatus of the present embodiment comprises a cylindrical container body 41 made of metal such as aluminum and copper, a lid 61 for closing an opening of a base 41A formed at one end of the container body 41 by drawing or welding, and a baffle 71 for securely holding adsorbent A charged into the container body 41.
Here, the base 41A is formed at its outer periphery with a screw groove 41B, and an end surface of the opening of the base 41A is finished into a flat surface. The base 41A is formed on its inside wall with a projection 41C for locking the baffle 71.
The lid 61 comprises a thin sealing plate 61A made of resin or metal having low gas-permeability, and a reinforcing plate 61B made of metal. The reinforcing plate 61B is formed at its center with a hole 61C. The lid 61 is of a laminated form such that the reinforcing plate 61B is provided on the base 41A and the sealing plate 61 is provided on the reinforcing plate 61B.
The baffle 71 is formed into a cup-like shape comprising a bottom portion71A and a cylindrical portion 71B. The bottom portion 71A includes a large number of holes 71C. The size of the hole 71C is set such that the adsorbent A will not pass through the hole 71C.
Here, the relation between the shape of the adsorbent A and the hole 71 suitable for this kind of replacing gas collecting trap apparatus will be explained.
The adsorbent A which is formed into spherical or columnar shape is suitable. More specifically, such shape of adsorbent, e.g., a spherical body having a diameter of 4 to 6 mm or 6 to 8 mm, or a columnar body having a diameter of 5 mm and a length of about 7 mm is suitable. On the other hand, it is preferable that the hole 71C has a diameter of 3 mm or less when the spherical adsorbent A having a diameter of 4 to 6 mm is used, that the hole 71C has a diameter of 5 mm or less when the spherical adsorbent A having a diameter of 6 to 8 mm is used, and that the hole 71C has a diameter of 4 mm or less when the columnar adsorbent A having a diameter of 5 mm and a length of about 7 mm is used. It is preferable that the opening rate of the baffle 71 by the hole 71C is 60% or higher.
According to the present embodiment, since the container body 41 made of metal such as aluminum and copper, heat generated when the replacing gas is absorbed can be transmitted from the container body 41 to outside. Further, in the present embodiment, by securely holding the adsorbent A charged in the container body 41 by the baffle 71, it is possible to prevent the adsorbent A from being crushed by vibration or the like. Further, in the present embodiment, since the hole 71C of the bottom portion 71A has such a size that the adsorbent A can not pass through, it is possible to prevent the adsorbent from being got into the refrigeration cycle of the air conditioner. Further, in the present embodiment, the end surface of the opening of the base 41A is finished into the flat surface, and the reinforcing plate 61B and the sealing plate 61A are laminated on each other such that the reinforcing plate 61B is provided onto the base 41A. Therefore, the lid 61 can reliably hold hermeticality, and the operability is excellent.
Next, a method for producing the replacing gas collecting trap apparatus of the present embodiment will be explained.
In the replacing gas collecting trap apparatus of the present embodiment, the heated adsorbent A is first charged into the container body 41. Then, the baffle 71 is inserted into the base 41A until the baffle 71 abuts against the projection 41C, and the adsorbent A is securely held by this baffle 71. In this state, a small amount of gas such as CO₂, O₂, N₂, a noble gas, e.g., He or the like is charged into the container body 41A and the latter is sealed by the lid 61. The lid 61 is provided on the base 41A by laminating the reinforcing plate 61B and the sealing plate 61A in this order.
In the above method, the adsorbent A which is previously heated is charged into the container body41A. But, the adsorbent A may be heated after the adsorbent A is charged into the container body 41A, but before the sealing by the lid 61 by heating the container body 41A. Although it is preferable that gas absorbed by the adsorbent A is degassed by heating the adsorbent A before sealing, it is not essential to have a heating step of the adsorbent A.
Fig.6 is a schematic sectional side view of a replacing gas collecting trap apparatus, and Fig.7 is a side view of a baffle used for the replacing gas collecting trap apparatus. In the present embodiment and the subsequent embodiments, members similar to those of the previous embodiment will be designated by the same reference numerals, and detailed explanation thereof will be omitted.
The replacing gas collecting trap apparatus of the present embodiment uses a baffle 72 instead of the baffle 71 in the previous embodiment shown in Figs.3 to 5.
The baffle 72 comprises a cage-shaped net-like mesh member 72A, and a cylindrical portion 72B. Each of clearances formed by the net of the mesh member 72A has such a size that the adsorbent A cannot pass through.
Here, it is preferable that the maximum size of the clearance formed by the net of the mesh member 72A is 3 mm or less when the spherical adsorbent A having a diameter of 4 to 6 mm is used, 5 mm or less when the spherical adsorbent A having a diameter of 6 to 8 mm is used, and 4 mm or less when the columnar adsorbent A having a diameter of 5 mm and a length of about 7 mm is used. It is preferable that the opening rate by the mesh member 72A is 60% or higher.
Fig.8 is a side view of a baffle used of another embodiment.
The baffle 73 of the present embodiment has a mesh member 73 projecting longer as compared with the baffle 72. Although it is not illustrated in an accompanying drawing, it is preferable that the projecting length of the mesh member 73A is 1/3 or longer of the depth of the container body in which the adsorbent A is charged. By elongating the projecting length of the mesh member 73A in this manner, the absorbing speed of the replacing gas can be increased. The preferences concerning clearances formed by the net of the mesh member 73A are the same as those of the mesh member 72A as explained above.
Figs.9 and 10 are schematic sectional side views of essential portions of replacing gas collecting trap apparatuses of other embodiments.
Baffles 74 and 75 respectively shown in Figs.9 and 10 are made of fiber member such as synthetic fiber, natural fiber and steel wool. Especially, the baffle 74 is made by forming the fiber member into a spherical shape and inserting the fiber member from the opening of the base 41A such that a portion of the baffle 74 is disposed inside of the enlarged portion of the container body which is deeper portion from the base 41A. If the portion of the baffle 74 is disposed such as to be inside of the enlarged portion of the container body which is deeper portion from the base 41A in this manner, it is possible to prevent the baffle 74 from falling out, and moreover, to enlarge the introducing passage of the replacing gas in the vicinity of the inlet to the adsorbent A. As shown in Fig. 10, the baffle 75 is entirely disposed in an enlarged portion of the container body deeper than the base 41A. If the baffle 75 is disposed in the enlarged portion in this manner, it is possible to prevent the baffle 75 from falling out, and moreover, to enlarge the introducing passage of the replacing gas in the vicinity of the inlet to the adsorbent A.
Fig.11 is a schematic sectional side view of a replacing gas collecting trap apparatus. In the present embodiment and the subsequent embodiments, members similar to those of the previous embodiment will be designated by the same reference numerals, and detailed explanation thereof will be omitted.
In addition to the adsorbent A, replacing gas B is charged into the replacing gas collecting trap apparatus of the present embodiment. The replacing gas collecting trap apparatus of the present embodiment comprises a cylindrical container body 42 made of metal such as aluminum and copper, a lid 62 for sealing the opening of the base 42A formed at one end of the container body 42 by drawing or welding, and a partition wall 81 for dividing the interior of the container body 42 into two chambers.
Here, the base 42A is formed at its outer periphery with a screw groove 42B, and an end surface of the opening of the base 42A is finished into a flat surface.
The lid 62 comprises a thin sealing plate 62A made of resin or metal having low gas-permeability, and a reinforcing plate 62B made of metal. The reinforcing plate 62B is formed at its center with a hole 62C. The lid 62 is provided with the reinforcing plate 62B and the sealing plate 62A which are laminated on each other such that the sealing plate 62A is provided onto the base 42A. The partition wall 81 is formed at its center portion with a thinner portion 81A.
As described above, in the present embodiment, the partition wall 81 is provided for dividing the interior of the container body 42 into the two chambers, the replacing gas B is charged on the side of the base 42A, and the adsorbent A is charged into the deep side. Therefore, this container can also serve as the replacing gas charging container 20 shown in Fig.1.
When the replacing gas collecting trap apparatus of the present embodiment is used, it is necessary to provide a blade such as a needle which is longer at least than a distance from the lid 62 to the partition wall 81A.
Fig.12 is a schematic sectional side view of a replacing gas collecting trap apparatus of another embodiment.
Like the previous embodiment shown in Fig.11, replacing gas B is also charged, in addition to the adsorbent A, into the replacing gas collecting trap apparatus of the present embodiment. The replacing gas collecting trap apparatus of the present embodiment comprises a cylindrical container body 43 made of metal such as aluminum and copper, a lid 62 for closing an opening of a base 43A formed at one end of the container body 43 by drawing or welding, and a partition wall 81 for dividing the interior of the container body 43 into two chambers.
Here, the base 43A is formed at its outer periphery with a screw groove 43B, and an end surface of the opening of the base 43A is finished into a flat surface.
As described above, in the present embodiment, the partition wall 81 is provided for dividing the interior of the container body 42 into the two chambers, the adsorbent A is charged on the side of the base 42A, and the replacing gas B is charged into the deep side. Therefore, this container can also serve as the replacing gas charging container 20 shown in Fig.1.
When the replacing gas collecting trap apparatus of the present embodiment is used, it is necessary to provide a blade such as a needle which is longer at least than the distance from the lid 62 to the partition wall 81A. Further, it is necessary that the baffle 71 can be opened by a blade such as a needle.
Fig.13 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus of another embodiment.
In the replacing gas collecting trap apparatus of the present embodiment, a container body 44 is formed at its one end with a base 44A formed with a ring-like recess 44B. The base 44A includes display means 91. The display means 91 is provided therein with a float 91A which can move depending upon a flowing direction of gas. The float 91A is designed such that the float 91A is located far side from the opening of the base 44A as shown in Fig.13 when the replacing gas is being absorbed through the base 44A, and is located near side of the opening of the base 44A when the gas is flowing out through the base 44A.
As described above, unlike the previous embodiments shown in up to Fig.12, in the present embodiment, the coupling connection can be carried out between the connecting apparatus and the trap apparatus by providing the recess 44B. Especially, when the display means 91 is provided as in the present embodiment, the coupling connection by the recess 44B is preferable because it can shorten the length of the base 44A.
As in the present embodiment, by providing the display means 91 capable of visually informing the direction of flow of the gas in the base 44, the certainty of the operation can be enhanced.
Incidentally, the coupling connection by the recess 44B and the display means 91 of the present embodiment can also be applied to the other embodiments. Especially, if they are applied to the embodiments in which the container includes both the adsorbent A and the replacing gas B therein like those shown in Figs.11 and 12, high effect can be obtained.
Fig.14 is a schematic sectional side view of an essential portion of a replacing gas collecting trap apparatus of another embodiment.
The replacing gas collecting trap apparatus of the present embodiment comprises a cylindrical container body 45 made of metal such as aluminum and copper, an insect valve 63 for closing an opening of a base 45A formed at one end of the container body 45 by drawing or welding, and a baffle 71 for securely holding adsorbent A charged into the container body 45. The base 45A is formed at its outer periphery with a screw groove 45B, and an end surface of the opening of the base 45A is finished into a flat surface. The base 45A is formed therein with a projection 45C for locking to the baffle 71.
The insect valve 63 comprises a valve core 63A, a resilient body 63B for biasing the valve core 63A, a valve seat 63C which is opened and closed by the movement of the valve core 63A, and a connecting member 63D connecting the valve core 63A and the resilient body 63B. When the replacing gas collecting trap apparatus is not used, in the insect valve 63, the valve seat 63C is always held in the closed state by the valve core 63A. When the container body 45 is maintained at negative pressure, it is necessary that the biasing force of the resilient body 63B has such a strength that the valve seat 63C is not opened by the negative pressure. When the replacing gas collecting trap apparatus is used, in the insect valve 63, the valve core 63A is pushed by the valve body provided in the connecting apparatus 50, and the valve seat 63C is opened.
According to the replacing gas collecting trap apparatus of the present embodiment, the container can be re-useable by providing opening/closing means such as the insect valve 63.
Fig. 15 is a perspective view of an outward appearance of a replacing gas collecting trap apparatus of another embodiment.
The replacing gas collecting trap apparatus of the present embodiment, the container body 46 is made of flexible film such as laminate film. The container body 46 is provided with a lid 62 for sealing the opening of a base 46A, and the base 46A is formed at its outer periphery with a screw groove 46B.
It is preferable that an inner surface or an outer surface, or both inner and outer surfaces of the flexible film are provided with metal material such as aluminum material by, for example, vapor deposition. By providing the metal material, the strength is enhanced, and the heat generated at the time of adsorption of the replacing gas can easily be diffused.
When the inner volume of the container body 46 may be varied and material thereof is soft like in this embodiment, it is preferable, instead of directly providing the base 46A with the screw groove 46B as in the present embodiment, to provide a connection member separately on the base 46A or to provide the coupling connection by forming a recess as shown in the embodiment of Fig. 13 . In the above embodiment, the lids 61, 62 are formed of the sealing plates 61A, 62A and the reinforcing plates 61B, 62B, respectively, but each of them may be formed of single metal material or a single resin material having low gas-permeability. As the resin material having low gas-permeability, polyphenylene sulfide (PPS), polyvinylidene fluoride (PVDF), or polytetrafluoroethylene (PTFE) can be used.
Next, an installing method of the above air conditioner will be explained.
Before the air conditioner is installed, refrigerant gas is charged into the pipes on the side of the outdoor A such as the compressor 1 and the outdoor unit heat exchanger 3. At that time, in addition to the refrigerant gas which is necessary for driving, the refrigerant gas for purge operation is charged into the outdoor unit A. On the other hand, the pipes on the side of the indoor unit B such as the indoor unit heat exchanger 6, as well as the connecting pipes 9 and 10 are not sealed and are opened into the atmosphere.
First, the outdoor unit A and the indoor unit B are connected through the connecting pipes 9 and 10. At that time, the liquid-side two-way valve 7 and the connecting pipe 9 are not hermetically connected to each other but are loosely connected such that gas can slightly leak. The screw 7a of the liquid-side two-way valve 7 and the screw 8a of the gas-side three-way valve 8 are closed.
Next, the connecting apparatus.30 is mounted to the service port 8b of the gas-side three-way valve 8. When the connecting apparatus 30 is mounted to the service port 8b, the valve core 82 in the service port 8b is pushed by the valve rod 35 in the connecting apparatus 30 so that the service port 8b is opened. Thereafter, by mounting the replacing gas charging container 20 to the connecting apparatus 30, the opening of the replacing gas charging container 20 is opened by the blade of the connecting apparatus 30. As a result, the replacing gas in the replacing gas charging container 20 is introduced into the connecting pipe 10 and the indoor unit B from the service port 8b through the connecting apparatus 30, and introduced into the connecting pipe 9. By the introduced replacing gas, the air in the connecting pipes 9 and 10 as well as in the indoor unit B is discharged into the atmosphere together with the introduced replacing gas from a loosened portion of flare portion of the liquid-side two-way valve 7.
Here, confirming that gas is leaking from a space between the liquid-side two-way valve 7 and the connecting pipe 9 and that a predetermined amount of gas has been discharged, then, the connecting portion between the liquid-side two-way valve 7 and the connecting pipe 9 is hermetically closed. The predetermined amount of discharged gas may be measured using a flowmeter, but if the amount of gas in the replacing gas charging container 20 is set slightly greater than the volume in the pipe in the indoor unit B and the connecting pipes 9 and 10 so that one air conditioner can be installed using one replacing gas charging container 20, the connecting portion between the liquid-side two-way valve 7 and the connecting pipe 9 may be hermetically closed when a sound of gas leaking out becomes small without using the flowmeter.
Next, the connecting apparatus 30 is detached from the service port 8b in a state where the replacing gas charging container 20 is left mounted to the connecting apparatus 30.
In the case that inert gas is not removed from the air conditioner, the screw 7a of the liquid-side two-way valve 7 and the screw 8a of the gas-side three-way valve 8 are opened in this state, and the refrigerant in the outdoor unit A is allowed to flow into the indoor unit B.
In the case that the introduced inert gas is removed, the screw 7a of the liquid-side two-way valve 7 and the screw 8a of the gas-side three-way valve 8 are not opened at this time, and the procedure proceeds to an replacing gas collecting step as shown in Fig.2.
The replacing gas collecting step is achieved by connecting the replacing gas collecting container 40 to the service port 8b.
One method therefor is to connect the connecting apparatus 50 to the replacing gas collecting container 40 by threadedly engaging the male screw 41 of the replacing gas collecting container 40 with the female screw 54 of the connecting apparatus 50. In this state, the replacing gas collecting container 40 is opened by the blade provided in the connecting apparatus 50.
Then, confirming that a hole is formed in a tip end of the replacing gas collecting container 40, the other end of the connecting apparatus 50 is connected to the service port 8b. By threadedly engaging the connecting apparatus 50 with the service port 8b, the valve rod 55 of the connecting apparatus 50 pushes the valve core 82 in the service port 8b. Then, the replacing gas collecting container 40 and the service port 8b are brought into communication with each other, and the replacing gas in the connecting pipes 9 and 10 as well as the pipes in the indoor unit B is introduced from the service port 8b into the replacing gas collecting container 40. By first connecting the connecting apparatus 50 and the replacing gas collecting container 40 in this manner, it is possible to prevent the air in the atmosphere from mixing into the replacing gas by the replacing gas's flowing out from the service port 8b.
Another method is to first connect the other end of the connecting apparatus 50 to the service port 8b and then, to connect the replacing gas collecting trap apparatus 40 to the connecting apparatus 50. By first connecting the connecting apparatus 50 to the service port 8b in this manner, the air in the connecting apparatus 50 can be pushed out by the replacing gas.
The introduced replacing gas is absorbed and collected to the absorbent in the replacing gas collecting trap apparatus 40.
Then, the connecting apparatus 50 is detached from the service port 8b, and the screw of the liquid-side two-way valve 7 is completely opened. The connecting apparatus 50 is detached from the service port 8b in a state where the replacing gas collecting trap apparatus 40 is still connected to the connecting apparatus 50.
Lastly, the screw 8a of the gas-side three-way valve 8 is also opened completely, and the installing operation of the air conditioner is completed.
The air in the refrigeration cycle can be removed by carrying out the installation in accordance with the above-described step.
Although the method for installing the outdoor unit having the normal two-way valve and three-way valve was explained in the above embodiments, the present invention can also be applied to an outdoor unit having a three-way valve and another three-way valve. Further, the present invention should not be limited to the two-way valve and three-way valve, and the invention can also be applied to an air conditioner having a valve including a service port.
Next, another embodiment of the trap apparatus will be explained using Figs.16 to 21.
Figs.16 to 18 show the trap apparatus according to the other embodiment, wherein Fig.16 is a schematic sectional side view of a replacing gas collecting trap apparatus of the embodiment, Fig.17 is a view of an outward appearance of the replacing gas collecting trap apparatus, and Fig.18 is an enlarged sectional view of a recess 100A.
In the trap apparatus 47A, spherical zeolite A is charged into an aluminum container body. The zeolite A has 6 to 8 mesh diameter. The trap apparatus 47A is provided therein with a baffle 76 for separating an inlet 48 and the zeolite A, and the zeolite A is securely held thereby. The baffle 76 is provided with holes of such a size that the zeolite A cannot pass through. In the present embodiment, the opening rate of the baffle was set to 60%, and 100g of zeolite was charged in total. An internal pressure indicating portion 100A having a recess-shape is provided in the vicinity of the inlet of the container body. As shown in Fig.5, the internal pressure indicating portion 100A is made of three layer laminate member, which is made of nylon 101, aluminum 102, nylon 103. The recess-shape is set such that its recessed amount becomes 2 mm at internal pressure of 20 mmHg and the recess-shape becomes flat at atmospheric pressure.
Figs.19 to 21 show a replacing gas collecting trap apparatus of a next embodiment, wherein Fig. 19 is a schematic sectional side view of the replacing gas collecting trap apparatus, Fig.20 is a view of an outward appearance of the replacing gas collecting trap apparatus, and Fig. 21 is an enlarged sectional view of an inner pressure indicating portion 100B.
An interior of a container of the trap apparatus 47B is the same as that of the immediately previous embodiment, and the internal pressure indicating portion 100B which is colored by strain is provided in the vicinity of an inlet of the container body. As shown in Fig.21, in the internal pressure indicating portion 100B, a coloring matter layer 112 is printed on a surface of a PET 111, and the coloring matter 112 is further coated with a transparent over coat layer 113. The internal pressure indicating portion 110 is designed such hat it is colored green by strain generated when the internal pressure is 50 mmHg.
Next, a method for installing the air conditioner will be explained with reference to Figs.1 and 2.
Before the air conditioner is installed, refrigerant gas is charged into the pipes on the side of the outdoor A such as the compressor 1 and the outdoor unit heat exchanger 3. At that time, refrigerant gas which is necessary for driving as well as is used for the purging operation is charged into the outdoor unit A. On the other hand, the pipes on the side of the indoor unit B such as the indoor unit heat exchanger 6, as well as the connecting pipes 9 and 10 are not sealed and are opened into the atmosphere. First, the outdoor unit A and the indoor unit B are connected through the connecting pipes 9 and 10. At that time, the screw 7a of the liquid-side two-way valve 7 and the screw 8a of the gas-side three-way valve 8 are closed. A carbon dioxide cylinder 20 is mounted to the service port 8b of the gas-side three-way valve 8 of the outdoor unit A through a connecting apparatus 30. After the carbon dioxide cylinder 20 is mounted to the service port 8b, the flare portion of the liquid-side two-way valve 7 is slightly loosened. By pushing the carbon dioxide cylinder 20 against the connecting apparatus 30 while the carbon dioxide cylinder 20 being rotated, the carbon dioxide in the carbon dioxide cylinder 20 is introduced into the connecting pipes 9 and 10 and the indoor unit B. Air in the connecting pipe 9 and 10 and the indoor unit B is discharged out into the atmosphere from the loosened portion of the flare portion of the liquid-side two-way valve 7. At that time, the flare portion of the liquid-side two-way valve 7 is tightly closed in a state where the pressure in the connecting pipe 9 and 10 and the indoor unit B at positive pressure (about 0.1 kgf/cm²). Next, the connecting apparatus 30 is removed from the service port 8b together with the carbon dioxide cylinder 20. Then, as shown in Fig.2 (numeral 40 in Fig. 2 will hereafter be regarded as numeral 47), the gas collecting trap apparatus 47 is mounted to the service port 8b by the connecting apparatus 50. At that time, the operation will be started by confirming that the inside of the trap apparatus is negative pressure state by checking the pressure indicating portion 100 provided in the vicinity of the container body of the trap apparatus 47 by means of the depth of the recess or the color which changes in accordance with the strain. Then, the trap apparatus 47 is pushed against the connecting apparatus 50 while rotating the trap apparatus 47 so as to be mounted. By mounting in this way, the interior of the replacing gas collecting trap apparatus 47 is brought into communication with the connecting pipe 10, and the interior pressure of the replacing gas collecting trap apparatus 47 once becomes the substantially atmospheric pressure. At that time, the shape of the pressure indicating portion 100 is changed to the flat plate shape or projection shape. Or the pressure indicating portion 100 is changed in color or the color is disappeared. By bringing the trap apparatus 47 and the connecting pipe 10 into communication with each other, carbon dioxide in the connecting pipe 9 and10 the indoor unit B is introduced through the service port 8b into the trap apparatus 47. The introduced carbon dioxide is physically absorbed and collected by the zeolite in the trap apparatus 47, and the interior of the trap apparatus 47 is brought into a sufficiently negative pressure state again. As a result, the shape of the pressure indicating portion 100 is change into the recess shape again, or the coloration or the coloring is changed. By confirming the change of these states, it is possible to ensure the inside negative pressure state. After the carbon dioxide is collected in this way, the screw portion 7a of the liquid-side two-way valve 7 is slightly loosened, the refrigerant gas in the outdoor unit A is introduced, thereby bringing the pressure in the connecting pipe 9and 10 and the pipe of the indoor unit B into positive pressure (about 0.2 kgf/cm²). At that time, the shape of the pressure indicating portion 100 is changed again to the flat plate shape or projection shape. Or the pressure indicating portion 100 is changed in color or the color is disappeared. Thereafter, the connecting apparatus 50 is removed from the service port 8b together with the trap apparatus 47, and the screw portion 7a of the liquid-side two-way valve 7 is completely opened. Lastly, the screw portion 8a of the gas-side three-way valve 8 is also completely opened, and the installing operation of the air conditioner is completed.
In the above installing operation, the refrigerant charged into the outdoor unit A is introduced into the connecting pipes 9 and 10 and the indoor unit B before the connecting apparatus 50 is detached from the service port 8b together with the trap apparatus 47. This is for preventing the air from entering inside from outside during the final operation even though the negative pressure state is established. If the connecting apparatus 50 is designed such that it can be detached from the service port 8b instantaneously, it is unnecessary to introduce the refrigerant into the connecting pipe 9 and 10 and the indoor unit B.
Using the trap apparatus 47A of the previous embodiment shown in Figs.16 to 18 and the trap apparatus 47B of the latter embodiment shown in Figs.19 to 21, the air conditioner was installed under the operational environment of 20°C. The volume of the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 was 1.5 liters in the above embodiments. As a result, in both cases using the trap apparatuses 47A and 47B, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in four minutes.
The three layer laminate member was used in the above described embodiments, a layer or layers applicable to the present invention is not limited to this structure. As the metal material of a laminate structure, aluminum, titanium, copper, magnesium, alloy thereof, stainless steel and the like can be used. As a resin material, other PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PEN (polyethylene naphthenate), PPS (polyphenylene sulfide), PI (polyimide) and the like can be used. By using the laminate member, a metal sandwiched therein could be made as thin as 10 to 50 microns, and since it is reinforced from opposite sides, the sensitivity and the reliability of the pressure indicating portion was enhanced.
The recess-shape was set such that its recessed amount becomes 2 mm at internal pressure of 20 mmHg, and the recessed amount which was effective in the present invention was 0.5 to 2 mm. It was difficult to provide an internal pressure indicating member having a high reliability if the recessed amount was 0.5 mm or less since it was difficult for an operator to confirm, and if it was 2 mm or more since the variation amount with respect to the internal pressure was too great. The variation amount is of importance for the operator, and an internal pressure indicating member having high reliability can be obtained if the internal pressure indicating portion is designed such that when the recessed amount is set to 0.5 mm, it assumes the projection shape under the atmospheric pressure, and when the recessed amount is set to 2 mm, it assumes the flat plate shape under the atmospheric pressure.
In this embodiment, the internal pressure indicating portion is designed such that the recessed shape becomes flat plate shape under the atmospheric pressure, and when the internal pressure is 20 mmHg, the recessed amount becomes 2 mm. Alternatively, the indicating member may be designed such that it is allowed to hold the projection shape under the atmospheric pressure, and the indicating member is recessed under the negative pressure, and the indicating member is inverted into the projecting shape when the pressure is brought into the atmospheric pressure again. With this design, the operator can easily confirm. With this alternative embodiment, the boundary value in terms of shape change set in a range of 50 to 100 mmHg was effective, taking the reliability of the installation into consideration.
Although the above embodiments employ the collecting trap apparatus which is provided with the pressure indicating portion, it is also possible to provide the pressure indicating portion on a common connecting apparatus which serves the function of both the connecting apparatus 30 and the connecting apparatus 50. With this arrangement, the same effect of the pressure indicating portion as that of the above described embodiments can be obtained. In that case, although the negative pressure state in the collecting trap container itself cannot be confirmed by the pressure indicating portion on the common connecting apparatus, it is possible to confirm the negative pressure state necessary for confirming the completion of the installation. Therefore, it is possible to sufficiently ensure the precision of the installation. When a pressure indicating portion is provided on the trap apparatus, the trap apparatus itself may not be reused, but it is thrown away after use. But if the connecting apparatus is provided with the pressure indicating portion, the container may not be thrown away after use and can be reused semi-permanently.
In these embodiments, after the inside air was replaced by carbon dioxide, next operation was carried out in a state where the pressure in each of the connecting pipes and the indoor unit was kept at about 0.1 kgf/cm². The level of the positive pressure required at that time is slightly positive as compared with the atmospheric pressure, and it is preferable that this pressure is 0.3 kgf/cm² or lower. With this pressure level, when the pipes are brought into communication with the inside of the carbon dioxide trap apparatus, convection of gas is generated and carbon dioxide can swiftly be collected. For obtaining the same effect, if the pressure in the carbon dioxide trap apparatus is set to sufficiently negative pressure lower than 1 mmHg, the convection of gas from the connecting pipes and the indoor unit to the carbon dioxide trap apparatus can be obtained, thereby carbon dioxide can swiftly be collected.
Although 100g of zeolite was used when the volume of the indoor unit and the connecting pipes was 1.5, the weight of zeolite which could obtain the effect of these embodiments was 60g or greater per one liter of the volume of the indoor unit and the connecting pipes. With this weight, carbon dioxide could be trapped in two to five minutes and the negative pressure state of 10 to 30 mmHg could be obtained. Although there is no problem even if the amount of zeolite exceeds the above value, if the amount of zeolite is excessively increased, it is not preferable because the trap apparatus for accommodating the trap material becomes too bulky. If the zeolite is less than 60g, the speed with which a pressure reaches negative pressure becomes slow, and the object of the present invention becomes difficult to be achieved. Further, if water is absorbed as contamination object, this hinders the trap of the carbon dioxide. Therefore, 60 to 100g is practically preferable.
Further, the case in which the carbon dioxide is used as the replacing gas and the zeolite is used as the gas collecting trap agent was explained, the applicable range of the present invention should not be limited to this. If the gas collecting trap agent effectively collects the replacing gas, and sufficient negative pressure state can be achieved at the time of collection, other combinations can also be applied.
Although the method for installing the outdoor unit having the normal two-way valve and three-way valve was explained, the present invention can also be applied to an outdoor unit having a three-way valve and another three-way valve. Further, although the installation was carried out using two kinds connecting apparatus for the two-way valve, the connecting apparatus may have T-bifurcation shape, a carbon dioxide supplying portion and a carbon dioxide absorbing portion can be separated from one connecting portion.
Further, a dryer disposed in the outdoor unit was shown. According to an installing method using a vacuum pump, water existing in the indoor unit and the connecting pipes can also be eliminated by the sufficient operation time of the vacuum pump, but it is impossible to eliminate completely the water by a purge method using the replacing gas like the present invention. Therefore, by providing the dryer in the refrigeration cycle, it can ensure the long term reliability of the air conditioner.
Next, another embodiment of the replacing gas collecting trap apparatus which can be used in the present invention as claimed will be explained using Figs.22 to 31.
Figs.22 and 23 show a replacing gas collecting trap apparatus of the other embodiment, wherein Fig.22 is a schematic sectional side view of the replacing gas collecting trap apparatus of the embodiment, and Fig.23 is a view of an outward appearance of the replacing gas collecting trap apparatus.
In the trap apparatus 47C, spherical zeolite A is charged into an aluminum container body. The zeolite A has 6 to 8 mesh diameter. The trap apparatus 47C is provided therein with a baffle 77 for separating an inlet 48 and the zeolite A, and the zeolite A is securely held. The baffle 77 has holes of such a size that the zeolite A cannot pass through. In the present embodiment, the opening rate of the baffle was set to 60%, and 100g of zeolite was charged in total. A rectangular color change label depending on temperature 120 capable of indicating about 10°C is adhered to an outer side of the container body.
Figs.24 and 25 show a replacing gas collecting trap apparatus of the next embodiment, wherein Fig.24 is a schematic sectional side view of the replacing gas collecting trap apparatus, and Fig.25 is a sectional view taken along the line A-A in Fig. 24. In the trap apparatus 47D, an aluminum rod 130 is disposed at the substantially central portion of a container body. Other structures are substantially the same as those of the previous embodiment, and a rectangular color change label depending on temperature 120 capable of indicating about 10°C is adhered to an outer side of the container body.
Figs.26 and 27 show a replacing gas collecting trap apparatus of the next embodiment, wherein Fig.26 is a schematic sectional side view of the replacing gas collecting trap apparatus, and Fig.27 is a sectional view taken along the line B-B in Fig.26. In the trap apparatus 47E, four aluminum fins 131 are projecting from an inner wall of a container body toward its center. Other structures are substantially the same as those of the previous embodiments, and a rectangular color change label depending on temperature 120 capable of indicating about 10°C is adhered to an outer side of the container body.
Figs.28 and 30 show a replacing gas collecting trap apparatus of the next embodiment, wherein Fig.28 is a schematic sectional side view of a replacing gas collecting trap apparatus used in the embodiment, Fig.29 is a sectional view taken along the line C-C in Fig.28, and Fig.30 is an enlarged sectional view of an essential portion X of an internal structure body in Fig. 29. The trap apparatus 47F is provided therein with an aluminum honeycomb structure body 132. The honeycomb structure body 132 has 300 cells/inch², and volume of 70Φ × 90mm, and is provided on its surface with a coating layer 133 mainly made of zeolite in the amount of 100g in total, and a rectangular color change label depending on temperature 120 capable of indicating about 10°C is adhered to an outer side of the container body.
Figs.31 and 32 show a replacing gas collecting trap apparatus of the next embodiment, wherein Fig.31 is a schematic sectional side view of the replacing gas collecting trap apparatus used for the embodiment, and Fig. 32 is a sectional view taken along the line D-D in Fig. 31. In the trap apparatus 47G, an aluminum rod 134 is disposed at the substantially central portion of a container body. Other structures are substantially the same as those of the previous embodiments, and a rectangular color change label depending on temperature 120 capable of indicating about 10°C is adhered to an outer side of the container body.
Explanation of another embodiment follows. In a replacing gas collecting trap apparatus of this embodiment, 1g of calcium hydroxide is mixed into 100g of zeolite, and other structures are the same as those shown in Fig.22. A rectangular color change label depending on temperature 120 capable of indicating about 20°C is adhered to an outer side of the container body.
Another embodiment will be explained. In a replacing gas collecting trap apparatus of this embodiment, 1g of calcium hydroxide is mixed into 100g of zeolite, and other structures are the same as those shown in Figs.28 to 30. A rectangular color change label depending on temperature 120 capable of indicating about 20°C is adhered to an outer side of the container body.
Next, a method for installing the air conditioner will be explained with reference to Figs.1 and 2.
Before the air conditioner is installed, refrigerant gas is charged into the pipes on the side of the outdoor A such as the compressor 1 and the outdoor unit heat exchanger 3. At that time, refrigerant gas which is necessary for driving as well as which is used for the purge operation is charged into the outdoor unit A. On the other hand, the pipes on the side of the indoor unit B such as the indoor unit heat exchanger 6, as well as the connecting pipes 9 and 10 are not sealed and are opened into the atmosphere.
First, the outdoor unit A and the indoor unit B are connected through the connecting pipes 9 and 10. At that time, the screw 7a of the liquid-side two-way valve 7 and the screw 8a of the gas-side three-way valve 8 are closed. A carbon dioxide cylinder 20 is mounted to the service port 8b of the gas-side three-way valve 8 of the outdoor unit A through a connecting apparatus 30.
After the carbon dioxide cylinder 20 is mounted to the service port 8b, the flare portion of the liquid-side two-way valve 7 is slightly loosened. When the carbon dioxide cylinder 20 is pushed against the connecting apparatus 30 while being rotated, the carbon dioxide in the carbon dioxide cylinder 20 is introduced into the connecting pipes 9 and 10 and the indoor unit B. Air in the connecting pipes 9 and 10 and the indoor unit B is discharged out into the atmosphere from the loosened portion of the flare portion of the liquid-side two-way valve 7.
At that time, the flare portion of the liquid-side two-way valve 7 is tightly closed in a state where the pressure in the connecting pipes 9 and 10 and the indoor unit B at positive pressure (about 0.1 kgf/cm²).
Next, the connecting apparatus 30 is removed from the service port 8b together with the carbon dioxide cylinder 20. Then, as shown in Fig.2, the gas collecting trap apparatus 47 is mounted to the service port 8b using the connecting apparatus 50. The trap apparatus 47 is mounted such that the trap apparatus 47 is pushed against the connecting apparatus 50 while rotating the trap apparatus 47. By mounting in this way, the interior of the replacing gas collecting trap apparatus 47 is brought into communication with the connecting pipes 9 and 10 and the indoor unit B. If the replacing gas collecting trap apparatus 47 and the connecting pipe 9 and 10 and the indoor unit B are brought into communication, carbon dioxide in the connecting pipes 9 and 10 and the indoor unit B is introduced from the service port 8b into the trap apparatus 47. The introduced carbon dioxide is physically absorbed and collected by the zeolite in the trap apparatus 47. When calcium hydroxide is added, it chemically reacts with carbon dioxide and collects the carbon dioxide.
After the carbon dioxide is collected, the screw portion 7a of the liquid-side two-way valve 7 is slightly loosened, the refrigerant gas in the outdoor unit A is introduced, thereby bringing the pressure in the connecting pipes 9 and 10 and the pipe of the indoor unit B into positive pressure (about 0.2 kgf/cm²). Thereafter, the connecting apparatus 50 is removed from the service port 8b together with the trap apparatus 47, and the screw portion 7a of the liquid-side two-way valve 7 is completely opened. Lastly, the screw portion 8a of the gas- side three-way valve 8 is also completely opened, and the installing operation of the air conditioner is completed.
Using the trap apparatus 47C of the previous embodiment shown in Figs.22 and 23, the air conditioner was installed under the operational environment of 20°C. The volume of the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 was 1.5 liters in the above embodiment.
As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in four minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47D of the previous embodiment shown in Figs.24 and 25, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in four minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47E of the previous embodiment shown in Figs.26 and 27, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in four minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47F of the previous embodiment shown in Figs. 28 to 30, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in two minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47G of the previous embodiment shown in Figs.31 and 32, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in two minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47H of the previous embodiment shown in Fig.22 in which calcium hydroxide is mixed, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in three minutes. The change of temperature of the outer side surface of the container body is shown in Fig.33.
Using the trap apparatus 47I of the previous embodiment shown in Figs.28 to 30 in which calcium hydroxide is mixed, the air conditioner was installed under the operational environment of 20°C. As a result, the pressure in the pipe of the indoor unit B including the indoor unit heat exchanger 6 and the connecting pipes 9 and 10 reached sufficient negative atmosphere (10 mmHg or less) in one minute. The change of temperature of the outer side surface of the container body is shown in Fig.33.
In the embodiments shown in reference to Figs. 24 to 32, an aluminum rod, fins and a honeycomb structure body were used as material having excellent thermal conductivity, but materials which can be used in the present invention should not be limited to those. The purpose is to efficiently transmit the reaction heat caused by reaction between the gas collecting agent and gas to the container body, and sufficient thermal conductivity could obtained also fromsuchmaterials comprising copper, graphiteblank, aluminum, copper or graphite compound.
In the last two embodiments, the trap agent in which 1g of calcium hydroxide is mixed into 100g of zeolite was used. In order to effectively confirm with precision of the installing operation with temperature variation of the container body which is aimed by the present invention, it is preferable that temperature increase of about 20°C with respect to the operation atmosphere temperature can be ensured. For this purpose, it is conceived that 0.5 to 5 part by weight calcium hydroxide with respect to 100 part by weight zeolite is preferable, and particularly 0.5 to 2 part by weight calcium hydroxide is more preferable. If calcium hydroxide slightly exists, this exhibits catalyst effect, and abruptly reacts with the carbon dioxide. Therefore, the reaction speed is varied also if there is the moisture in the operation environment. When the overall factors were taken into consideration, the above ratios were found to be preferable. Even if calcium hydroxide is not used with zeolite, about 10°C temperature increase can be confirmed, but if the calcium hydroxide is auxiliary added, the temperature increase is higher and the speed is higher so that it is easy to obtain the effect of temperature indicating. As a result, the certainty of the operation is enhanced. However, if excessive calcium hydroxide is used, the reaction heat becomes too high, it becomes impossible to touch the trap container body with bare hands, and it becomes necessary to cool the container body on the contrary.
The trap apparatus to which the color change label depending on temperature is previously adhered is used in the above embodiments, the temperature indicating member may be selected in accordance with the operation atmosphere temperature. For example, the operation temperature is largely varied depending on winter and summer. Therefore, it is possible to adhere several kinds of color change labels depending on temperature in accordance with the seasonal temperature variation, or it is also possible to adhere of one or more of the several kinds of color change labels depending on temperature when the air conditioner is actually installed in accordance with the operation temperature at the installation site.
In the above embodiments, after the inside air was replaced by carbon dioxide, next operation was carried out in a state where the pressure in each of the connecting pipes and the indoor unit was kept at about 0.1 kgf/cm². The level of the positive pressure required at that time is slightly positive as compared with the atmospheric pressure, and it is preferable that this pressure is 0.3 kgf/cm² or lower. With this pressure level, when the pipes are brought into communication with the inside of the carbon dioxide trap apparatus, convection of gas is generated and carbon dioxide can swiftly be collected. For obtaining the same effect, if the pressure in the carbon dioxide trap apparatus is set to sufficient negative pressure lower than 1 mmHg, the convection of gas from the connecting pipes and the indoor unit to the carbon dioxide trap apparatus can be obtained, thereby swift collection of the carbon dioxide can be achieved.
Further, the honeycomb structure body was used in each of the embodiments shown in Figs.28 to 32, but the same effect can be achieved if corrugated structure body is used. The structure body which can be used in the present invention should not be limited to only these. Any structure may be used if the structure has communication paths from its inlet to the bottom and the gas collecting trap agent can be supported on the surface or inside of the structure in a way that the zeolite has sufficiently great contact area for trapping the gas. The trap apparatus having such integral structure body is easy to transported as one of installing tools, and even if an impact is applied, the possibility that the gas collecting agent such as zeolite is crushed into powder is greatly reduced.
In the above embodiments, although 100g of zeolite was used when the volume of the indoor unit and the connecting pipes was 1.5 liters, the weight of zeolite which could obtain the effect of the present invention was 60g or greater per one liter of the volume of the indoor unit and the connecting pipes. With this weight, carbon dioxide could be trapped in two to five minutes and the negative pressure state of 10 to 30 mmHg could be obtained. Although there is no problem even if the amount of zeolite exceeds the above value, if the zeolite is excessively increased, it is not preferable because the container for accommodating the trap material becomes too bulky. If the zeolite is less than 60g, the speed with which a pressure reaches negative pressure becomes slow. Further, if water is absorbed as contamination object, this hinders the trap of the carbon dioxide as well. Therefore, it is conceived that 60 to 100g is practically preferable.
If the above embodiments are compared, the honeycomb structure body of excellent thermal conductivity that is coated with the gas collecting trap agent has excellent in terms of the speed with which a pressure reaches negative pressure and excellent transmitting speed of the reaction heat. However, in this case, the hermetical container necessary for accommodating 100g of trap zeolite is large. And if the spherical zeolite particles as in the embodiment shown in Fig.22 is directly accommodated, the container is compact. Therefore, it is preferable to select a suitable trap apparatus while taking time required for installing operation, the precision and a size of tool required for the operation into consideration.
Further, in the above embodiments, the case in which the carbon dioxide was used as the replacing gas, and the zeolite only or the compound of the zeolite and the calcium hydroxide is used as the gas collecting trap agent is explained. However, the applicable range of the present invention should not be limited to these specific embodiments. If the gas collecting trap agent functions with respect to the replacing gas, and sufficient negative pressure state can be achieved at the time of collection, other combinations can also be possible.
Although the method for installing the outdoor unit having the normal two-way valve and three-way valve was explained in the above embodiment, the present invention can also be applied to an outdoor unit having a three-way valve and another three-way valve. Further, although the installation was carried out using two kinds connecting apparatus for the two-way valve, the connecting apparatus may have T-bifurcation shape, carbon dioxide may be supplied from one of the connecting portions, and a replacing gas supplying portion and a collecting trap apparatus portion can be separated from one connecting portion.
Further, a dryer disposed in the outdoor unit was shown. According to an installing method using a vacuum pump, water existing in the indoor unit and the connecting pipes can also be eliminated by the sufficient operation time of the vacuum pump, but it is impossible to eliminate completely the water by a purge method using the replacing gas like the present invention. Therefore, by providing the dryer in the refrigeration cycle, it is easy to ensure the long term reliability of the air conditioner.
A color change label depending on temperature which can be used in the present invention can utilize inorganic compound which has effects to be caused by heating such as release of crystalline water, variations in crystallinity, and variation in the number of ligands. In the case of organic compound, the color change label depending on temperature can utilize changes of chemical structure or crystallinity caused by heating. Further, in the case of a mixture comprising several kinds of materials, any color change label depending on temperature may be used if it is colored or changed in color, or the color is disappeared, thereby informing whether a temperature is changed. The coloring, the change in color or disappearance of color may be reversible or non-reversible.

Claims

A replacing gas collecting trap apparatus (40) used for installing an air conditioner (Z) which is comprised of an outdoor unit (A) including a compressor (1) and an outdoor unit heat exchanger (3) and refrigerant gas is charged into both of said compressor (1) and said outdoor unit exchanger (3); an indoor unit (B) including an indoor unit heat exchanger (6) which is opened into atmosphere; and a connecting pipe (9) connecting said outdoor unit (A) and said indoor unit (B),
charactereized in that
a container body (41); and a gas collecting trap agent charged in said container body (41) for collecting gas by physical absorbing reaction, chemical reaction or combination thereof; and a color change label depending on temperature (120) as a temperature indicating portion provided on said container body (41).
A replacing gas collecting trap apparatus according to claim 1,
wherein a structure body made of material having excellent thermal conductivity is disposed in said container body (41) so as to come into contact with an inner wall of said container (41).
A replacing gas collecting trap apparatus according to claim 2,
wherein said structure body is a fin shape or a rod shape.
A replacing gas collecting trap apparatus according to claim 1,
wherein, a structure body including carries which have excellent thermal conductivity and are coated with a coating layer mainly made of said gas collecting trap agent is provided in said container body (41).
A replacing gas collecting trap apparatus according to claim 4,
wherein said structure body is a honeycomb structure body or a corrugated structure body.
A replacing gas collecting trap apparatus according to any one of claims 1 to 5,
wherein said structure body or said carrier is mainly made of aluminum, copper, graphite or compound thereof.
A replacing gas collecting trap apparatus according to claim 1,
wherein said replacing gas is carbon dioxide, said gas collecting trap agent is mainly made of zeolite and calcium hydroxide, and said gas collecting trap agent traps said carbon dioxide.
A replacing gas collecting trap apparatus according to claim 7,
wherein said gas collecting trap agent comprises 100 parts by weight zeolite and 0.5 to 5 parts by weight calcium hydroxide.
A method for installing an air conditioner (Z) for connecting an indoor unit (B) and an outdoor unit (A) by a connecting pipe (9),
characterized in that
replacing gas is introduced into said indoor unit (B) and said connecting pipe (9) at the time of installing operation so that air in said indoor unit (B) and said connecting pipe (9) is replaced by said replacing gas and then, a collecting trap apparatus (40) is connected to a portion of said air conditioner (Z), said replacing gas is collected by said gas collecting trap agent in said container (41), and reaction heat of said gas collecting trap agent charged in said container (41) is detected by a color change label depending on temperature (120) adhered to the outer side of said container (41), thereby confirming that the interior is in the negative pressure state and thereby completing installation step.
A method for installing an air conditioner (Z) for connecting an indoor unit (B) and an outdoor unit (A) by a connecting pipe (9),
characterized in that
replacing gas is introduced into said indoor unit (B) and said connecting pipe (9) at the time of installing operation so that air in said indoor unit (B) and said connecting pipe (9) is replaced by said replacing gas and then, a color change label depending on temperature capable of indicating that a temperature of a gas collecting trap container (41) is increased by +10°C to 30°C with respect to the operational atmosphere temperature is attached to an outer sided surface of said gas collecting trap container (41) and then, said gas collecting trap apparatus (40) is connected to a portion of said air conditioner (Z) so that gas is collected by a gas collecting trap agent in said container (41), and a fact that an interior of said container (41) is in a negative pressure state is indicated by said color change label depending on temperature (120), thereby completing installation step.