EP1933040B1 - Turboventilateur et climatiseur - Google Patents

Turboventilateur et climatiseur Download PDF

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Publication number
EP1933040B1
EP1933040B1 EP06811172.3A EP06811172A EP1933040B1 EP 1933040 B1 EP1933040 B1 EP 1933040B1 EP 06811172 A EP06811172 A EP 06811172A EP 1933040 B1 EP1933040 B1 EP 1933040B1
Authority
EP
European Patent Office
Prior art keywords
blade
hub
runners
runner
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP06811172.3A
Other languages
German (de)
English (en)
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EP1933040A4 (fr
EP1933040A1 (fr
Inventor
Takashi Ikeda
Atsushi Edayoshi
Kazutaka Suzuki
Katsumi Shibayama
Hiroshi Nakashima
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
Original Assignee
Mitsubishi Electric Corp
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Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to EP15181444.9A priority Critical patent/EP2980414B1/fr
Publication of EP1933040A1 publication Critical patent/EP1933040A1/fr
Publication of EP1933040A4 publication Critical patent/EP1933040A4/fr
Application granted granted Critical
Publication of EP1933040B1 publication Critical patent/EP1933040B1/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00—Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007—Indoor units, e.g. fan coil units
    • F24F1/0059—Indoor units, e.g. fan coil units characterised by heat exchangers
    • F24F1/0067—Indoor units, e.g. fan coil units characterised by heat exchangers by the shape of the heat exchangers or of parts thereof, e.g. of their fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/281—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for fans or blowers
    • F04D29/282—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for fans or blowers the leading edge of each vane being substantially parallel to the rotation axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/40—Organic materials
    • F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/24—Means for preventing or suppressing noise

Definitions

  • the present invention relates to a turbofan molded out of a thermoplastic resin and an air conditioner on which the turbofan is mounted.
  • turbofan molded out of a thermoplastic resin in which rigidity of the turbofan is assured by ribs each constructed by a runner of injected resin to realize lighter weight by reducing the thickness (refer to, for example, Japanese Patent Application No. 3,131,625 (p. 3 and 4 and FIGS. 1 and 3 )).
  • turbofan in which the material is decreased by forming a recess in an intersection of a blade and a main plate to realize cost reduction (refer to, for example, Japanese Utility Model Application Laid-open No. 4-116698 (p. 1 and FIG. 1 )).
  • turbofan including a plurality of blades having similar sectional shapes in which thickness gradually increases from a shroud to a main plate, and the distance between neighboring blades is gradually narrowed from the shroud to the main plate.
  • turbofan using a thick hollow blade, thereby shortening cooling and hardening time at the time of molding, preventing deformation at the time of cooling and hardening, and reducing plastic material (refer to, for example, Japanese Utility Model Application Laid-open No. 4-116699 (p. 1 and FIG. 1 )).
  • the conventional turbofan in the Japanese Patent Application No. 3,131,625 has ribs for reinforcement to realize a thinner main plate, the ribs also serving as a runner of a resin for improvement in moldability.
  • the strength of a resin merging portion, at which resins flowing from the ribs merge at the time of molding, is low.
  • the resin merging portion is positioned almost at the same distance from neighboring ribs, and the strength of the portion is low.
  • the conventional turbofan has a blade front-end rib positioned near the front end of a blade and extending in the radial direction, a blade rear-end rib positioned near the rear end of the blade and extending in the radial direction, a connection rib for connecting the blade front-end rib and the blade rear-end rib, and a blade reinforcement rib.
  • resin is injected from one resin injection port.
  • the resin injected from the resin injection port flows to the ribs, in each of the blade front-end rib and the blade rear-end rib, the resin flows in two ways in the radial direction to the rotation center side and the outer periphery side.
  • the resin flows in a direction having a radial-direction component and a circumferential-direction component.
  • the resin flows in the direction opposite to the connection rib. That is, the resin injected from one injection port flows in the plurality of ribs extending in the radial direction.
  • the resins flowing out from the ribs are merged and the resin merging portion is formed.
  • the resin merging portion is also formed between resins flowing out from neighboring resin injection ports.
  • a number of resin marging portions are created in the entire of the turbofan, and it limits improvement in strength of the turbofan.
  • a plurality of holes for cooling a motor are formed in a projected portion of a main plate near the rotation axis.
  • the resin merging portion is formed on a motor cooling hole as an opening portion having low strength, the strength becomes lower.
  • a crack occurs in the resin merging portion around the motor cooling hole.
  • the portions of low strength are connected, a problem occurs such that the crack extends.
  • the resin merging portion may extend to the outer peripheral end of the fan. It causes a problem such that the crack occurring in the resin merging portion extends to the outer peripheral end, the fan is easily broken, and the product quality deteriorates.
  • the blade does not have a hollow structure and the thickness in portions of the blade largely varies, so that a temperature difference occurs in the portions of the blade at the time of molding. Consequently, a cavity is generated due to uneven flow of the resin and local thickness reduction (hereinbelow, called locally small thickness) occurs. It causes a problem that moldability deteriorates. Since the whole blade is made of a resin, as compared with a blade having a hollow shape, a larger amount of resin is necessary. The fan becomes heavy and cost of the fan becomes high. Accordingly, an air conditioner on which the turbofan is mounted becomes heavy. There is a problem that portability for the worker is low.
  • a centrifugal fan described in the Japanese Utility Model Application Laid-open No. 4-116699 has a thick hollow blade.
  • the air passage area of the fan is reduced. Consequently, there is the possibility that noise increases due to increase in passage air velocity.
  • the blade sections perpendicular to the rotation axis are the same. When the blades is released from a mold at the time of performing injection molding, there is no draft. The fan has a problem that the resin is adhered to the mold and breakage occurs.
  • US 2003/198556 discloses a turbofan and a mold used to manufacture the turbofan, which enables the turbofan to be integrally molded by a single molding process.
  • the turbofan has a rotating plate coupled to a shaft of a driving motor at its center, a plurality of blades radially disposed at and integrally formed with a periphery of the rotating plate, and a ring-shaped shroud integrally formed with front ends of the blades to face the rotating plate.
  • the present invention has been achieved to solve the problems as described above, and an object of the invention is to obtain a reliable turbofan which is prevented frombeing broken at the time of transportation or the like by realizing improvement in moldability and strength of the turbofan made of a thermoplastic resin, and an air conditioner on which the turbofan is mounted.
  • Another object of the invention is to obtain a turbofan realizing reduced noise and an air conditioner on which the turbofan is mounted.
  • a fan can be prevented from being broken by an impact because of the configuration that the resin merging portion is not connected to the motor cooling hole. Consequently, the strength can be improved, and an effect that a reliable turbofan can be obtained is produced.
  • a turbofan (hereinafter, simply called a fan) according to a first embodiment of the present invention will be described hereinafter with reference to the drawings.
  • FIG. 1A is a plan view of a fan according to the embodiment viewed from a shroud side, and shows a blade by partly cutting the shroud away.
  • FIG. 1B is a side view of the fan of FIG. 1A .
  • the left half of FIG. 1B shows a side face, and the right half shows a longitudinal section taken along O-O1-O2-O3 of FIG. 1A .
  • FIG. 2 is a perspective view showing an under face of the fan according to the embodiment, that is, viewed from the side opposite to the shroud.
  • a fan 1 is constructed by a disc-shaped main plate 2.
  • a center portion of the main plate 2 has a projected shape which is projected in the rotation axis direction, and a motor (not shown) is disposed in the space surrounded by the projection.
  • the projection will be called a hub 2a.
  • a boss 2c is formed in the center of the hub 2a, that is, in the center of the main plate 2, and the shaft of a motor is fixed to the boss 2c.
  • a portion in which the motor is mounted is called a fan outside of the main plate 2.
  • a plurality of, for example, seven blades 3 are provided in a flat plate portion on the outer peripheral side of the fan inside opposite to the fan outside.
  • a hub upper thick portion 2d is provided, which is thicker than a thickness t0 of an inclined face of the hub 2a.
  • the blade 3 uses, as a base portion, a flat portion on the outer peripheral side of the main plate 2 and has a hollow bag shape which is upright from a blade opening 3b in the base portion in the projection direction of the hub 2a.
  • a blade opening 3b is positioned between a blade inner-radius-side end 3a and a blade outer-radius-side end 3c.
  • a center line 3a-3c of the blade opening 3b and the radius of the main plate 2 are disposed so as to intersect at a predetermined angle of, for example, about 45°. As shown in FIG.
  • a plurality of blades 3 are disposed at variable pitches so that at least part of circumferential-direction mounting pitch angles ⁇ 1, ⁇ 2, ⁇ 3, ..., and ⁇ 7 with respect to the rotational axis varies.
  • the fan 1 is driven by the motor and rotates in the direction of the arrow D around a rotation center O.
  • a shroud 4 is provided around the fan 1 as shown in FIG. 1B and is fixed to each of the blades 3 from above in FIG. 1B .
  • a fan internal air duct 6 is formed by being sandwiched between the shroud 4 and the main plate 2 near the hub 2a, and a fan external air duct 7 is constructed by the hub 2a on the side where motor is disposed.
  • motor cooling holes 5 which are constituted of a plurality of openings are formed at almost equidistant positions from the rotation center O around the rotation center O, thereby providing communication between the fan internal air duct 6 and the fan external air duct 7.
  • FIG. 1A for example, seven motor cooling holes 5 are provided.
  • Each of the motor cooling holes 5 is arranged on a straight line O-3a connecting one blade inner-radius-side end 3a and the rotation center O.
  • the plurality of motor cooling holes 5 are also formed so that at least part of circumferential-direction mounting pitch angles ⁇ 1, ⁇ 2, ⁇ 3, ..., and ⁇ 7 of the plurality of motor cooling holes 5 varies.
  • reference numeral 10 denotes a mark of a resin injection port used for injecting the resin at the time of molding the main plate 2 and the blades 3.
  • the mark 10 is positioned near a folding part between the hub 2a and the flat part of the main plate 2 and near the blade inner-radius-side end 3a in the flat part and will be called a resin injection port 10.
  • Runners 9 serving as paths of the resin at the time of molding are formed in the fan.
  • the runner 9 corresponds to a portion which is a space larger in the thickness direction than main parts of the main plate 2 so that the resin can pass easily.
  • the resin in the runner 9 is solidified and remains, and the thickness of the runner portion is larger than the minimum thickness t0 of the portion other than the runner in the main plate 2.
  • One of the runners 9 is a hub runner 9a for forming the hub at the time of molding.
  • seven hub runners 9a are radially formed in the hub 2a and extend linearly in the radial direction of the fan from the resin injection ports 10 toward the rotation center O without crossing other runners to positions near the motor cooling holes 5.
  • the hub runner 9a is thicker than the minimum thickness t0 in the inclined face of the hub 2a and has a predetermined thickness t1 (> t0).
  • the motor cooling holes 5 are disposed near ends on the fan center side of the hub runners 9a, and the blade inner-radius-side ends 3a of the blades 3 are disposed near the other ends on the outer radius side of the fan of the hub runners 9a.
  • a center line 11 in the width direction of each of the linear hub runners 9a is arranged so as to extend on the motor cooling hole 5.
  • the blade inner-radius-side end 3a, the resin injection portion 10, the hub runner 9a, and the motor cooling hole 5 are disposed so as to position on an almost straight line extending in the radial direction using the rotation center O as a start point.
  • the mounting pitch angles ⁇ in the circumferential direction of the blades 3 are set as unequal pitch angles, so that the motor cooling holes 5, the hub runners 9a, and the resin injection ports 10 are similarly formed at unequal pitches with respect to the rotation center O.
  • the mounting pitch angles ⁇ of the blades 3 are identical pitch angles
  • the mounting pitch angles in the circumferential direction of the motor cooling holes 5, the hub runners 9a, and the resin injection ports 10 are similarly identical pitch angles.
  • a blade runner 9b is formed around the blade opening 3b.
  • the blade runner 9b is a runner for forming the blade 3 when the resin is made to flow in at the time of molding.
  • the blade runner 9b has a predetermined thickness t2 (> t0) larger than the thickness t0 of the outer-radius-side flat plate portion of the main plate 2.
  • a connection runner 9c is a runner for connecting the hub runner 9a and the blade runner 9b.
  • the connection runner 9c is formed, for example, with the same thickness t1 as that of the hub runner 9a and a width smaller than that of the hub runner 9a and that of the blade runner 9b.
  • a part E2 of the air blowing out from the fan 1 passes through the motor cooling holes 5 connecting the fan internal air duct 6 to the fan external air duct 7 and flows in the fan external air duct 7 while turning due to friction with the hub 2a.
  • the part E2 of air current passes through the motor cooling holes 5 and flows in the fan internal air duct 6 under negative pressure.
  • a motor is mounted on the side of the fan external air duct 7 surrounded by the hub 2a and fixed to the fan 1 at the boss 2c. With the air current E2, the motor is cooled.
  • FIG. 3 is a bottom view of the fan.
  • the hub runners 9a are runners each provided between a center-side end 9a1 to a fan outer-radius-side end 9a2.
  • the motor cooling holes 5 are disposed near the fan center-side ends 9a1 and the blade inner-radius-side ends 3a are disposed near the fan outer-radius-side ends 9a2.
  • a part of the resin flows in the hub runners 9a and, after that, flows in the hub 2a in the main plate and forms the portion. Another part flows from the connection runners 9c to the blade runners 9b, flows to the blades 3 and the main plate 2 around the blades 3, and forms the portions.
  • the flow of resin is shown by the arrow B in FIG. 3 .
  • the resin flows via the runners 9 to the mold as shown by the arrows B, and the resin flowing from neighboring runners 9 collides and merges at a resin merging portion located so as to be almost equidistant from the neighboring runners.
  • the resin merging portion is indicated by a broken line A.
  • the resin injected from the resin injection ports 10 and led to the hub runners 9a flows smoothly in one direction toward the rotation center O in the radial direction. Further, the resin flowing in a hub runner 9a flows toward a neighboring hub runner 9a, so that a resin merging portion A is formed between neighboring hub runners 9a. Since the motor cooling holes 5 are arranged so as to avoid resin merging portions A, a resin merging portion A near a motor cooling hole 5 is formed, not in connection with the motor cooling hole 5, but between the neighboring motor cooling holes 5.
  • the resin merging portion A is not coupled to the motor cooling hole 5 as an opening having low strength against impact, occurrence of a crack connected to the motor cooling hole 5 and the resin merging portion A can be prevented, and the strength of the molded fan 1 can be improved. Therefore, even if an impact is applied in the direction of the rotation axis of the fan 1 at the time of transportation or the like, for example, in the vertical direction of FIG. 1B and a crack occurs in the periphery of the motor cooling hole 5, extension of the crack in the radial direction of the main plate 2 can be prevented. Consequently, the fan 1 can be prevented from being broken, and reliability against the impact on the fan 1 can be improved.
  • the runners 9 are not complicatedly branched.
  • a runner 9 is branched to two runners; the hub runner 9a, and the connection runner 9c at the resin injection port 10, and is branched into the blade runner 9b in two directions at the connection part of the connection runner 9c and the blade runner 9b. Since the strength is low in the resin merging portion A as described above, it is preferable to set the number and length of the resin merging portions A as small as possible.
  • the resin merging portion A is not formed by the resin injected from the one resin injection port 10 but is formed by the contact portion of the resin injected from the neighboring resin injection ports 10. Consequently, the number of the resin merging portions A can be decreased as a whole.
  • the runners 9 are constructed relatively simply, the resin flows along the runners 9 more easily, occurrence of shrinkage is reduced, and moldability can be improved.
  • one end of the resin merging portion A is in contact with the boss 2c.
  • the resin merging portion A extends in the radial direction between the neighboring motor cooling holes 5.
  • the other end is in contact with the center of the blade 3.
  • the outer-radius-side end of the resin merging portion A formed in the main plate 2 is in contact with the blade runner 9b.
  • the resin merging portion A formed in the main plate 2 can be made shorter, that is, the portion with low strength can be shortened.
  • the fan 1 with high reliability in strength can be obtained. Even if a crack occurs near the resin merging portion A and extends along the resin merging portion A at the time of transportation or the like, since the outer-radius-side end of the resin merging portion A is in contact with the thick blade runner 9b, the crack stops at this part. Further, in the case where the crack does not stop by the blade runner 9b, the whole blade 3, which is connected to the blade runner 9b and has height in the axial direction, serves as a strength member. Consequently, the fan 1 can be prevented from being completely broken down, and reliability against an impact can be improved.
  • the configuration of the resin merging portion A and the runners 9 will be described in detail hereinbelow.
  • the number of pieces, the shape, and the angle with respect to the radius of the blades 3, the shape and configuration of the runners 9, the positions of the resin injection ports 10, the shape and position of the motor cooling hole 5, and the like are set as described above. That is, one end of the resin merging portion A is in contact with the boss 2c, the resin merging portion A extends in the radial direction between the neighboring motor cooling holes 5, and the other end is in contact with the center of the blade 3. With the configuration, the fan 1 having reliability against an impact can be obtained.
  • FIG. 4 is a partly enlarged view of FIG. 3 .
  • FIG. 5 is a view illustrating a cross section taken along line H1-H2 of FIG. 4 .
  • the resin injection port 10 is provided, for example, in the hub runner 9a at a position close to the connection runner 9c. Two neighboring resin injection ports 10m and 10n will be described as an example.
  • the resin injection port 10m is connected to a hub runner 9am, a blade runner 9bm, and a connection runner 9cm. The resin is injected from the resin injection port 10m to mold the blade 3m and the main plate 2 around the blade 3m.
  • a resin injection port 10n is connected to a hub runner 9an, a blade runner 9bn, and a connection runner 9cn.
  • the resin is injected from the resin injection port 10n to mold the blade 3n and the main plate 2 around the blade 3n.
  • the blade 3 formed upright on the main plate 2 has a predetermined thickness t3 (> t0) and the thickness in the blade 3 is almost uniform.
  • the area L should be formed with the resin injected from the resin injection port 10n.
  • the resin injected from the resin injection port 10n not the resin injected from the resin injection port 10m, is used as the resin for forming a flat part 3cmt of the blade outer-radius-side end of the blade 3m, the resin merging portion A formed between the hub runners 9an and 9am is surely brought in contact with the blade 3m.
  • the runners 9 should be constructed so that the distance from the resin injection port I0n is shorter than the distance from the resin injection port 10m with respect to the lengths of the flow paths of the resin flowing to the flat part 3cmt at the blade outer periphery.
  • the number of pieces and the shape of the blades 3, the shape and configuration of the runners 9, the positions of the resin injection ports 10, the shape and position of the motor cooling hole 5, resin injection speed, and the like, are fittingly set and, for example, a simulation is performed.
  • a part in which the resin merging portion A is to be formed in the fan at the time of molding can be examined.
  • the configuration should be so constructed that one end of the resin merging portion A obtained by the simulation comes in contact with the boss 2c and extends in the hub 2a between the neighboring motor cooling holes 5, and the other end comes in contact with the blade runner 9b.
  • the turbofan includes: the disc-shaped main plate 2; the projected hub 2a formed by making a center portion of the main plate 2 project in the rotation axis direction; the plurality of blades 3 each using the outer-periphery-side flat part of the main plate 2 as the base and vertically provided in the projecting direction of the hub 2a; the plurality of motor cooling holes 5 formed in the hub 2a and for cooling a motor disposed in a space having a projection shape surrounded by the hub 2a; the plurality of hub runners 9a which are provided radially in the hub 2a and into which a resin is made to flow at the time of molding, thereby forming the hub 2a; and the resin merging portion A formed by merging the resin flowing out from the neighboring hub runners 9a at the time of molding.
  • the plurality of motor cooling holes 5 provided in the hub 2a is disposed at portions on extended lines of the hub runners 9a to the rotation center O so that coupling between the motor cooling holes 5 having low strength to impact and the resin merging portion A is surely prevented, and the fan having high reliability against an impact is obtained.
  • Each runner 9 as a path of the resin is formed so as to be separated to a hub runner 9 a and a blade runner 9b.
  • Aconnection runner 9c for connecting the runners 9a and 9b is provided and, further, the resin is injected from the resin injection port 10 provided in any one of the runners 9a, 9b, and9c.
  • either of the resin flowing in the hub runner 9a and the resin flowing in the blade runner 9b necessarily flows via the connection runner 9c. Consequently, the balance between the amount of the resin flowing in the hub runner 9a and that of the resin flowing in the blade runner 9b can be adjusted according to settings of the width and thickness of the connection runner 9c.
  • the resin injection port 10 is directly provided in the hub runner 9a in the embodiment, the resin injection port 10 may be provided in the blade runner 9b or the connection runner 9c. In the case of providing the resin injection port 10 in the connection runner 9c, by making the thickness and width of the runner between the resin injection port 10 and the hub runner 9a and those of the runner between the resin injection port 10 and the blade runner 9b different from each other in accordance with the flow rate of resin required, the balance of the resin amounts can be adjusted.
  • the blade 3 Since the blade 3 has the hollow shape and the blade opening 9b is provided around the opening 3b, the weight can be reduced because of the hollow shape, and the resin runs to the whole mold more easily at the time of molding the blades 3. Consequently, the blade 3 can be made thinner and lighter.
  • the weight in the fan peripheral portion with respect to the rotation center is reduced. Therefore, the centrifugal force at the time of rotation is reduced and a stress applied to the root of the main plate as the base of the blade 3 is reduced. As a result, the strength of the fan 1 can be improved, and breakage at the time of rotation can be prevented.
  • the portion of the blade runner 9b remains as the resin in a molded body, the thickness of the connected part of the blade 3 and the main plate 2 on which stress is concentrated can be increased by the blade runner 9b.
  • the resin flowability is improved by the blade runner 9b, moldability can be improved, and strength of the turbofan can be improved.
  • each of the runners 9 is continuously formed in the radial direction from the rotation center side to the outer periphery of the main plate 2.
  • the resin injected from the resin injection port 10 is branched to the resin flowing toward the rotation center and the resin flowing toward the outer periphery side in main flow directions. After that, the resin does not flow backward but flows to the main plate 2 in the periphery while flowing through the runners 9.
  • the resin flow directions are relatively simple, so that a portion in which the resin merging portion A is formed can be predicted clearly. There are also effects that the resin can flow smoothly, moldability can be improved, and the very reliable fan 1 can be obtained. Further, the distance of the resin merging portion A can be shortened, and deterioration in the strength of the turbofan can be prevented.
  • the number of the resin merging portions A can be decreased, the mold design can be simplified, and occurrence of cavity and locally small thickness due to uneven flow can be prevented.
  • FIG. 6 is a partly enlarged view of FIG. 1B .
  • the hub runner 9a having the thickness t1 is projected from the hub 2a having the thickness t0 to the fan external air duct 7 side only by the thickness difference (t1-t0) in the wall face constructing the hub 2a of the fan external air duct 7.
  • the motor cooling hole 5 is positioned on the extension line of the hub runner 9a on the rotation center side. Consequently, the hub runner 9a functions as an air guiding plate and induces air current G toward the motor cooling hole 5.
  • the hub runner 9a serves as an air guiding plate to the air current G, thereby increasing the current of air flowing on the surface of a motor mounted in the portion surrounded by the hub 2a and accelerating cooling of the motor.
  • temperature protection control is performed such that power supply to the motor is stopped when the temperature increases to certain temperature in temperature rise of the motor.
  • the motor can be efficiently driven without executing the temperature protection control. Further, breakage of the motor caused by the high temperature of the motor can be also prevented.
  • a plurality of sets each constructed by the blade 3, the blade runner 9b, the hub runner 9a, the connection runner 9c, and the motor cooling hole 5 are provided radially around the rotation axis O as a center.
  • all of the blades 3 constructing the fan 1 have almost the same arrangement that the resin injection port 10, the hub runner 9a, the blade runner 9b, the connection runner 9c, and the motor cooling hole 5 are prepared for the blade. Therefore, by injecting almost the same amount of resin to the plurality of resin injection ports 10, the resin flows in similar directions in the entire disc-shaped fan 1, and the blades 3 can be formed under similar molding conditions. Consequently, there is an effect such that, in a fan completed by molding, occurrence of cavity and locally small thickness caused by uneven flow can be prevented as a whole, and a turbofan having high reliability in strength is obtained.
  • the molding can be performed under similar molding conditions, and an effect similar to the above is produced.
  • the disposal relation of the blade 3 to the motor cooling hole 5 can be made almost similar to the motor cooling holes 5 constructing the fan 1. Consequently, turbulent air flow E2 from the fan external air duct 7 to the fan internal air duct 6 via the motor cooling hole 5 goes to the rear side of the blade 3 formed by the blade runner 9b connected to the hub runner 9a closest to the motor cooling hole 5.
  • the turbulent air flows E2 from the motor cooling holes 5 flow between the blades 3 and 3 respectively and they do not directly collide with each other. Therefore, without being subjected to large pressure fluctuations, the turbofan realizing reduced noise can be obtained.
  • the number of motor cooling holes 5 may be smaller than that of the hub runners 9a.
  • the motor cooling holes 5 may not be provided on the rotation center O side of all of the hub runners 9a.
  • the fan shape is so constructed as shown in FIG. 1 that a plurality of sets each made of the blade 3, the blade runner 9b, the hub runner 9a, the connection runner 9c, and the motor cooling hole 5 are provided radially around the rotation axis O as a center, and at least one of angles each formed between neighboring sets is different from the other angles.
  • the air current E2 released to the outside from the motor cooling hole 5 and the air flow E1 blowing off from the blade 3 are prevented from having periodicity. Therefore, noise due to the number of revolutions of the fan can be prevented and quietness in the sense of hearing is maintained.
  • each of the blades 3 has almost the same arrangement with respect to the resin injection port 10, the hub runner 9a, the blade runner 9b, and the motor cooling hole 5. Therefore, the molding conditions can be made almost the same, occurrence of cavity and locally small thickness caused by uneven flow can be prevented, and the turbofan having high reliability in strength is obtained.
  • the positional relations between the motor cooling holes 5 and the blades 3 can be made equal, the air current E2 flowing from the fan external air duct 7 to the fan internal air duct 6 can smoothly pass between the blades and to the outside. Effects that noise can be reduced and, further, moldability is high are produced.
  • FIG. 7 is a flowchart showing the fan molding process.
  • a mold for molding the fan 1 having the shape shown in FIGS. 1 to 6 is fixed (ST1), and the thermoplastic resin is injected from the resin injection ports 10 (ST2).
  • the injected resin flows through the hub runners 9a, the connection runners 9c, and the blade runners 9b and, further, spreads from the runners 9 to the main plate 2 and the blades 3.
  • the whole fan is filled with the resin in a few msec.
  • the fan is cooled to harden the thermoplastic resin (ST3).
  • the molded fan 1 is released and removed from the mold (ST4).
  • the shroud 4 is fixed to the suction side of the fan 1 (ST5).
  • the program advances to a process such as attachment of the shaft of a motor.
  • the minimum thickness of the part other than the runners 9 of the main plate 2 is t0
  • the thickness of the hub runner 9a is t1
  • the thickness of the blade runner 9b formed around the opening 3b of the blade having a hollow shape is t2
  • the thickness of the blade 3 having a hollow shape is t3.
  • At least the thicknesses t1, t2, and t3 are set to be larger than the thickness t0.
  • a portion having the maximum thickness is set as the thickness of the runner 9.
  • the thicknesses of the runners 9 include the thickness of the main plate 2 and the thickness of the portion projected from the main plate face.
  • FIG. 8 is a graph showing molding time with respect to the ratio t1/t0 of the thickness t1 of the hub runner 9a to the minimum thickness t0 of the portion other than the runner in the main plate 2.
  • the axis of abscissa shows t1/t0, and the axis of ordinate indicates the molding time (sec).
  • the molding time denotes time required for ST2 to ST4 in the flowchart shown in FIG. 7 , which is the time from the resin injection to the removing from the mold after cooling.
  • t1/t0 is 1.0 or less
  • the thickness t1 of the hub runner 9a is equal to or less than the minimum thickness t0 of the portion other than the runners in the main plate 2
  • the runner 9a is thinner, flow of the resin is not good, it takes time for the resin to flow in the whole mold, and molding time increases.
  • t1/t0 is larger than 2.0
  • the thickness t1 of the hub runner 9a is larger than twice as large as the minimum thickness t0 of the portion other than the runners in the main plate 2, it takes time to cool down the resin, and the time until removing increases.
  • the production amount can be increased.
  • electricity used by a molding machine can be also reduced so that energy can be saved.
  • FIG. 9 is a graph showing molding time with respect to the ratio t2/t0 of the thickness t2 of the blade runner 9b to the minimum thickness t0 of the portion other than the runners in the main plate 2.
  • the axis of abscissa shows t2/t0, and the axis of ordinate indicates the molding time (sec).
  • the molding time denotes time required for ST2 to ST4 in the flowchart shown in FIG. 7 , which is the time from the resin injection to the removing after cooling.
  • t2/t0 is 1.0 or less
  • the thickness t2 of the blade runner 9b is equal to or less than the minimum thickness t0 of the portion other than the runners in the main plate 2
  • the runner 9b is thinner, flow of the resin is not good, it takes time for the resin to flow in the whole mold, and molding time increases.
  • t2/t0 is larger than 2.0
  • the thickness t2 of the blade runner 9b is larger than twice as large as the minimum thickness t0 of the portion other than the runners in the main plate 2, it takes time to cool down the resin, and the time until removing increases.
  • the production amount can be increased.
  • electricity used by a molding machine can be also reduced so that energy can be saved.
  • the molding time can be shortened, the amount of the resin can be decreased, and reduction in the weight and cost of the fan 1 can be also achieved.
  • the thickness t1 of the hub runner 9a and the thickness t2 of the blade runner 9b have been described separately, it is also possible to satisfy one of the thicknesses or both of them. In the configuration where both of the thicknesses t1 and t2 are satisfied, the molding time can be further shortened effectively.
  • FIGS. 10A and 10B and FIG. 11 show the configuration of one blade 3.
  • FIGS. 10A and 10B and FIG. 11 are diagrams illustrating the blade 3 according to the embodiment.
  • FIG. 10A is a side view of one blade.
  • FIG. 10B is a view illustrating a transverse section taken along line Z-Z of FIG. 10A .
  • FIG. 11 is an explanatory view illustrating vertical section taken along line Y-Y of FIG. 10B .
  • a blade inner-radius-side hollow 3dc and a blade outer-radius-side hollow 3dd of a blade hollow 3d tilt to the inside of the hollow shape with respect to a linear line X parallel with the rotation axis at arbitrary angles ⁇ 1 and ⁇ 2, respectively, that is, the blade hollow 3d is tapered from the blade opening 3b, as a base, formed in the main plate 2 to the blade suction-side end 3e toward the inside of the hallow shape.
  • the blade inner-radius-side end 3a and the blade outer-radius-side end 3c also tilt to the inside of the hollow shape, with respect to the linear line X parallel with the rotation axis at the arbitrary angles ⁇ 1 and ⁇ 2, respectively, that is, the blade ends 3a, 3c are tapered from the blade opening 3b to the blade suction-side end 3e toward the inside of the hallow shape.
  • a blade front hollow 3da in the rotation direction D of the blade 3 and a blade rear hollow 3db as a side face in the inverse rotation direction of the blade 3 tilt to the inside of the hollow shape with respect to the linear line X parallel with the rotation axis at arbitrary angles ⁇ 3 and ⁇ 4, respectively, that is, the side surfaces 3da, 3db of the blade hollow 3d are tapered from the blade opening 3b to the blade suction-side end 3e toward the inside of the hallow shape.
  • the blade inner-radius-side surface 3f and the blade outer-radius-side surface 3g also tilt with respect to the linear line X parallel with the rotation axis, at the arbitrary angles ⁇ 3 and ⁇ 4, respectively, that is the blade hollow 3d is tapered from the blade opening 3b to the blade suction-side end 3e toward the inside of the hallow shape.
  • the blade 3 and the blade hollow 3d have a tapered shape from the main plate 2 to the shroud 4 and tilt to the inside of the hollow at the predetermined angles ⁇ 1 and ⁇ 2, and the predetermined angles ⁇ 3 and ⁇ 4. Consequently, at the time of releasing the mold from the fan mold body in the rotation axis direction, the resin and the mold can be smoothly separated from each other because of the tilt.
  • the blade 3 can be prevented from being adhered to the mold and broken, so that moldability can be improved.
  • the mold On completion of cooling and hardening of the resin, the mold is in close contact with the standing faces 3a, 3c, 3f, and 3g of the fan mold body on the outside of the blade 3 having the hollow shape, and further with the standing faces 3dc, 3dd, 3da, and 3db of the fan mold body on the inside or the hollow side of the blade 3.
  • the standing faces on both of the outside and inside of the hollow are tapered from the base in the vertical direction. Consequently, the mold can be easily released on both of the outside of the blade 3 and inside of the hollow of the blade 3.
  • the weight of the blade 3 having the hollow shape can be reduced as compared with that of the blade 3 which does not have a hollow shape.
  • the thickness of the blade 3 is not uniform, poor molding due to variations in cooling and hardening time of the resin occurs, and there is a problem of low moldability.
  • the thickness of the blade 3 is made almost uniform, so that the cooling and hardening time of the resin can be made almost uniform, poor molding can be prevented, and moldability can be improved.
  • the turbofan includes: the disc-shaped main plate 2; the projected hub 2a formed by making the center portion of the main plate 2 project in the rotation axis direction; and the plurality of blades 3 each of which has the hollow shape, and is provided so as to stand on the outer-periphery-side flat part of the main plate 2 as a base in the projecting direction of the hub 2a, the base having the opening 3b.
  • the standing faces 3a, 3g, 3c, and 3f on the outside of the blade 3 having the hollow shape and the standing faces 3da, 3db, 3dc, and 3dd on the inside or the hollow side of the blade 3 tilt to the inside of the hollow, and the outside of the blade 3 and the hollow inside are tapered from the base.
  • the cooling and hardening time of the resin can be made uniform, and the turbofan having excellent moldability can be obtained.
  • the whole fan 1 can be made lighter.
  • FIG. 12 is a graph showing fan molding time (sec) and noise value (dB) when all of the angle ⁇ 1 of the blade inner-radius-side end 3a with respect to the rotation axis, the angle ⁇ 2 of the blade outer-radius-end 3c with respect to the rotation axis, the tilt angle ⁇ 3 of the blade front hollow 3da with respect to the rotation axis, and the tilt angle ⁇ 4 of the blade rear hollow 3db with respect to the rotation axis are set to the same tilt angle ⁇ , and the tilt angle ⁇ is changed.
  • the axis of abscissa denotes the tilt angle ⁇ and the axis of ordinate indicates the molding time (sec) and the noise value (dB).
  • the noise value (dB) was measured at a point located just below the fan and apart from the fan by 2 m.
  • the molding time is time corresponding to ST2 to ST4 in the flowchart showing the molding process shown in FIG. 7 .
  • the molding time will be described on the basis of the graph shown in FIG. 12 .
  • the blade 3 has a shape widened from the main plate 2 side toward the shroud 4 side, so that the mold cannot be released, and the configuration is impossible.
  • ⁇ 0°
  • friction between the blade 3 and the mold is large. If the mold is not released slowly, the blade 3 is broken due to adhesion to the mold, so that long molding time is necessary.
  • mold release is facilitated, and mold release time can be shortened. Further, the surface area of the blade 3 increases, and cooling area also increases, so that cooling time is shortened.
  • the molding time can be shortened.
  • the tilt angle ⁇ is 1°
  • the molding time becomes about the half of that in the case where the tilt angle ⁇ is 0°. Therefore, when the tilt angle ⁇ is 1° or larger, the molding time is shortened, and moldability is high.
  • the turbofan having small noise change and high moldability is obtained.
  • each of the predetermined tilt angles ⁇ is set in the range of 1° ⁇ ⁇ ⁇ 3°. It produces an effect that the turbofan having small noise change and high moldability is obtained.
  • the blade inner-radius-side end 3a, the blade outer-radius-side end 3c, the blade suction-side end 3e, the blade front side 3f on the front side in the blade rotation direction, and the blade rear side 3g on the rear side in the blade 3 have almost uniform thickness.
  • the invention is not limited to the configuration, and they may be slightly different from each other due to molding error and the like.
  • the width in the rotation direction is small, and it is difficult to make the thicknesses uniform in this part. It is sufficient to make the thickness of the blade 3 almost uniform with fluctuation to a certain extent.
  • the resin is injected uniformly and cooled uniformly. Thus, a preferable mold body can be obtained.
  • the mold is released in the rotation axis direction and in parallel with the rotation axis.
  • the mold may be also released in the rotation axis direction while slightly turning the mold around the rotation axis as a center.
  • FIG. 13 is a bottom view of the turbofan 1 molded with another runner configuration.
  • the same reference numerals as those of FIG. 3 express the same or corresponding parts.
  • runners 9d for cooling holes each formed so as to surround the motor cooling hole 5 are provided. By connecting the runner 9d and the hub runner 9a, an integral runner is formed.
  • part of the resin injected from the resin injection port 10 at the time of molding flows from the hub runner 9a to the runner 9d for a cooling hole and further flows to the hub 2a and the boss 2c.
  • the resin flowing in the hub runner 9a is branched to two directions in the cooling hole runner 9d, and flows in the cooling hole runner 9d provided around the motor cooling hole 5.
  • the resin merges again with reliability on the side of the boss 2c of the motor cooling hole 5, and flows toward the boss 2c.
  • the cooling runner 9d the flowability of the resin around the motor cooling hole 5 improves, so that moldability can be improved.
  • the resin in the cooling hole runner 9d is hardened to remain around the motor cooling hole 5 as an opening, and the periphery of the motor cooling hole 5 is made thick. Consequently, the strength around the motor cooling hole 5, which tends to decrease due to the opening, can be improved. Thus, the turbofan having durability against a breakage even with an impact applied is obtained.
  • FIG. 14 is a bottom view of the turbofan 1 molded with further another runner configuration.
  • the same reference numerals as those of FIG. 3 express the same or corresponding parts.
  • the linear hub runner 9a is connected to the cooling hole runner 9d around the motor cooling hole 5 and is further connected to a hub upper thick portion 2d.
  • the rotation center side of the motor cooling hole 5 is the hub upper thick portion 2d which is thicker than the portion other than the runners in the main plate 2.
  • part of the resin injected from the resin injection port 10 at the time of molding flows from the hub runner 9a to the runner 9d for a cooling hole and further flows to the hub upper thick portion 2d, thereby forming the portion.
  • the resin flowing in the hub runner 9a is branched to two ways in the cooling hole runner 9d, and flows in the cooling hole runner 9d provided around the motor cooling hole 5. After the resin flows around the motor cooling hole 5, the resin f lows to the hub upper thick portion 2d connected to the periphery of the motor cooling hole 5, thereby forming the hub upper thick portion 2d.
  • the resin in the cooling hole runner 9d is hardened to remain around the motor cooling hole 5 as an opening, and the periphery of the motor cooling hole 5 is made thick. Consequently, the strength around the motor cooling hole 5, which tends to decrease due to the opening, can be improved.
  • moldability and strength can be improved by improvement in the flowability of the resin around the motor cooling hole 5. The turbofan having durability against a breakage even with an impact applied is obtained.
  • the cooling hole runner 9d is directly connected to the hub upper thick portion 2d around the boss, which is thicker than the hub inclination face. Consequently, the resin smoothly flows to the hub upper thick portion 2d, and the resin flowing in the cooling hole runner 9d reliably merges again on the front side in the resin flowing direction of the motor cooling hole 5, that is, on the boss 2c side of the motor cooling hole 5, and the merged resin flows to the hub upper thick portion 2d. Therefore, the resin can be reliably injected to the periphery of the motor cooling hole 5 as an opening by an amount of the thickness of the cooling hole runner 9d. Thus, the strength around the motor cooling hole 5, which tends to decrease due to the opening, can be improved.
  • the turbofan realizing improved moldability and strength by improvement in the flowability of the resin around the motor cooling hole 5 can be obtained.
  • FIG. 15 is a perspective view of the turbofan according to the embodiment and having another configuration, viewed from below.
  • FIG. 16 is a partly enlarged perspective view showing a part of FIG. 15 .
  • FIGS. 17A and 17B and FIGS. 18A and 18B are explanatory views illustrating one blade 3.
  • FIG. 17A is a side view of the blade 3 and
  • FIG. 17B is a transverse section taken along line Z-Z of FIG. 17A .
  • FIG. 18A is a cross section taken along line Y-Y of FIG. 17B .
  • FIG. 18B is an enlarged view of the portion of a circle M in FIG. 18A .
  • FIG. 19 is an explanatory view illustrating a part of the bottom face of the turbofan 1.
  • the configuration of the turbofan shown here is another configuration of the blade runner 9b provided around the blade opening 3b formed in the base of the blade 3.
  • the blade runner 9b is provided around the opening in the blade 3 having a hollow shape, and the blade runner 9b on the front side in the blade rotation direction is called a blade front runner 9ba, and the blade runner 9b on the rear side in the blade rotation direction is called a blade rear runner 9bb.
  • the projection height from the face of the main plate 2 of the blade front runner 9ba and that from the face of the main plate 2 of the blade rear runner 9bb are made different from each other.
  • the projection height in the rotation axis direction of the blade front runner 9ba is set to be larger than that of the blade rear runner 9bb by a predetermined height, and the blade front runner 9ba is made project to the outside of the fan.
  • FIG. 16 is an enlarged view showing this state. If the blade front runner 9ba and the blade rear runner 9bb have the same height, at the time of rotation of the fan, the flow around the main plate 2 is apart from the blade front runner 9ba and collides with the corner of the blade rear runner 9bb, so that pressure fluctuation occurs, causing a problem such that noise occurs in the narrow band.
  • the flow near the blade opening 3b is as shown by the arrow C in FIG. 18A .
  • the flow after departing from the blade front runner 9ba draws a parabola which curves to the outside of the main plate 2 and flows so as to approach the main plate 2 again on the rear side in the rotation direction of the blade rear runner 9bb. If the blade front runner 9ba is set to be higher, the air current C curves to the outside from the surface of the main plate 2 so that the departing distance from the main plate 2 increases.
  • the resin flows to the blade 3 more smoothly. As a result, shrinkage can be prevented, and moreover, the strength in the blade front runner 9ba improves, so that the strength of the fan also improves.
  • the blade front runner 9ba higher than the blade rear runner 9bb by predetermined height so as to project toward the outside of the fan, the light, strong, highly reliable, and low-noise turbofan, which can be prevented from being broken at the time of rotation and transportation, is achieved.
  • the difference ⁇ t (shown in FIG. 18B ) between the height of the blade front runner 9ba and the height of the blade rear runner 9bb of the blade runner 9b formed so as to surround the blade 3, with respect to the maximum opening diameter F of the blade opening 3b of the blade having a hollow structure shown in FIG. 19 will be described.
  • the maximum opening width F is the diameter of an inscribing circle of the opening on the face of the main plate 2, and ⁇ t denotes the difference between the height of the blade front runner 9ba and the height of the blade rear runner 9bb.
  • FIG. 20 is a graph showing the relation between the ratio ( ⁇ t/F) % and the noise value (dB) with the same air volume.
  • the axis of abscissa denotes the ⁇ t/F (%) and the axis of ordinate indicates the noise value (dB). The noise value was measured just below the fan and 2m apart therefrom.
  • the turbofan so that the difference between the projection height of the blade front runner 9ba and the projection height of the blade rear runner 9bb with respect to the maximum opening diameter F of the blade opening 3b is set in the range of 4% ⁇ ⁇ t/F s 22%, the noise can be suppressed, which is generated in the narrow band at the time of rotation of the fan since the flow around the main plate 2 is apart from the blade front runner 9ba, collides with the corner of the blade rear runner 9bb so that pressure fluctuation occurs.
  • the turbofan so that the ratio ⁇ t/F of the difference At of the projection heights of the blade front runner 9ba and the blade rear runner 9bb to the maximum opening diameter F of the blade opening 3b of the blade having the hollow structure lies in the range of 4% s ⁇ t/F s 22%, noise can be reduced.
  • the turbofan having high reliability in strength is obtained.
  • the resin flows easily to the boss 2c near the top of the main plate 2, and the resin flowability in the whole main plate can be improved.
  • the blade 3 has the hollow structure, the weight of the turbofan as a whole can be reduced.
  • the blade hollow 3d has the tapered shape having a molding draft angle, which is tilted at the predetermined angle ⁇ from the main plate 2 toward the shroud 4, so that the mold can be easily released, breakage of the blade due to adhesion of the blade 3 to the mold can be prevented, and moldability is high. Since the thickness of the blade 3 is almost uniform, the cooling and hardening time can be made uniform. Therefore, occurrence of poor molding caused by unevenness due to variations in the cooling and hardening time can be prevented to a certain degree.
  • the fan in which the plurality of blades 3 are constructed by seven blades and, accordingly, seven runners 9 and seven motor cooling holes 5 are provided has been described.
  • the number of blades 3, the number of runners 9, and the number of the motor cooling holes 5 are not limited to the above but may be arbitrary.
  • the number of the motor cooling holes 5 is the same as that of the hub runners 9a, as described above, the number of motor cooling holes 5 may be set to be smaller than the number of hub runners 9a.
  • the motor cooling hole 5 is disposed on the extension line of the hub runner 9a, the motor cooling hole 5 and the resin merging portion do not meet with each other, so that the strength is high. Consequently, even in the case where the number of motor cooling holes 5 is set to be smaller than that of the hub runners 9a, it is preferable to dispose the motor cooling hole 5 on the extension line of the hub runner 9a.
  • the strength of the hub 2a of the fan can be increased.
  • FIGS. 21 to 23 show an example of the configuration in which the turbofan 1 described in the embodiment is mounted on an air conditioner.
  • FIG. 21 is a perspective view showing a state where an air conditioner is mounted in the ceiling, viewed from a room.
  • FIG. 22 is a vertical cross section of the air conditioner.
  • FIG. 23 is a horizontal cross section of the air conditioner. An example of mounting the turbofan 1 in a recessed air conditioner in the ceiling will be described.
  • the air conditioner shown in FIG. 21 is a recessed air conditioner in the ceiling and faces a room 19 through a decorative panel 13 having an almost square shape.
  • a suction grille 13a as an air suction port to the air conditioner body, and a filter 20 for removing dust from air passing through the suction grille 13a are disposed.
  • the decorative panel 13 also has panel's blowout ports 13b formed along sides of the decorative panel 13. Each of the panel's blowout ports 13b has a wind direction vane 13c.
  • an air conditioner body 12 is disposed with a top plate 12c facing up for the room 19, side plates 12d are attached to the sides of the top plate 12c, and is mounted so that the lower side opens to the room 19.
  • a body's suction port 12a in the center portion of the under face of the air conditioner body 12 is disposed so as to communicate with the suction grille 13a of the decorative panel 13.
  • Body's blowout ports 12b disposed around the body' s suction port 12a are disposed so as to communicate with the panel's blowout ports 13b.
  • the air conditioner body 12 has therein the fan 1, a bell mouth 14 forming a suction air path of the turbofan, and a motor 8 for rotating the fan 1.
  • a heat exchanger 15 is disposed in a discharge air path extending from a part between the blades as an air current blowing part in the fan 1 to the panel's blowout ports 13b.
  • the heat exchanger 15 has aluminum fins 15a and heat transfer tubes 15b.
  • the heat exchanger 15 has a configuration that the plurality of aluminum fins 15a each having a rectangular shape, which extend in the height direction of the air conditioner body 12, that is, in the vertical direction are stacked at predetermined intervals and the heat transfer tubes 15b in a plurality of stages penetrate the fins in the stack direction.
  • the heat exchanger 15 is formed almost in a C shape so as to surround the periphery side of the turbofan 1.
  • a header 16 for adjusting an amount of refrigerant to each of the heat transfer tubes 15b is attached to the heat transfer tubes 15b at one of two ends of the heat exchanger 15 having an almost C shape.
  • a refrigerant such as carbon dioxide is circulated in the heat transfer tubes 15b.
  • the air conditioner is held so that the rotation axis direction of the turbofan 1 is perpendicular, that is, the rotary shaft of the fan motor 8 is perpendicular.
  • the air conditioner body 12 is loaded onto a truck or the like and carried in a state where the body top plate 12c becomes an under face or the bell mouth 14 side of the air conditioner body 12 becomes the under face.
  • the turbofan 1 By the improvement in the moldability of the turbofan 1, the turbofan 1 can be made thinner and lighter, and the weight of the whole product can be reduced. Since the strength reliability is improved, the turbofan 1 can be prevented from being damaged by an impact such as vibration at the time of transportation. The product reliability of the air conditioner can be also improved.
  • the present invention is not limited to the recessed air conditioner shown in FIGS. 21 to 23 .
  • the air conditioner having the panel's blowout ports 13b in four directions in the ceiling has been described here, two panel's blowout ports 13b may be provided in two directions so as to face each other.
  • the air conditioner may not be entirely mounted in a recess in the ceiling but maybe mounted in a state where it is projected downward from the surface of the ceiling.
  • the air conditioner is not limited to a ceiling mounting type but may be a wall mounting type.
  • turbofan according to the embodiment By applying the turbofan according to the embodiment to an air conditioner having another configuration on which the turbofan is mounted, in a manner similar to the above, breakage of a fan during product transportation can be prevented, and a quiet and light air conditioner with low noise, high product quality, and high portability is obtained.
  • the invention is not limited to the air conditioner but can be also applied to a ventilation fan and an air cleaner each including a turbofan, and effects similar to the above can be obtained.
  • the plurality of hub runners 9a which are connected to the resin injection ports 10 and extended linearly in the fan radial direction with a thickness larger than that of the inclined face of the hub 2a of the main plate, are provided in predetermined intervals in the side face on the motor side of the main plate 2.
  • the resin merging portion A is not connected to the motor cooling hole 5 as an opening having low strength against an impact but is formed between the motor cooling holes 5. Consequently, the resin flows easily to the boss 2c to improve moldability, and the resin merging portion formed in the main plate 2 can be made short.
  • the turbofan is resistant to breakage.
  • the improved moldability and high reliability against an impact of the turbofan can be achieved.
  • the motor cooling holes 5 are disposed near the fan center-side ends 9a1 of the hub runners 9a, and at least the number of the motor cooling holes 5 and the number of the hub runners 9a are the same. Further, the blade inner-radius-side ends 3a are disposed near the fan outer-radius-side ends 9a2 of the hub runners 9a.
  • the hub runners 9a and the blade runners 9b formed so as to surround the openings 3b of the blades 3 are connected to each other via the connection runners 9c, so that the resin merging portion A made of the resin flowing from the hub runners 9a is formed between the motor cooling holes 5 with reliability. As a result, even if an impact is applied in the axial direction (vertical direction in FIG.
  • the turbofan is resistant to breakage.
  • the improved moldability and high reliability against an impact of the turbofan can be achieved. Since the hub runner 9a and the blade runner 9b are not integrally formed, the amount of injection of the resin injected from the resin injection port 10 between the hub runner 9a and the blade runner 9b can be adjusted. Therefore, occurrence of cavity and locally small thickness due to uneven flow can be prevented, and thereby deterioration in strength can be prevented. Since the resin flows more easily because of the blade runners 9b, the thickness of the blade 3 can be reduced, and the thickness of the connection part of the blade 3 and the main plate 2 on which stress is concentrated can be increased. Thus, both improvement in moldability and improvement in strength of the turbofan can be realized by improvement in the resin flowability.
  • the main current direction of the resin is the radial direction so that the flow direction is less complicated as compared with the conventional case where ribs forming runners to one resin injection port 10 are numerous, the resin merging portion A can be made clearer, the number of resin merging portions A can be reduced, the mold design can be simplified, occurrence of cavity and locally small thickness due to uneven flowcan be prevented, and deterioration in strength of the turbofan can be prevented.
  • the hub runner 9a Since the hub runner 9a is projected to the fan external air duct 7 side of the main plate, the hub runner 9a can also serve as an air guide for inducing f low G toward the motor cooling hole 5.
  • air flowing on the surface of the fan motor 8, which is mounted on the side of the fan external air duct 7 of the hub 2a and fixed to the turbofan 1 by the boss 2c increases, so as to cool the motor more easily. Therefore, the temperature protection control for coping with the motor temperature rise is made unnecessary and, further, breakage of the motor due to high temperature can be also prevented.
  • the resin injection port provided near the blade inner-radius-side end and the blade runner formed so as to surround the main-plate-side opening of the blade having the hollow shape are connected to each other via the connection runner.
  • the blade inner-radius-side hollow, the blade outer-radius-side hollow, the blade front hollow surface, and the blade rear hollow surface of the blade hollow are faces tilted at an arbitrary angle ⁇ with respect to the rotation axis.
  • the blade inner-radius-side end, the blade outer-radius-side end, the blade suction-side end, and the blade front-side end on the front side and the blade rear-side end on the rear side in the blade rotation direction are formed so as to have almost the same thickness in the entire blade.
  • the blade and the blade hollow are formed so as to be tapered from the main plate toward the shroud. Since the blade has a hollow structure, the weight of the blade can be reduced. Because of almost uniform thickness, occurrence of poor molding caused by variations in the cooling and hardening time of the resin due to non-uniform blade thickness is suppressed, so that moldability is high. In addition, since each of the blade and the blade hollow has a tapered shape at a molding draft angle, which is tilted at the predetermined angle from the main plate toward the shroud, the mold can be easily released, breakage of the blade due to adhesion of the blade to the mold can be prevented, and moldability is high.
  • a turbofan made of a thermoplastic resin including: a disc-shaped main plate having a projected hub formed by making a center portion so as to cover a motor, a plurality of motor cooling holes formed in the hub, for communicating the motor and the inside of the fan, and a boss as a fixing part to a rotary shaft of a motor, which is provided in the center portion of the hub; a plurality of blades; and a shroud for coupling the plurality of blades to form an air intake wall, a plurality of hub runners each of which is connected to a resin injection port formed in a main plate flat portion near the blade inner-radius-side end, made thicker than the inclined face of the main plate, and extended linearly in the radial direction of the fan, is provided in predetermined intervals on the motor-side side face of the main plate.
  • the hub runners are so formed that a resin merging portion formed between neighboring hub runners is not connected at least to the motor cooling holes.
  • the blade inner-radius-side hollow, the blade outer-radius-side hollow, the blade front hollow surface, and the blade rear hollow surface of the blade hollow are faces tilted at an arbitrary angle ⁇ with respect to the rotation axis.
  • the blade inner-radius-side end, the blade outer-radius-side end, the blade suction-side end, and the blade front-side end on the front side and the blade rear-side end on the rear side in the blade rotation direction are formed so as to have almost the same thickness in the entire blade.
  • the blade and the blade hollow are formed so as to be tapered from the main plate toward the shroud.
  • the hub runners Because of the hub runners, resin flowability in the hub and the main plate is high, and moldability is high. Since the hub runners are formed so that the resin merging portion does not communicate with at least the motor cooling holes, breakage of the fan due to an impact at the time of transportation or the like is prevented. Since the blade has a hollow structure, the weight of the turbofan as a whole can be reduced. Because of almost uniform thickness, occurrence of poor molding caused by variations in the cooling and hardening time of the resin due to non-uniform blade thickness is suppressed, so that moldability is high.
  • each of the blade and the blade hollow has a tapered shape at a molding draft angle, which is tilted at the predetermined angle from the main plate toward the shroud, the mold can be easily released, breakage of the blade due to adhesion of the blade to the mold can be prevented, and moldability is high.
  • the weight of the outer peripheral portion of the turbofan relative to the rotation center of the turbofan is reduced. Consequently, centrifugal force at the time of rotation is lessened, the stress applied on the root of the blade on the main plate is reduced, and strength can be improved. Thus, breakage of the turbofan at the time of rotation can be prevented. As a result, the lightweight and high-reliability turbofan having high moldability and strength is obtained.
  • the blade inner-radius-side hollow, the blade outer-radius-side hollow, the blade front hollow surface, and the blade rear hollow surface of the blade hollow are faces tilted at a tilt angle ⁇ of 1° to 3° with respect to the rotation axis.
  • the blade inner-radius-side end, the blade outer-radius-side end, the blade suction-side end, and the blade front-side end on the front side and the blade rear-side end on the rear side in the blade rotation direction are formed so as to have almost the same thickness in the entire blade.
  • the blade and the blade hollow are formed so as to be tapered from the main plate toward the shroud. Since the blade has a hollow structure, the weight canbereduced.
  • the mounting pitch angles ⁇ in the circumferential direction of the blades 3 are set as unequal pitch angles and, simultaneously, the pitch angles ⁇ in the circumferential direction of the motor cooling holes 5 are unequal pitch angles in correspondence with the blades 3.
  • the hub runners 9a extending linearly in the radial direction from the fan rotation center O are also arranged at unequal pitches in correspondence with the blades 3 and the motor cooling holes 5.
  • One resin injection port 10, the hub runner 9a, the blade runner 9b, and the motor cooling hole 5 are disposed almost by the same arrangement. Consequently, molding conditions hardly change, occurrence of cavity and locally small thickness due to uneven flow can be prevented, and deterioration in strength of the turbofan can be prevented.
  • the turbulent flow E2 from the fan outer air duct 7 to the fun inner air duct 6 via the motor cooling hole 5 does not directly collide with the blade 3, the turbofan is not largely subj ected to pressure fluctuations so that noise can be reduced.
  • the resin flowing out from the resin injection port 10 flows from the hub runner 9a toward the cooling hole runner 9d and flows to the boss 2c. Since there is the cooling hole runner 9d around the motor cooling hole 5, after the resin flows in, the resin is merged again on the rear side in the resin flowing direction of the motor cooling hole, and the merged resin flows to the boss 2c. consequently, unlike the conventional technique in which there is no cooling hole runner around the cooling hole and the resin is not easily re-merged on the rear side in the resin flowing direction of the cooling hole, can be improved. As a result, improvement in both moldability and strength is realized by improvement in the resin flowability around the motor cooling hole, and the turbofan, which is resistive to breakage even when an impact, is applied, is obtained.
  • the production amount can be increased in the same time, electricity required for a molding machine can be also reduced, and energy can be saved.
  • the blade front runner corresponding to the side face in the blade rotation direction of the blade runner formed so as to surround the opening on the outer side of the main plate of the blade having a hollow structure has a height larger than the blade rear runner corresponding to the side face on the opposite side in the blade rotation direction and is formed so as to project to the outside of the fan. Consequently, the noise can be suppressed, which is generated in the narrow band at the time of rotation since the flow around the main plate is apart from the blade front runner, collides with the corner of the blade rear runner, so that pressure fluctuation occurs.
  • a re-attachment point of the air flow after departing from the blade front runner to the rear side in the rotation direction of the blade rear runner is moved to the rear side of the blade opening so that the air current is smoothly re-attached.
  • noise can be reduced.
  • a turbofan made of a thermoplastic resin including: a disc-shaped main plate having a projected hub formed by making a center portion so as to cover a motor, a plurality of motor cooling holes formed in the hub for communicating the motor and the inside of the fan, and a boss as a fixing part fixed to a rotary shaft of a motor, which is provided in the center portion of the hub; a plurality of blades; and a shroud for coupling the plurality of blades to form an air intake wall, a plurality of hub runners each of which is connected to a resin injection port formed in a main plate flat portion near the blade inner-radius-side end, made thicker than the inclined face of the main plate, and extended linearly in the radial direction of the fan, is provided in predetermined intervals on the motor-side side face of the main plate.
  • the hub runners are so formed that a resin merging portion formed between neighboring hub runners is not connected at least to the motor cooling holes.
  • the blade inner-radius-side hollow, the blade outer-radius-side hollow, the blade front hollow surface, and the blade rear hollow surface of the blade hollow are faces tilted at an arbitrary angle ⁇ with respect to the rotation axis.
  • the blade inner-radius-side end, the blade outer-radius-side end, the blade suction-side end, and the blade front-side end on the front side and the blade rear-side end on the rear side in the blade rotation direction are formed so as to have almost the same thickness in the entire blade.
  • the blade and the blade hollow are formed so as to be tapered from the main plate toward the shroud.
  • the blade runner formed so as to surround the opening on the outside of the main plate of the blade having the hollow structure is connected via the connection runner.
  • the blade front runner corresponding to the side face in the blade rotation direction of the blade runner has a height larger than that of the blade rear runner corresponding to the side face on the opposite side in the blade rotation direction and is formed so as to project to the outside of the fan. Because of the hub runners, resin flowability in the hub and the main plate is high, and moldability is high. Since the hub runners are formed so that the resin merging portion is not connected to at least the motor cooling holes, breakage of the fan due to an impact at the time of transportation or the like is prevented. Since the blade has a hollow structure, the weight of the turbofan as a whole can be reduced.
  • each of the blade and the blade hollow has a tapered shape at a molding draft angle, which is tilted at the predetermined angle from the main plate toward the shroud, the mold can be easily released, breakage of the blade due to adhesion of the blade to the mold can be prevented, and moldability is high.
  • the noise can be suppressed, which is generated in the narrow band at the time of rotation, since the flow around the main plate is apart from the blade front runner, collides with the corner of the blade rear runner, so that pressure fluctuation occurs.
  • a re-attachment point of the air flow after departing from the blade front runner to the rear side in the rotation direction of the blade rear runner is moved to the rear side of the blade opening so that the air current is smoothly re-attached.
  • noise can be reduced.
  • the blade front runner becomes thicker, the resin flows to the blade more smoothly at the time of molding, and shrinkage can be prevented.
  • the strength in the blade front runner improves, so that the strength of the turbofan also improves. As a result, a lightweight, strong, and low-noise turbofan which can be prevented from being broken at the time of rotation and transportation can be obtained.
  • the turbofan is formed so that the ratio ⁇ t/F of the difference ⁇ t between the height of the blade front runner 9ba and the height of the blade rear runner 9bb with respect to the maximum opening diameter F of the blade opening 3b lies in the range of 4% to 22%.
  • the noise can be suppressed, which is generated in the narrow band since the flow around the main plate is apart from the blade front runner, collides with the corner of the blade rear runner so that pressure fluctuation occurs.
  • a re-attachment point of the air flow after departing from the blade front runner to the rear side in the rotation direction of the blade rear runner is moved to the rear side of the blade opening, so that the air current is smoothly re-attached on the rear side of the blade rear opening, so that noise can be reduced.
  • a peak sound due to rotation speed, which is generated by separating the flow at the blade front runner with a too large thickness, is suppressed, and deterioration in noise can be prevented. Consequently, reduction in noise can be achieved.
  • An air conditioner including: the turbofan 1 having any one of the configurations described in the first embodiment; and the heat exchanger disposed on the suction side or the blowout side of the turbofan can be thinned because of improvement in the moldability of the turbofan 1 and, accordingly, the weight can be reduced.
  • the air conditioner has high reliability in strength. Consequently, at the time of mounting after transportation, the turbofan 1 is not found broken due to an impact such as vibrations at the time of transportation, so that the product reliability is high.
  • the product weight can be also reduced only by the reduced weight of the turbofan 1.
  • the present invention also provides an air conditioner recessed in a ceiling, having the following configuration.
  • Side plates and the top plate of the air conditioner body are formed by plate members.
  • the inside of the air conditioner body including the side plates and at least a part of the ceiling serves as an air path wall using heat insulating material.
  • a motor and the turbofan 1 having at least one of the configurations described in the first embodiment are mounted around the center of the air conditioner body.
  • a bell mouth constituting a suction port of the turbofan and a suction port of the body is disposed in the center portion of the under face of the air conditioner body.
  • a heat exchanger is vertically arranged so as to surround the turbofan.
  • a drain pan made of foam is disposed under the heat exchanger.
  • a body's blowout port is provided in a position around the body's suction port and almost along the side plate of the air conditioner body.
  • a decorative panel having a panel's suction port and a panel's blowout port communicating with the body's suction port and the body's blowout port, respectively, is attached to the under face of the body.
  • the air conditioner can be thinned because of improvement in the moldability of the turbofan 1 and, accordingly, the weight can be reduced.
  • the air conditioner has high reliability in strength. Consequently, at the time of mounting after transportation, the turbofan 1 is not found broken due to an impact such as vibrations at the time of transportation, so that the product reliability is high.
  • the product weight can be also reduced only by the reduced weight of the turbofan 1.

Claims (10)

  1. Turboréacteur (1) qui comprend :
    une plaque principale en forme de disque (2) ;
    un moyeu en saillie (2a) formé en plaçant une partie centrale de la plaque principale (2) en saillie dans la direction de l'axe de rotation ;
    et
    une pluralité de pales (3) qui sont chacune prévues à la verticale dans la direction de saillie du moyeu (2a), en utilisant une partie plate côté périphérie extérieure de la plaque principale (2) comme base,
    le turboréacteur étant caractérisé en ce qu'il comprend en outre :
    une pluralité d'orifices de refroidissement de moteur (5) qui sont formés dans le moyeu (2a) de façon à refroidir un moteur (8) disposé dans un espace qui possède une forme de saillie et entouré par le moyeu (2a) ;
    une pluralité de marques de passages de moyeu (9a) formées en solidifiant une résine dans les passages de moyeu, les passages de moyeu étant prévus radialement dans le moyeu (2a) et formant le moyeu (2a) en faisant circuler une résine thermoplastique au moment du moulage ; et
    des parties de fusionnement de résine (A) qui sont chacune formées en fusionnant la résine thermoplastique qui sort des passages de moyeu voisins au moment du moulage,
    dans lequel les orifices de refroidissement de moteur (5) sont disposés de façon à éviter les parties de fusionnement de la résine (A).
  2. Turboréacteur (1) selon la revendication 1,
    dans lequel chacune des pales (3) présente une forme creuse qui possède une ouverture dans la base, le turboréacteur comprenant une pluralité de marques de passages de pales (9b) formées en solidifiant une résine dans les passages de pales, les passages de pales étant prévus autour des bases des pales (3) de façon à former les pales (3), et une pluralité de marques de passages de liaison (9c) formées en solidifiant une résine dans les passages de liaison, chacun des passages de liaison reliant l'un des passages de moyeu (9a) à l'un des passages de pales positionnés près du passage de moyeu, et
    la résine thermoplastique est injectée par des ports d'injection (10) formés dans les passages de moyeu, les passages de liaison, ou les passages de pales, et s'écoule dans l'ensemble des passages, afin d'effectuer un moulage.
  3. Turboréacteur selon la revendication 1 ou 2,
    dans lequel la pluralité d'orifices de refroidissement de moteur (5) formés dans le moyeu (2a) est disposée dans des parties situées sur des lignes d'extension des marques des passages de moyeu (9a), vers le centre de rotation.
  4. Turboréacteur (1) selon la revendication 3,
    dans lequel des nombres identiques d'orifices de refroidissement de moteur (5) et de marques de passages de moyeu (9a) sont prévus.
  5. Turboréacteur (1) selon l'une quelconque des revendications 1 à 4,
    dans lequel les marques des passages de moyeu (9a) se projettent entre la face de la plaque principale (2) du moyeu (2a) et le côté de disposition du moteur.
  6. Turboréacteur (1) selon l'une quelconque des revendications 2 à 5,
    dans lequel une pluralité de groupes chacun composés de la pale (3), de la marque de passage de pale (9b), de la marque de passage de moyeu (9a), de la marque de passage de liaison (9c), et de l'orifice de refroidissement de moteur (5) est prévue radialement autour de l'axe de rotation comme centre.
  7. Turboréacteur (1) selon la revendication 6,
    dans lequel au moins l'un des angles (δ1 à δ7) chacun formés entre les groupes voisins est différent des autres angles.
  8. Turboréacteur (1) selon l'une quelconque des revendications 1 à 7, qui comprend en outre une pluralité de marques de passages d'orifices de refroidissement (9d) formées en solidifiant une résine dans les passages d'orifices de refroidissement, les passages d'orifices de refroidissement étant respectivement reliés aux passages de moyeu et formés de façon à entourer les orifices de refroidissement de moteur (5).
  9. Turboréacteur (1) selon l'une quelconque des revendications 2 à 8,
    dans lequel, lorsqu'au moins n'importe laquelle de l'épaisseur des marques des passages de moyeu (9a) et de l'épaisseur des marques des passages de pales (9b) est définie comme « t » et l'épaisseur minimale d'une partie différente des marques des passages dans la plaque principale (2) est définie comme « t0 », le rapport t/t0 est défini comme étant de 1,1 ≤ t/t0 ≤ 2.
  10. Climatiseur qui comprend :
    le turboréacteur (1) selon l'une quelconque des revendications 1 à 9 ;
    et
    un échangeur thermique (15),
    dans lequel l'air aspiré depuis un port d'aspiration par le turboréacteur (1) fait l'objet d'un échange thermique avec un réfrigérant dans l'échangeur thermique (15), et l'air résultant est évacué par un port d'évacuation.
EP06811172.3A 2005-10-06 2006-10-04 Turboventilateur et climatiseur Active EP1933040B1 (fr)

Priority Applications (1)

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EP15181444.9A EP2980414B1 (fr) 2005-10-06 2006-10-04 Turbofan et conditionneur d'air

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2005293705 2005-10-06
PCT/JP2006/319832 WO2007040236A1 (fr) 2005-10-06 2006-10-04 Turboventilateur et climatiseur

Related Child Applications (2)

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EP15181444.9A Division EP2980414B1 (fr) 2005-10-06 2006-10-04 Turbofan et conditionneur d'air
EP15181444.9A Division-Into EP2980414B1 (fr) 2005-10-06 2006-10-04 Turbofan et conditionneur d'air

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Publication Number Publication Date
EP1933040A1 EP1933040A1 (fr) 2008-06-18
EP1933040A4 EP1933040A4 (fr) 2015-03-18
EP1933040B1 true EP1933040B1 (fr) 2016-08-10

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JP (2) JP4559472B2 (fr)
CN (1) CN100559031C (fr)
ES (2) ES2800055T3 (fr)
WO (1) WO2007040236A1 (fr)

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JP4559472B2 (ja) 2010-10-06
JPWO2007040236A1 (ja) 2009-04-16
WO2007040236A1 (fr) 2007-04-12
EP1933040A4 (fr) 2015-03-18
CN101099044A (zh) 2008-01-02
EP2980414B1 (fr) 2020-05-27
ES2589903T3 (es) 2016-11-17
EP2980414A1 (fr) 2016-02-03
JP2010216486A (ja) 2010-09-30
JP5121887B2 (ja) 2013-01-16
EP1933040A1 (fr) 2008-06-18
CN100559031C (zh) 2009-11-11
ES2800055T3 (es) 2020-12-23

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