EP3511640A1

EP3511640A1 - Filter cleaning device

Info

Publication number: EP3511640A1
Application number: EP17848312.9A
Authority: EP
Inventors: Tetsuya Sato
Original assignee: Sharp Corp
Current assignee: Sharp Corp
Priority date: 2016-09-12
Filing date: 2017-01-18
Publication date: 2019-07-17
Also published as: EP3511640A4; WO2018047365A1; JPWO2018047365A1; CN109690202A

Abstract

A filter cleaning device (20) cleans off dust (D) adhering to a filter (21). The filter cleaning device (20) includes a front surface brush (23) (dust removal member) that removes dirt and dust from a surface of the filter (21), a filter drive gear (24) (filter drive section) that moves the filter (21) along the front surface brush (23), and a rear surface roller (41) (rotating member) disposed opposite the front surface brush (23) with the filter (21) in between, and that rotates with the movement of the filter (21).

Description

Technical Field

The present invention relates to a filter cleaning device provided for air conditioners and other filter-equipped devices for the removal of dust adhering to a filter.

Background Art

In air conditioners, the air intake opening of the indoor unit is provided with a filter for removing dust in the air drawn into the air conditioner. In traditional air conditioners, dust is manually cleaned off from the filter. That is, a filter needs to be manually cleaned after removing it from the indoor unit by hand.
However, the filter removal procedure can be a complicated process when the indoor unit is installed in certain places. Particularly, filter cleaning is a very laborious procedure when the indoor unit is installed high up. Newer air conditioners are equipped with an automatic filter cleaning function that automatically cleans a filter within the air conditioner, without requiring filter removal.
For example, PTL 1 discloses an air conditioner indoor unit having a filter cleaning mechanism that automatically removes dirt and dust adhering to a filter. The air conditioner indoor unit (2) described in PTL 1 removes dirt and dust from a filter (21) while conveying the filter (21). The air conditioner indoor unit (2) includes a roller (41) having a plurality of thin line members (411a) that penetrates through a mesh of the filter (21), wherein the roller (41) conveys the filter (21) as it rotates with the thin line members (411a) brought into mesh with the mesh of the filter (21); and a brush (61) provided opposite the roller (41) with the filter (21) in between. The thin line members (411a) project out of the roller (41) in a predetermined direction with respect to the radial direction of the roller (41), and the brush (61) rotates in the opposite direction from the direction that raises the thin line member (411a).

Citation List

Patent Literature

PTL 1: JP-A-2011-80636

Summary of Invention

Technical Problem

Air conditioners provided with an automatic filter cleaning function as in PTL 1 are provided with a filter-pressing rotating member (for example, the roller 41 of PTL 1) disposed opposite the brush with the filter in between. The rotating member has an axially-long cylindrical form, and is disposed in front of an indoor heat exchanger. The rotating member is provided with a filter-conveying gear (for example, a roller gear 32 of PTL 1) at at least one end portion of the length of the cylindrical member.
The rotating member disposed opposite the brush with the filter in between typically rotates on the same axis as the gear conveying a filter. Accordingly, the rotating member has substantially the same diameter as the gear, in order to push the filter toward the brush.
However, the provision of the rotating member blocks the passage of air into the indoor heat exchanger. Specifically, the filter cleaning device (to be specific, the rotating member) narrows the passage of air from the air intake opening to the indoor heat exchanger. The narrow passage of air increases the possibility of a performance drop in the air conditioner.
It is accordingly an object of the present invention to provide a filter cleaning device that reduces narrowing of an air passage.

Solution to Problem

According to an aspect of the present invention, there is provided a filter cleaning device for cleaning off dust adhering to a filter,
the filter cleaning device comprising:

a dust removal member that removes dirt and dust from a surface of the filter;
a filter drive section that moves the filter along the dust removal member; and
a rotating member disposed opposite the dust removal member with the filter in between, and that rotates with movement of the filter.

The filter cleaning device according to the aspect of the present invention may be such that:

the filter has a plurality of raised portions formed along a direction of movement of the filter,
the filter drive section has rotating gears that are brought into mesh with the raised portions, and
the rotating member has a smaller diameter than the rotating gears.

The filter cleaning device according to the aspect of the present invention may be such that the rotating member is located within the rotating gears as viewed from side.
The filter cleaning device according to the aspect of the present invention may be such that:

the filter has a plurality of raised portions formed along a direction of movement of the filter, and
the rotating member has gears that are brought into mesh with the raised portions.

The raised portions brought into mesh with the gears of the rotating member may be the same or different members from the raised portions brought into mesh with the rotating gears of the filter drive section.
The filter cleaning device according to the aspect of the present invention may be such that the rotating member has a surface provided with a brush.
The filter cleaning device according to the aspect of the present invention may be such that the rotating member rotates as a result of the brush provided on the surface of the rotating member contacting a back surface of the filter.

Advantageous Effects of Invention

With an aspect of the present invention, it is possible to reduce narrowing of an air passage through which outside air is drawn into an air conditioner through a filter.

Brief Description of Drawings

FIG. 1 is a perspective view showing an external appearance of an indoor unit of an air conditioner according to an embodiment of the present invention.
FIG. 2 is a perspective view showing the indoor unit of FIG. 1 with a front panel open.
FIG. 3 is a cross sectional view of a configuration inside of the indoor unit shown in FIG. 1, showing a cross sectional configuration of a portion where a rotating gear of a filter drive section is disposed.
FIG. 4 is a perspective view showing a filter and a filter cleaning device provided in the indoor unit shown in FIG. 1.
FIG. 5 is a perspective view showing the filter cleaning device of FIG. 4 with one of the dust boxes removed.
FIG. 6 is a perspective view showing a filter supporting unit portion of the filter cleaning device shown in FIG. 4.
FIG. 7 is a cross sectional view of a partial configuration inside the indoor unit of FIG. 1, showing a cross sectional configuration of a portion where a rear surface roller is mounted.
FIG. 8 is an elevational view of the left side of the filter supporting unit shown in FIG. 6.
FIG. 9(a) is a diagram schematically showing a cross sectional configuration of the filter and the filter cleaning device shown in FIG. 4, and FIG. 9(b) is a schematic view representing a positional relationship between a filter drive gear, and a rotating gear of the rear surface roller.
FIG. 10 is a perspective view showing a configuration of the filter provided in the indoor unit according to First Embodiment.
FIG. 11 is a plan view showing a configuration of the filter provided in the indoor unit according to First Embodiment.
FIG. 12 is a perspective view showing the left side of the filter supporting unit of a filter cleaning device provided in an indoor unit according to Second Embodiment.
FIG. 13 is a perspective view showing a configuration of the filter provided in the indoor unit according to Second Embodiment.
FIG. 14 is a plan view showing a configuration of the filter provided in the indoor unit according to Second Embodiment.
FIG. 15 is a perspective view showing the left side of the filter supporting unit of a filter cleaning device provided in an indoor unit according to Third Embodiment.
FIG. 16 is a perspective view showing a configuration of the filter provided in the indoor unit according to Third Embodiment.

Description of Embodiments

Embodiments of the present invention are described below with reference to the accompanying drawings. In the following descriptions, like elements are given like reference numerals. Such like elements will be referred to by the same names, and have the same functions. Accordingly, detailed descriptions of such elements will not be repeated.

First Embodiment

First Embodiment describes an example of an air conditioner equipped with a filter cleaning device for automatically cleaning a filter. FIG. 1 shows an external configuration of an indoor unit 1 of an air conditioner according to the present embodiment. FIG. 2 shows the indoor unit 1 with a front panel 11 open. FIG. 3 shows a configuration inside of the indoor unit 1.

Overall Configuration of Air Conditioner

The overall configuration of the air conditioner according to the present embodiment is described below. The air conditioner according to the present embodiment is a separate-type air conditioner, and is configured mainly from the indoor unit 1 and an outdoor unit (not illustrated).
The outdoor unit includes a compressor, an outdoor heat exchanger, a four-way valve, and an outside fan, among others. These form a refrigeration cycle with an indoor heat exchanger 31 (see FIG. 3) provided on the indoor unit 1 side.
The configuration of the indoor unit 1 is described below, with reference to FIGS. 1 to 3. As shown in FIG. 1, the indoor unit 1 is substantially cuboid in shape, and is typically used by being hung up in the wall of a room. The indoor heat exchanger 31 is provided in the indoor unit 1, as mentioned above. The indoor heat exchanger 31 is connected to the compressor and other components of the outdoor unit via refrigerant pipes (not illustrated). The indoor unit 1 and the outdoor unit constitute a refrigeration cycle, making the air conditioner functional. A controller for controlling the refrigeration cycle is provided in an electrical component unit inside the indoor unit 1.
As shown in FIG. 3, the main components of the indoor unit 1 include a cabinet 10, a filter cleaning device 20, a filter 21, an air conditioning unit 30, and the electrical component unit (not illustrated). The following describes these constituting members in detail.
The cabinet 10 is a substantially cuboidal, resin-molded product. As shown in FIG. 1, the cabinet 10 is configured mainly from the front panel 11, a main body panel 12, and a back panel 13. As shown in FIG. 3, the cabinet 10 houses the filter cleaning device 20, the filter 21, the air conditioning unit 30, and the electrical component unit, among others.
For the purpose of explanation, the front side of the indoor unit 1 is the side the front panel 11 is disposed, and the back side of the indoor unit 1 is the side the back panel 13 is disposed. The direction from the front to the back side of the indoor unit 1, or from the back to the front side of the indoor unit 1 will be referred to as depth direction. The up-and-down direction or vertical direction refers to a direction from the top to bottom, or from the bottom to top of the indoor unit 1 when it is installed normally. The direction intersecting or orthogonal to the up-and-down direction will be referred to as horizontal direction or lateral direction.
The cabinet 10 has an intake opening 14 in its top surface. Room air is drawn into the indoor unit 1 through the intake opening 14 from a room installed with the indoor unit 1. As shown in FIG. 3, the filter 21 is disposed directly below the intake opening 14.
The front panel 11 lies on the front surface (front side) of the cabinet 10. The front panel 11 is attached to the main body panel 12, and is openable and closable. FIG. 2 shows the front panel 11 open. As shown in FIG. 2, dust boxes 22R and 22L for the filter cleaning device 20 are disposed on the back side of the front panel 11.
An exhaust opening for discharging the air drawn through the intake opening is provided in a bottom part of the main body panel 12, and an openable and closable flap 15 is provided at the exhaust opening. The flap 15 is connected to a drive motor (not illustrated). The drive motor is in communication with the electrical component unit by being connected thereto via a signal line. During the air conditioner operation, the drive motor adjusts the rotation angle of the flap 15 according to a control signal from the controller provided in the electrical component unit.
For example, in a cooling operation, the controller provided in the electrical component unit opens the flap 15, and adjusts the rotation angle of the flap 15 so that the flap 15 guides cool air obliquely upward toward and along the ceiling. In a heating operation, the controller provided in the electrical component unit opens the flap 15, and adjusts the rotation angle of the flap 15 so that the flap 15 deflects the forward moving warm air toward the floor. The cooling operation may start with rapid cooling, in which the rotation angle of the flap 15 is adjusted to guide cool air toward the floor. At the end of operation, the flap 15 is closed to close the exhaust opening.
As shown in FIG. 3, the air conditioning unit 30 has an indoor heat exchanger 31 and a crossflow fan 32 as its main components.
The indoor heat exchanger 31 combines a plurality of heat exchangers in the form of a roof (an inverted V shape) over the crossflow fan 32. These heat exchangers each have a structure in which large numbers of heat dissipating fins (not illustrated) are attached to a heat exchanger tube (not illustrated) that is horizontally folded back and forth multiple times. The heat exchangers function as evaporators in a cooling operation, and as condensers in a heating operation.
The crossflow fan 32 is connected to a drive motor (not illustrated) . During the air conditioner operation, the drive motor drives and rotates the crossflow fan 32, and the crossflow fan 32 draws room air into the cabinet 10, and supplies the drawn air to the indoor heat exchanger 31. The crossflow fan 32 also sends air into the room after the heat exchange in the indoor heat exchanger 31. The drive motor is in communication with the electrical component unit by being connected thereto via a signal line, and operates according to a control signal sent from the controller provided in the electrical component unit.
The electrical component unit is disposed at, for example, a right end portion inside the cabinet 10. The electrical component unit is configured from a central processing arithmetic unit (controller), and a signal sending and receiving unit, among others. The electrical component unit is connected to the constituting members of the refrigeration cycle via signal lines. The controller in the electrical component unit controls the refrigeration cycle, and operates the air conditioner in cooling or heating mode according to user instructions, and detection signals from various sensors (e.g., temperature sensors) detecting the room temperature and the outside temperature.
The electrical component unit is also connected, via signal lines, to the drive motor of the crossflow fan 32, the drive motor of the flap 15, the drive motor of the filter cleaning device 20, and to the power supply unit that supplies power to the components of the filter cleaning device 20.
The filter 21 is provided between the intake opening 14 and the indoor heat exchanger 31. For the purpose of explanation, the surface of the filter 21 facing the intake opening 14 will be referred to as front surface, and the surface of the filter 21 facing the indoor heat exchanger 31 will be referred to as back surface. As shown in FIG. 3, the filter 21 is disposed by conforming to the shape of the intake opening 14 provided for the cabinet 10. The filter 21 traps dust and other foreign objects contained in the air drawn into the indoor unit 1 through the intake opening 14. This reduces the amount of dust and foreign objects entering the indoor unit 1.
In the indoor unit 1 according to the present embodiment, two filters 21 are disposed side by side (see FIG. 4). The left filter and the right filter will be distinguished from each other by referring to these filters as left filter 21L and right filter 21R, respectively, if need be. The number and the location of filters are not limited to this example in the air conditioner of an aspect of the present invention. For example, the filter may be configured as a single filter completely covering the intake opening 14.
The filter cleaning device 20 is a device that removes dust and foreign objects adhering to the filter 21. The filer 21, which is rectangular in shape, is attached to the filter cleaning device 20 by conforming to the shape of the filter cleaning device 20. The filter cleaning device 20 is provided with a dust box 22 that collects dust, dirt, and other foreign objects removed from the filter 21. The dust box 22 is provided for each filter 21. Specifically, in the indoor unit 1 of the present embodiment, the dust box 22 is provided for each of the right filter 21R and the left filter 21L. The left and right dust boxes will be distinguished from each other by referring to these boxes as left dust box 22L and right dust box 22R, respectively, if need be (see FIGS. 2 and 4, and elsewhere).

Filter Cleaning Device

The following describes the specific configurations of the filter 21 and the filter cleaning device 20 of the indoor unit 1, with reference to FIGS. 4 to 11.
FIG. 4 shows the overall configuration (including the filters 21R and 21L) of the filter cleaning device 20. FIG. 5 shows the filter cleaning device 20 with the right dust box 22R removed from the main body part of the filter cleaning device 20. FIG. 6 shows a filter supporting unit 25 of the filter cleaning device 20. FIG. 7 shows specific configurations of the constituting members of the filter cleaning device 20, including a front surface brush 23, a filter drive gear 24, and a rear surface roller 41. FIG. 8 shows more specific configurations of the filter drive gear 24 and the rear surface roller 41. FIG. 9 (a) shows how dust on the filter 21 is brushed off with the front surface brush 23. FIG. 9(b) shows the filter drive gear (filter drive section) 24, and a rotating gear 41a for the rear surface roller 41 (rotating member).
The filter cleaning device 20, for the most part, is disposed on the front side of the filter 21. The filer 21 is disposed so that, during the air conditioning operation of the air conditioner, only the front end portion of the filter 21 overlies the filter cleaning device 20, as shown in FIGS. 3 and 4, and elsewhere. For cleaning of the filer 21 with the filter cleaning device 20, a drive motor 24M drives and moves the filter 21 so that the filter 21 moves past the front surface brush 23 of the filter cleaning device 20 with the filter surface completely covering the front surface brush 23.
The filter 21 is configured from a mesh portion 51, and a frame (frame portion) 52 surrounding the mesh portion 51. FIGS. 10 and 11 show a more specific configuration of the filter 21.
As shown in FIGS. 10 and 11, the frame 52 includes vertical rims 52V constituting the vertical portion (a direction parallel to the direction of movement) of the frame, and horizontal rims 52H constituting the horizontal portion (a direction crossing the direction of movement) of the frame. The filter 21 is detachably supported by the filter supporting unit 25 (described later).
The mesh portion 51 is, for example, a polyethylene terephthalate mesh. The frame 52 is formed of, for example, a synthetic resin such as polypropylene resin. The mesh portion 51 and the frame 52 may be molded as a single unit using a synthetic resin such as polypropylene resin.
The frame 52 has a plurality of ribs 53. The ribs 53 extend vertically or horizontally in the frame 52 at substantially regular intervals. That is, the surface of the mesh portion 51 is compartmentalized in the form of a grid. The strength of the filter 21 improves with this configuration.
Preferably, the ribs 53 are provided on the back side of the filter 21. In this way, the mesh portion 51 can have substantially a flat front surface. With the filter 21 having substantially a flat front surface, dust and foreign objects adhering to the front surface of the filter 21 can easily be removed with the filter cleaning device 20.
In the present embodiment, the frame 52 has a plurality of racks (raised portions) 54 formed on the back side of the vertical rims 52V. The racks 54 are brought into mesh with the filter drive gear 24 that drives and moves the filter 21. Driving and rotating the filter drive gear 24 with the drive motor 24M causes the filter 21 to move in a coordinated fashion along the guides 25a (see FIG. 3, and elsewhere) of the filter supporting unit 25. That is, the filter 21 moves along the guides 25a of the filter supporting unit 25 in depth direction and in up-and-down direction inside the indoor unit 1 as the drive motor 24M drives and rotates the filter drive gear 24.
The configuration of the filter cleaning device 20 is described below. As shown in FIG. 3, the filter cleaning device 20 includes the dust box 22, the front surface brush (dust removal member) 23, the filter drive gear 24, the rear surface roller (rotating member) 41 (see FIG. 5), and the filter supporting unit 25 as its main constituting members, among others.
The dust, dirt, and other foreign objects removed from the surface of the filter 21 with the front surface brush 23 accumulate in the dust box 22. The dust box 22 is disposed in front of the front side of the filter 21. The dust box 22 (specifically, the right dust box 22R and the left dust box 22L) extends from one end to the other end of the filter along the lateral direction (horizontal direction) of the filter 21 (see FIG. 4).
The dust box 22 is detachably installed with respect to the filter cleaning device 20. Specifically, as shown in FIG. 5, the dust box 22 is disposed in a dust box container 29 of the filter supporting unit 25 of the filter cleaning device 20. The dust box 22 has a locking mechanism (not illustrated) for fixing the dust box 22 to the indoor unit 1. For example, the locking mechanism can release the lock when a lock release lever 71 provided at an upper middle portion of the dust box 22 is pulled down. This allows a user to remove the dust box 22 from the main body portion of the indoor unit 1 when, for example, throwing away dust that has accumulated in the dust box 22.
The front surface brush 23 has a narrow cylindrical shape (columnar shape) . The front surface brush 23 extends from one end to the other end of the dust box 22 (22R and 22L) along the lateral direction (horizontal direction) of the dust box 22.
The front surface brush 23 is disposed in such an orientation that its tip (or the surface) contacts the front surface of the filter 21, and brushes off dust D adhering to the filter 21 (see FIG. 9(a)). The front surface brush 23 can be formed by using, for example, brush hairs 23a (see FIG. 9(a)) obtained by bundling moderately rigid fibers (for example, synthetic fibers such as nylon, and natural fibers such as animal hair), or by using raised fibers or pile (for example, synthetic fibers such as nylon, and natural fiber such as animal hair) .
The front surface brush 23 has an internal roller. In other words, the brush hairs constituting the front surface brush 23 are implanted in the surface of the roller. Accordingly, the front surface brush 23 on the roller surface also rotates as the roller rotates. The roller is driven by a drive motor 23M. The drive motor 23M is a forward rotating motor, and rotates the front surface brush 23 in the direction of arrow R1 throughout the cleaning operation (see FIG. 9(a)).
The filter drive gear 24 is disposed opposite the front surface brush 23 with the filter 21 in between (see FIG. 9(a)). As shown in FIGS. 6 and FIG. 8 and elsewhere, the filter drive gear 24 is configured from a shaft portion 24a and gear portions (rotating gears) 24b.
The shaft portion 24a is mounted on the filter supporting unit 25, and disposed along the lateral direction (horizontal direction) of the filter 21 (see FIG. 6). Specifically, the shaft portion 24a for the right filter 21R extends from a right side wall portion 26 to a middle wall portion 27 of the filter supporting unit 25. The shaft portion 24a for the left filter 21L extends from the middle wall portion 27 to a left side wall portion 28 of the filter supporting unit 25. The shaft portion 24a is driven by the drive motor 24M. This drives the filter drive gear 24.
The gear portions 24b are provided at the both ends of the shaft portion 24a. The gear portions 24b rotate with the rotation of the shaft portion 24a driven by the drive motor 24M. The gear portions 24b face the plurality of racks (raised portions) 54 provided for the vertical rims 52V of the filter 21. That is, the racks 54 of the filter 21 are brought into mesh with the gear portions 24b of the filter drive gear 24. Accordingly, the filter 21 moves along the guides 25a of the filter supporting unit 25 as the drive motor 24M drives and rotates the filter drive gear 24.
The drive motor 24M is a forward and reverse rotating motor, and moves the filter 21 along the guides 25a of the filter supporting unit 25 by rotating the filter drive gear 24, as described above. Specifically, the filter 21 moves forward and downward along the guides 25a (direction of arrow M in FIG. 9(a)) when the drive motor 24M rotates in forward direction. In response, the front surface brush 23 brushes off the dirt and dust that has accumulated on the filter 21, into the dust box 22, as the filter 21 moves downward (see FIG. 9(a)). In a reverse rotation of the drive motor 24M, the filter 21 moves back and upward along the guides 25a, and returns to a predetermined position with a clean surface.
The rear surface roller 41 is disposed opposite the front surface brush 23 with the filter 21 in between (see FIG. 9(a)). For example, the rear surface roller 41 is disposed in front of and below the shaft portion 24a of the filter drive gear 24. The rear surface roller 41 has a narrow cylindrical shape (columnar shape). The rear surface roller 41 extends from one end to the other end of the filter 21 in the lateral direction (horizontal direction) of the filter 21. The rear surface roller 41 lies within the gear portions 24b of the filter drive gear 24.
The rear surface roller 41 has gears 41a at the both ends of its length. In the present embodiment, the rear surface roller 41 rotates by being driven by the filter 21. That is, the rear surface roller 41 rotates with the movement of the filter 21. Specifically, the gears 41a provided at the both ends of the rear surface roller 41 are brought into mesh with the racks 54 formed on the vertical rims 52V of the filter 21, and the rear surface roller 41 rotates as the filter 21 moves.
The racks 54 are also in mesh with the gear portions 24b of the filter drive gear 24. The racks 54 therefore have the width (for example, width W1 in FIG. 11) necessary to be brought into mesh with both the gear portions 24b of the filter drive gear 24, and the gears 41a of the rear surface roller 41. As described above, the filter 21 rotates by being driven by the filter drive gear 24. That is, the racks 54 travel in vertical and depth direction as the filter drive gear 24 rotates. This causes a rotation in the other pair of gears (i.e., the gears 41a of the rear surface roller 41) that are also in mesh with the racks 54. The racks 54 may be in mesh with the gear portions 24b of the filter drive gear 24 in portion A, and in mesh with the gears 41a of the rear surface roller 41 in portion B, and the portion A and the portion B may be separated with a gap in between (see FIG. 11).
The filter supporting unit 25 supports the filter 21. The filter supporting unit 25 has the guides 25a that guide the movement of the filter 21 being cleaned. The guides 25a are formed to move the filter 21 in a predetermined direction when the drive motor 24M moves the filter 21.
The filter supporting unit 25 has the right side wall portion 26, the middle wall portion 27, and the left side wall portion 28.
The right side wall portion 26 is a side wall extending in depth direction at the right edge of the filter supporting unit 25. The guide 25a is disposed on the left side (inside) of the right side wall portion 26. As shown in FIG. 4, on the right side wall portion 26 is provided a drive unit 60 that includes the drive motor 23M, the drive motor 24M for driving and moving the right filter 21R, and other drive members of the filter cleaning device.
The left side wall portion 28 is a side wall extending in depth direction at the left edge of the filter supporting unit 25. The guide 25a is disposed on the right side (inside) of the left side wall portion 28. Though not illustrated, on the left side wall portion 28 is provided a drive unit that includes the drive motor 24M for driving and moving the left filter 21L, and other filter drive members. The rotation of the front surface brush 23 provided for the left dust box 22L is driven by the drive motor 23M of the drive unit 60 provided on the right side wall portion 26. Here, the torque of the drive motor 23M transmits to the front surface brush 23 of the left dust box 22L via a drive gear through the front surface brush 23 of the right dust box 22R.
The middle wall portion 27 is a wall portion extending in depth direction at substantially the middle in the length of the filter supporting unit 25. The guides 25a are disposed on the both sides of the middle wall portion 27. These guides 25a have the same shape as the guides 25a provided on the left side wall portion 28 and the right side wall portion 26. The left guide 25a faces the guide 25a of the left side wall portion 28, and the right guide 25a faces the guide 25a of the right side wall portion 26. That is, one of the filters 21R and 21L (the filter 21L) is guided by the left guide 25a of the middle wall portion 27 and the guide 25a of the left side wall portion 28, and the other filter (21R) is guided by the right guide 25a of the middle wall portion 27 and the guide 25a of the right side wall portion 26.
The dust box container 29 for installation of the dust box 22 is provided below the front side of the filter supporting unit 25. The dust box container 29 is provided between the right side wall portion 26 and the middle wall portion 27, and between the left side wall portion 28 and the middle wall portion 27. The dust box 22R is installed in the dust box container 29 between the right side wall portion 26 and the middle wall portion 27. The dust box 22L is installed in the dust box container 29 between the left side wall portion 28 and the middle wall portion 27.

Rear Surface Roller

The following more specifically describes the configuration of the rear surface roller 41. The rear surface roller 41 includes the gears 41a, a brush 41b, and a rotation shaft 41p, among others.
As described above, the gears 41a are located at the both ends of the rear surface roller 41. As shown in FIG. 8, the gears 41a are located within the gear portions 24b of the filter drive gear 24.
The brush 41b is provided on the surface of the rear surface roller 41. The brush 41b is formed of brush hairs obtained by, for example, bundling a plurality of moderately rigid fibers (for example, synthetic fibers such as nylon, and natural fibers such as animal hairs) (see FIG. 9(a)). The material of the brush 41b may be the same material used for the front surface brush 23.
The brush 41b on the surface of the rear surface roller 41 is disposed in contact with the back surface of the filter 21. In a cleaning operation, the rear surface roller 41 rotates with the movement of the filter 21. Dust and foreign objects adhering to the front surface of the filter are pushed forward from behind by the brush 41b provided on the back side of the filter 21 disposed between the front surface brush 23 and the rear surface roller 41. This enables the front surface brush 23 rotating against the front surface of the filter 21 to remove dust even when it is adhering to the filter 21 rather strongly.
The rotation shaft 41p is located inside of the brush 41b. In other words, the brush hair constituting the brush 41b is implanted in the surface of the rotation shaft 41p. The rotation shaft 41p is rotatably mounted on rear surface roller supporting sections 42.
In the present embodiment, the rear surface roller 41 having the brush 41b on its surface is used as the rotating member disposed on the back side of the filter 21. However, in an aspect of the present invention, it is not necessarily required to provide a brush on the surface of the rotating member disposed on the back side of the filter 21.
The rear surface roller 41 is mounted on the filter supporting unit 25 with the rear surface roller supporting sections 42. The rear surface roller supporting sections 42 support the rear surface roller 41 from the both ends. As shown in FIG. 8, the rear surface roller supporting section 42 is disposed between the gear portion 24b of the filter drive gear 24, and the gear 41a of the rear surface roller 41. FIG. 7 shows a configuration around the rear surface roller supporting section 42.
As shown in FIG. 7, the rear surface roller supporting section 42 is mounted on the guide 25a provided on the filter supporting unit 25. The rear surface roller supporting section 42 is disposed so as to project forward from a lower end portion of the guide 25a. The rotation shaft 41p of the rear surface roller 41 is rotatably mounted at an end portion of the rear surface roller supporting section 42.
As shown in FIG. 9(a), the rear surface roller 41 has a smaller diameter (cross sectional diameter) than the gear portion 24b of the filter drive gear 24. This makes is possible to reduce the volume of the rear surface roller as compared to when the rear surface roller is provided as a single unit with the filter drive gear 24. With the configuration of the present embodiment, the rear surface roller 41 thus occupies a smaller volume in the passage of air drawn into the indoor unit 1 through the intake opening 14. This makes it possible to reduce the possibility of a performance drop of the air conditioner as might occur when the air passage is narrow and the air experiences high resistance as it is drawn into the air conditioner.
In the present embodiment, the diameter (cross sectional diameter) of the rear surface roller 41 is smaller than a half of the diameter of the gear portion 24b of the filter drive gear 24, as shown in FIG. 7. In this way, the main body portion (rotation shaft 41p) of the rear surface roller 41 has a smaller chance of contacting the shaft portion 24a of the filter drive gear 24. The tip of the brush hair of the rear surface roller 41 may slightly contact the shaft portion 24a. When sized as above, the rear surface roller 41 also can be disposed within the gear portions 24b of the filter drive gear 24, as viewed from side.
The rear surface roller 41 is disposed opposite the front surface brush 23 with the filter 21 in between. In this way, dust and other foreign objects strongly adhering to the filter 21 can be pushed from behind by the rear surface roller 41 toward the front surface brush 23.
Preferably, the rear surface roller 41 is located within the gear portions 24b of the filter drive gear 24 as viewed from the side of the filter cleaning device 20 (side view), as shown in FIG. 9(a). Here, the rear surface roller being located within the gear portions of the filter drive gear means that the rear surface roller is within (or inside of) the rotational trajectory of the gear portions of the filter drive gear, as viewed from side. In this way, the provision of the rear surface roller 41 can prevent narrowing of the air passage through the intake opening 14, and the air can experience less resistance as it is drawn into the air conditioner.

Operations of Filter and Rear Surface Roller

The following describes the operations of the filter 21 and the rear surface roller 41, with reference to FIG. 9(a) and other figures. As described above, the filter 21 moves as the filter drive gear 24 rotates. Specifically, the racks 54 provided on the vertical rims 52V of the filter 21 are brought into mesh with the gear portions 24b of the filter drive gear 24, and the filter 21 moves in the direction of arrow M with the rotation of the gear portions 24b (for example, in the direction of arrow R2).
The racks 54 provided on the vertical rims 52V of the filter are also in mesh with the gears 41a of the rear surface roller 41 located adjacent the gear portions 24b. Accordingly, the gears 41a rotate with the movement of the racks 54 in the operation that moves the filter 21. This causes the rear surface roller 41 to rotate in the direction of arrow R3 by following the movement of the filter 21 (arrow M).
The rotation directions of the front surface brush 23, the filter drive gear 24, and the rear surface roller 41 shown in FIG. 9 (a) are an example of the present invention. The front surface brush 23, the filter drive gear 24, and the rear surface roller 41 may rotate in different directions. In this case, an additional gear is provided between the racks 54 and the gears 41a, or the gears 41 are driven by using a different motor . However, in this case, a larger force is needed to convey the filter than when the directions of rotation are the same.
Preferably, the filter drive gear 24 and the rear surface roller 41 rotate in the same direction. In this way, the friction between the back surface of the filter 21 and the brush 4b on the rear surface roller 41 can be reduced.
Preferably, the pitch P1 of the teeth of the gear portions 24b of the filter drive gear 24, and the pitch P2 of the teeth of the gears 41a of the rear surface roller 41 are substantially the same, and match the pitch of the teeth on the racks 54 (see FIG. 9(b)). In this way, the filter 21 can move at a rate that matches the rotational speed of the rear surface roller 41. This makes it possible to reduce the amount of static electricity that generates on the filter 21.
In the present embodiment, the racks 54 provided on the vertical rims 52V of the filter 21 are brought into mesh with both the gear portions 24b and the gears 41a, as described above. Accordingly, the width W1 of the racks 54 in horizontal direction is larger than the width W2 of racks 254 of a common filter (for example, filter 221 shown in FIG. 16).
In the present embodiment, the rotation of the rear surface roller 41 is driven by the driving force of the drive motor 24M through the racks 54 of the filter 21. However, the aspect of the present invention is not limited to such a configuration. For example, a designated drive motor may be provided for the rear surface roller 41, and the rear surface roller 41 may be driven to rotate by a drive train different from that that moves the filter 21.
As described above, the filter cleaning device 20 of the present embodiment includes the filter drive gear 24 (filter drive section) that moves the filter 21 along the front surface brush 23 (dust removal member), and the rear surface roller 41 (rotating member) disposed opposite the front surface brush 23 with the filter 21 in between, and that rotates with the movement of the filter 21. With this configuration, the filter drive gear 24 (filter drive section) and the rear surface roller 41 (rotating member) can be configured from different members. The rotating member disposed opposite the front surface brush 23 (dust removal member) with the filter 21 in between can thus have a smaller diameter. In this way, air can experience less resistance as it is drawn into the air conditioner through the filter 21 from outside of the air conditioner.

Second Embodiment

Second Embodiment of the present invention is described below, with reference to FIGS. 12 to 14. Second Embodiment differs from First Embodiment in the configuration of the filter cleaning device in the indoor unit 1 of the air conditioner. Other configurations may be the same as in First Embodiment. Accordingly, the following descriptions of Second Embodiment focus mainly on the configuration of the filter cleaning device 120. Constituting members that can have the same configurations described in First Embodiment will be referred to by the same reference numerals used in First Embodiment, and will not be described.
FIG. 12 shows a partial view of a filter cleaning device 120 provided in the indoor unit 1 according to Second Embodiment. The main constituting members of the filter cleaning device 120 include a dust box 22, a front surface brush (dust removal member) 23, a filter drive gear 124, a rear surface roller (rotating member) 141, and a filter supporting unit 125. The dust box 22, the front surface brush (dust removal member) 23, and the filter supporting unit 125 (corresponding to the filter supporting unit 25) may have the same configurations described in First Embodiment.
As in First Embodiment, the filter drive gear 124 is disposed opposite the front surface brush 23 with the filter 121 in between. As shown in FIG. 12, the filter drive gear 124 is configured from a shaft portion 124a and gear portions (rotating gears) 124b.
The shaft portion 124a is disposed along the lateral direction (horizontal direction) of the filter 121. The shaft portion 124a is driven by the drive motor 24M. This rotates the filter drive gear 124.
The gear portions 124b are provided at the both ends of the shaft portion 124a. The gear portions 124b rotate as the drive motor 24M drives and rotates the shaft portion 124a. The gear portions 124b are disposed in positions facing a plurality of racks (raised portions) 154 provided on vertical rims 152V of the filter 121. That is, the racks 154 of the filter 121 are brought into mesh with the teeth of the gear portions 124b of the filter drive gear 124. Accordingly, the rotation of the filter drive gear 124 driven by the drive motor 24M moves the filter 121 along the guides 25a of the filter supporting unit 125.
The rear surface roller 141 is disposed opposite the front surface brush 23 with the filter 121 in between. For example, as shown in FIG. 12, the rear surface roller 141 is disposed in front of and below the shaft portion 124a of the filter drive gear 124. The rear surface roller 141 has a narrow cylindrical shape (columnar shape). The rear surface roller 141 extends from one end to the other end of the filter 121 along the lateral direction (horizontal direction) of the filter 121.
The rear surface roller 141 has a gear 141a in substantially the middle of the longitudinal direction. The rear surface roller 141 has a brush 141b on its surface, as in First Embodiment. As in First Embodiment, the rear surface roller 141 is mounted on the filter supporting unit 125 with rear surface roller supporting sections 142. Though not illustrated, a rotation shaft is provided inside of the brush 141b. The rotation shaft is rotatably mounted on the rear surface roller supporting sections 142. This allows the rear surface roller 141 to rotate.
As in First Embodiment, the rotation of the rear surface roller 141 is driven by the filter 121. That is, the rear surface roller 141 rotates with the movement of the filter 121. Specifically, the gear 141a provided for the rear surface roller 141 is brought into mesh with a second rack 155 formed on the filter 121, and the rear surface roller 141 rotates with the movement of the filter 121.
The following describes the configuration of the filter 121 provided in the filter cleaning device 120 of the present embodiment. FIGS. 13 and 14 show the configuration of the filter 121. The filter 121 is configured from a mesh portion 151, and a frame (frame portion) 152 surrounding the mesh portion 151.
The frame 152 includes vertical rims 152V constituting the vertical portion (a direction parallel to the direction of movement) of the frame, and horizontal rims 152H constituting the horizontal portion (a direction crossing the direction of movement) of the frame. The filter 121 is detachably supported by the filter supporting unit 125.
The mesh portion 151 is, for example, a polyethylene terephthalate mesh. The frame 52 is formed of, for example, a synthetic resin such as polypropylene resin. The mesh portion 151 and the frame 152 may be molded as a single unit using a synthetic resin such as polypropylene resin.
The frame 152 has a plurality of ribs 153. The ribs 153 extend vertically or horizontally in the frame 152 at substantially regular intervals. That is, the surface of the mesh portion 151 is compartmentalized in the form of a grid. The strength of the filter 121 improves with this configuration.
The ribs 153 are provided on the back side of the filter 121. In the present embodiment, a second rack having a plurality of raised portions (raised portions) 155 is formed on a rib 153C, which is the middle rib in the plurality of ribs 153 extending in vertical direction (a direction parallel to the direction of movement). The second rack 155 is disposed in positions facing the gear 141a provided for the rear surface roller 141. The gear 141a, by being in mesh with the second rack 155, rotates as the filters 121 moves.
The frame 152 has a plurality of racks (raised portions) 154 formed on the back side of the vertical rims 152V. The racks 154 are brought into mesh with the filter drive gear 124 that drives and moves the filter 121. Driving and rotating the filter drive gear 124 with the drive motor 24M causes the filter 121 to move in a coordinated fashion along the guides 25a of the filter supporting unit 125. That is, the filter 121 moves along the guides 25a of the filter supporting unit 125 in depth direction and in up-and-down direction inside the indoor unit 1 as the drive motor 24M drives and rotates the filter drive gear 124.
As described above, in the filter cleaning device 120 according to the present embodiment, the rotation of the rear surface roller 141 follows the second rack 155 formed on the vertically extending rib 153C in the middle portion of the filter 121. Accordingly, only one gear, 141a, is needed for the rear surface roller 141, and the rear surface roller 141 can rotate with the movement of the filter 121.
As described above, in the filter cleaning device of an aspect of the present invention, the rear surface roller 41 may rotate as a result of the racks 54 formed on the vertical rims 52V of the filter 21 being brought into mesh with the gears 41a of the rear surface roller 41, as in First Embodiment. Alternatively, the second rack 155 may be formed on, for example, the rib 153 of the filter 121, instead of the racks 154 formed on the vertical rims 152V of the filter 121, as in Second Embodiment, and the rear surface roller 141 may rotate as a result of the second rack 155 being brought into mesh with the gears 141a of the rear surface rollers 141. With the configuration of Second Embodiment, the vertical rims 152V of the filter 121 can have a smaller width than the vertical rims 52V of width W1 provided for the filter 21 of First Embodiment.
In the present embodiment, the gear 141a of the rear surface roller 141 is a single gear formed at substantially the middle of the rear surface roller 141 in longitudinal direction. However, the aspect of the present invention is not limited to this configuration. As another exemplary structure, the rear surface roller 141 may have two or more gears 141a formed on both sides of substantially the middle of the rear surface roller 141 in longitudinal direction. In this case, the gears 141a are formed preferably in positions corresponding to the ribs 153 of the filter 121. In this way, the second rack 155 can be formed on the rib 153, and brought into mesh with the gear 141a.

Third Embodiment

Third Embodiment of the present invention is described below, with reference to FIGS. 15 and 16. Third Embodiment differs from First Embodiment in the configuration of the filter cleaning device in the indoor unit 1 of the air conditioner. Other configurations may be the same as in First Embodiment. Accordingly, the following descriptions of Third Embodiment focus mainly on the configuration of the filter cleaning device 220. Constituting members that can have the same configurations described in First Embodiment will be referred to by the same reference numerals used in First Embodiment, and will not be described.
FIG. 15 shows a partial view of a filter cleaning device 220 provided in the indoor unit 1 according to Third Embodiment. The main constituting members of the filter cleaning device 220 include a dust box 22, a front surface brush (dust removal member) 23, a filter drive gear 224, a rear surface roller (rotating member) 241, and a filter supporting unit 225. The dust box 22, the front surface brush (dust removal member) 23, and the filter supporting unit 225 (corresponding to the filter supporting unit 25) may have the same configurations described in First Embodiment.
As in First Embodiment, the filter drive gear 224 is disposed opposite the front surface brush 23 with the filter 221 in between. As shown in FIG. 15, the filter drive gear 224 is configured from a shaft portion 224a and gear portions (rotating gears) 224b.
The shaft portion 224a is disposed along the lateral direction (horizontal direction) of the filter 221. The shaft portion 224a is driven by the drive motor 24M. This rotates the filter drive gear 224.
The gear portions 224b are provided at the both ends of the shaft portion 224a. The gear portions 224b rotate as the drive motor 24M drives and rotates the shaft portion 224a. The gear portions 224b are disposed in positions facing a plurality of racks (raised portions) 254 provided on vertical rims 252V of the filter 221. That is, the racks 254 of the filter 221 are brought into mesh with the teeth of the gear portions 224b of the filter drive gear 224. Accordingly, the rotation of the filter drive gear 224 driven by the drive motor 24M moves the filter 221 along the guides 25a of the filter supporting unit 225.
The rear surface roller 241 is disposed opposite the front surface brush 23 with the filter 221 in between. For example, as shown in FIG. 15, the rear surface roller 241 is disposed in front of and below the shaft portion 224a of the filter drive gear 224. The rear surface roller 241 has a narrow cylindrical shape (columnar shape). The rear surface roller 241 extends from one end to the other end of the filter 221 along the lateral direction (horizontal direction) of the filter 221.
As in First Embodiment, the rear surface roller 241 has a brush 241b on its surface. As in First Embodiment, the rear surface roller 241 is mounted on the filter supporting unit 225 with rear surface roller supporting sections 242. Though not illustrated, a rotation shaft is provided inside of the brush 241b. The rotation shaft is rotatably mounted on the rear surface roller supporting sections 242. This allows the rear surface roller 241 to rotate.
The rear surface roller 241 according to the present embodiment is not provided with the same gears provided for the rear surface roller in First and Second Embodiments. In the present embodiment, the rear surface roller 241 rotates under the frictional force created by the brush 241b contacting the back surface of the filter 221. This allows the rear surface roller 241 to rotate with the movement of the filter 221.
The following describes the configuration of the filter 221 provided in the filter cleaning device 220 of the present embodiment. FIG. 16 shows the configuration of the filter 221. The filter 221 is configured from a mesh portion 251, and a frame (frame portion) 252 surrounding the mesh portion 251. The mesh portion 251 may have the same configuration as the mesh portion 51 of First Embodiment.
The frame 252 includes vertical rims 252V constituting the vertical portion (a direction parallel to the direction of movement) of the frame, and horizontal rims 252H constituting the horizontal portion (a direction crossing the direction of movement) of the frame. The filter 221 is detachably supported by the filter supporting unit 225.
The frame 252 has a plurality of ribs 253. The ribs 253 may have the same configuration as the ribs 53 of First Embodiment.
The frame 252 has a plurality of racks (raised portions) 254 formed on the back side of the vertical rims 252V. The racks 254 are brought into mesh with the filter drive gear 224 that drives and moves the filter 221. Driving and rotating the filter drive gear 224 with the drive motor 24M causes the filter 221 to move in a coordinated fashion along the guides 25a of the filter supporting unit 225. That is, the filter 221 moves along the guides 25a of the filter supporting unit 225 in depth direction and in up-and-down direction inside the indoor unit 1 as the drive motor 24M drives and rotates the filter drive gear 224.
In the present embodiment, the racks 254 are brought into mesh with only the gear portions 224b of the filter drive gear 224. Accordingly, the racks 254 can have a smaller width W2 in horizontal direction than in the filter 21 of First Embodiment in which the racks are in mesh with both the gear portions 24b and the gears 41a. In this way, air can experience less resistance as it is drawn into the air conditioner.
As described above, in the filter cleaning device 220 according to the present embodiment, the rear surface roller 241 rotates as a result of the brush 241b provided on the surface of the rear surface roller 241 contacting the back surface of the filter 221. In this way, the rear surface roller 241 can rotate with the movement of the filter 221.
The embodiments disclosed herein are to be considered in all aspects only as illustrative and not restrictive. The scope of the present invention is to be determined by the scope of the appended claims, not by the foregoing descriptions, and the invention is intended to cover all modifications falling within the equivalent meaning and scope of the claims set forth below. A configuration based on a combination of different configurations of the embodiments described in this specification is also intended to fall within the scope of the present invention.

Reference Signs List

1: Indoor unit (of air conditioner)
20: Filter cleaning device
21: Filter
22: Dust box
23: Front surface brush (dust removal member)
24: Filter drive gear (filter drive section)
24b: Gear portion (rotating gear)
41: Rear surface roller (rotating member)
41a: Gear
41b: Brush (of rear surface roller)
54: Rack (raised portion) (of filter)
120: Filter cleaning device
121: Filter
124: Filter drive gear (filter drive section)
124b: Gear portion (rotating gear)
141: Rear surface roller (rotating member)
154: Rack (raised portion)(of filter)
155: Second rack (raised portion) (of filter)
220: Filter cleaning device
221: Filter
224: Filter drive gear (filter drive section)
224b: Gear portion (rotating gear)
241: Rear surface roller (rotating member)

Claims

A filter cleaning device for cleaning off dust adhering to a filter,
the filter cleaning device comprising:
a dust removal member that removes dirt and dust from a surface of the filter;

a filter drive section that moves the filter along the dust removal member; and

a rotating member disposed opposite the dust removal member with the filter in between, and that rotates with movement of the filter.
The filter cleaning device according to claim 1, wherein:
the filter has a plurality of raised portions formed along a direction of movement of the filter,

the filter drive section has rotating gears that are brought into mesh with the raised portions, and

the rotating member has a smaller diameter than the rotating gears.
The filter cleaning device according to claim 2,
wherein the rotating member is located within the rotating gears as viewed from side.
The filter cleaning device according to any one of claims 1 to 3, wherein:
the filter has a plurality of raised portions formed along a direction of movement of the filter, and

the rotating member has gears that are brought into mesh with the raised portions.
The filter cleaning device according to any one of claims 1 to 4, wherein the rotating member has a surface provided with a brush.
The filter cleaning device according to claim 5, wherein the rotating member rotates as a result of the brush provided on the surface of the rotating member contacting a back surface of the filter.