GB2549868A

GB2549868A - Outdoor unit for air conditioning devices

Info

Publication number: GB2549868A
Application number: GB1710252.6A
Authority: GB
Inventors: Abe Daisuke; Kitagawa Nobuyasu
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2015-02-13
Filing date: 2015-02-13
Publication date: 2017-11-01
Anticipated expiration: 2035-02-13
Also published as: GB201710252D0; GB2549868B; JPWO2016129117A1; WO2016129117A1; JP6320581B2

Abstract

An outdoor unit for air conditioning devices comprises a case in which an airflow path is formed, a fan that is mounted on the case and that blows air into the airflow path, and a control unit that is disposed to be adjacent to the airflow path in the case. The control unit comprises: a control box that houses a control board and that has an opening on a mounting face adjacent to the airflow path; a reactor unit that is electrically connected to the control board; a mounting plate that is fixed to the top of the opening from the inner face side of the mounting face of the control box and that holds the reactor unit to project from the opening of the control box into the airflow path; and a sealing member that is made from an elastic body and that is provided between the mounting plate and the reactor unit. The mounting plate has a projection that presses the sealing member into a location opposite the reactor unit so as to deform the same.

Description

DESCRIPTION Title of Invention

OUTDOOR UNIT OF AIR-CONDITIONING APPARATUS

Technical Field [0001]

The present invention relates to an outdoor unit of an air-conditioning apparatus in which a controller including a large-sized reactor unit is mounted. Background Art [0002]

Conventionally, electrical components constituting an inverter circuit or a high frequency suppressing circuit for driving a motor of a compressor are contained in an air-conditioning apparatus (for example, refer to Patent Literature 1). As shown in Patent Literature 1, a relatively large-sized reactor is included as electrical components contained in an outdoor unit, and the reactor unit and other electronic components, and other elements are in a state of being contained in a control box to be contained in a housing of an air-conditioning apparatus. Then, in the control box, an inverter circuit using the reactor is configured, and a driving power is supplied from the inverter circuit to motors of a compressor and a fan.

Citation List Patent Literature [0003]

Patent Literature 1: Japanese Unexamined Patent Application Publication No. 11- 75363

Summary of Invention Technical Problem [0004]

In recent years, input power is increased due to increase of horse power of an outdoor unit, and therefore, it is expected that an amount of heat generation of a reactor is also increased in response to increase in power consumption (amount of heat generation) of an inverter. Then, the reactor becomes a heat generator and effects of heat stress to other components in a control box cannot be ignored. Therefore, it can be considered that the reactor that is a heat generator is separated from the inside of the control box and cooled by an outdoor fan motor, to reduce the heat stress to the inside of the control box. On the other hand, when the reactor is separated from the inside of the control box, it is necessary to consider water resistance of the reactor so that water does not enter from a gap or the like between the reactor and the control box.

[0005]

The present invention has been made to solve the above problem, and has an object to provide an outdoor unit of an air-conditioning apparatus capable of improving heat insulation performance and water resistance performance of a reactor. Solution to Problem [0006]

An outdoor unit of an air-conditioning apparatus according to an aspect of the present invention includes: a housing in which an air path is formed; a fan that is attached to the housing and sends air into the air path; and a controller disposed at a position adjacent to the air path in the housing, wherein the controller includes: a control box that contains a control substrate and includes an opening in an attachment surface in contact with the air path; a reactor unit electrically connected to the control substrate; an attachment plate that is fastened onto the opening from an inner surface side of the attachment surface of the control box, and holds the reactor unit to be projected to inside of the air path from the opening of the control box; and a sealing member that is provided between the attachment plate and the reactor unit, and is made of an elastic body, and wherein the attachment plate includes a protrusion portion that presses the sealing member against a portion facing the reactor unit to elastically deform the sealing member.

Advantageous Effects of Invention [0007]

According to an outdoor unit of an air-conditioning apparatus of an embodiment of the present invention, a reactor unit is projected from a control box to be disposed in an air path, and therefore, the reactor unit can be effectively cooled. Moreover, due to pressing of a sealing member by a protrusion portion of an attachment plate, it is possible to prevent entry of water and secure water resistance, and to suppress heat transfer from the reactor unit to the control box to improve heat insulation properties.

Brief Description of Drawings [0008] [Fig. 1] Fig. 1 is an outer perspective view showing Embodiment 1 of an air-conditioning apparatus according to the present invention.

[Fig. 2] Fig. 2 is a perspective view showing an example of a controller mounted in the air-conditioning apparatus in Fig. 1.

[Fig. 3] Fig. 3 is a circuit diagram showing an example of a power supply circuit configured by a control substrate in a control box in Fig. 2.

[Fig. 4] Fig. 4 is a perspective view showing a state in which a reactor unit is attached to the control box in Fig. 2.

[Fig. 5] Fig. 5 is another perspective view showing the state in which the reactor unit is attached to the control box in Fig. 2.

[Fig. 6] Fig. 6 is a plan view showing an example of the reactor unit attached to the control box in Fig. 2.

[Fig. 7] Fig. 7 is a cross-sectional view showing a state in which the reactor unit is attached to the control box in Fig. 6.

[Fig. 8] Fig. 8 is a schematic view showing a comparative example in which a reactor unit is attached onto an air path.

[Fig. 9] Fig. 9 is a cross-sectional view showing a comparative example in which a reactor unit is attached onto an air path outside the control box.

[Fig. 10] Fig. 10 is a cross-sectional view showing a peripheral portion of a fastening part in the reactor unit in Fig. 9.

[Fig. 11 ] Fig. 11 is a cross-sectional view showing Embodiment 2 of an attachment plate in the air-conditioning apparatus according to the present invention.

[Fig. 12] Fig. 12 is a cross-sectional view showing a tip end shape of a protrusion portion in the attachment plate in Fig. 11.

[Fig. 13] Fig. 13 is a plan view showing Embodiment 3 of the attachment plate in the air-conditioning apparatus according to the present invention.

Description of Embodiments [0009]

Embodiment 1 hereinafter, embodiments of an air-conditioning apparatus according to the present invention will be described with reference to drawings. Fig. 1 is an outer perspective view showing Embodiment 1 of the air-conditioning apparatus according to the present invention. The air-conditioning apparatus 1 in Fig. 1 is an outdoor unit for air-heating or air-cooling, for example, and includes a housing 2, a fan 3 and a controller 10. The housing 2 contains, for example, a compressor, a heat exchanger and other devices constituting a refrigeration cycle, and in the housing 2, an air path 2A that serves as a path of air to be sent to the heat exchanger is formed. The fan 3 sends air into the air path 2A formed in the housing 2, and is attached to, for example, a top portion of the housing 2. Then, by rotational driving of the fan 3, air flows through the air path 2A from below upwards. Moreover, the rotation speed of the fan 3 varies according to an operation state of the air-conditioning apparatus, and therefore, an air volume in the air path 2A also varies.

[0010]

Fig. 2 is a perspective view showing an example of the controller mounted in the air-conditioning apparatus in Fig. 1, and the controller 10 will be described with reference to Fig. 1 and Fig. 2. The controller 10 controls the air-conditioning apparatus 1 and includes a control box 11, a control substrate 12 and a reactor unit 20. On the control substrate 12, for example, a power conversion circuit, such as an inverter circuit, is formed together with the reactor unit 20, and the control substrate 12 is contained in the control box 11. The control box 11 is formed into, for example, a rectangular shape, and is disposed at a position adjacent to the air path 2A in the housing 2. Consequently, air flows on an attachment surface 11A side of the control box 11. Note that the shape of the control box 11 is exemplified to be formed in a rectangular shape; however, the shape is not limited thereto and may be in a shape corresponding to a containing space, such as, for example, having cuttings formed on corner portions.

[0011]

The reactor unit 20 is a large-sized reactor in which a conductor wire is wound around a coil bobbin, and is disposed to project from the attachment surface 11A of the control box 11 towards the air path 2A side. Since the attachment surface 11A of the control box 11 is adjacent to the air path 2A, the reactor unit 20 is in a state of being disposed in the air path 2A.

[0012]

Fig. 3 is a circuit diagram showing an example of a power conversion circuit configured by the control substrate in the control box in Fig. 2. The power conversion circuit in Fig. 3 drives a motor of the fan and a motor of a not-shown compressor, and includes a DC reactor for power factor improvement configured with a noise filter 12A, a rectifier 12B, a smoothing capacitor 12C, an inverter circuit 12D mounted on the control substrate 12, and the reactor unit 20. An AC power supplied from a commercial power supply PS is subjected to noise elimination in the noise filter 12A, and thereafter, rectified to a DC power in the rectifier 12B. Thereafter, the rectified DC power is smoothed in the reactor unit 20 and the smoothing capacitor 12C, and supplied to the inverter circuit 12D. Then, by performing predetermined switching operation in the inverter circuit 12D, modes M of the fan and the compressor are driven.

[0013]

Here, with increase of horse power of the outdoor unit, the power consumption and the amount of heat generation of the inverter circuit 12D are increased, and in response thereto, the amount of heat generation of the reactor unit is also increased. Then, to prevent heat generation of the reactor unit 20 from becoming heat stress to the other electronic components in the control box 11, the reactor unit 20 is disposed inside the air path 2A and air flowing through the air path 2A, which is generated by the fan 3, is directly applied to the reactor unit 20, and thereby cooling is performed.

[0014]

Fig. 4 and Fig. 5 are perspective views showing a state in which the reactor unit is attached to the control box in Fig. 2, and Fig. 6 is a plan view showing an example of the reactor unit attached to the control box in Fig. 2. As shown in Fig. 4 and Fig. 5, the controller 10 includes an attachment plate 30 for fastening the reactor unit 20 to the control box 11. The control box 11 includes an opening 11x on the attachment surface 11A in contact with the air path 2A, and the attachment plate 30 is fastened onto the opening 11x of the control box 11 by use of attachment plate fastening members 41, such as screws.

[0015]

The reactor unit 20 includes a reactor main body 21 in which the coil bobbin and the conductor wire are resin sealed, holding jigs 22 attached to side surfaces of the reactor main body 21, and wiring 23 extending from the reactor main body 21.

The holding jig 22 is, for example, an L-shaped piece of hardware, and fastened onto each of both side surfaces of the reactor unit 20. Then, the holding jigs 22 are fastened to the attachment plate 30 by unit fastening members 42, such as screws, and thereby the reactor unit 20 is fastened to the attachment plate 30.

[0016]

The attachment plate 30 is, for example, formed in a flat-plate shape and includes a wiring hole 30x into which the wiring 23 of the reactor unit 20 is inserted. Then, the reactor unit 20 is fastened onto an inner surface side of the attachment surface 11A on the wiring hole 30x of the attachment plate 30 by the unit fastening members 42, such as screws. Moreover, the wiring 23 of the reactor unit 20 is electrically connected to the control substrate 12 in the control box 11 via the opening 11x and the wiring hole 30x. In this manner, the reactor unit 20 is brought into a state of being fastened to the control box 11 to be projected from the attachment surface 11A of the control box 11 toward the outside by use of the attachment plate 30.

[0017]

Fig. 7 is a cross-sectional view showing a state in which the reactor unit is attached to the control box in Fig. 6. The controller 10 includes a sealing member 50 provided between the reactor unit 20 (the reactor main body 21 and the holding jigs 22) and the attachment plate 30. The sealing member 50 is made of, for example, an elastic body, such as an eptsealer, and prevents water from entering between the reactor unit 20 and the attachment plate 30.

[0018]

Flere, in the attachment plate 30, on a facing surface that faces the sealing member 50, multiple protrusion portions 31 are formed on portions to which the holding jigs 22 are attached. The protrusion portion 31 is, for example, formed in a slit shape extending in the width direction (the direction of arrow X), and the multiple protrusion portions 31 are formed in the height direction (the direction of arrow Z). When the holding jigs 22 of the reactor unit 20 are attached to the attachment plate 30, the protrusion portions 31 press the sealing member 50 to compress thereof. Then, the sealing member 50 is elastically deformed, and thereby water resistance between the reactor unit 20 (the holding jigs 22) and the attachment plate 30 is secured. Particularly, in Fig. 7, the multiple protrusion portions 31 are provided to enclose the unit fastening member 42.

[0019]

At this time, the water resistance can be guaranteed by managing compressibility in pressing the sealing member 50 by the height of the protrusion portions 31. The height of the protrusion portions 31 is set to provide the compressibility corresponding to characteristics of the sealing member 50 to be compressed. For example, when the sealing member 50 has a thickness of 10 mm and the protrusion portion 31 has a height of 2 mm, the compressibility to the sealing member 50 is 80%, and thereby water resistance of the sealing member 50 can be guaranteed. Further, the reactor unit 20 is attached to the control box 11 via the sealing member 50 and the attachment plate 30. Consequently, heat transfer of heat generated by the reactor unit 20 to the control box 11 side can be suppressed.

[0020]

Moreover, the sealing member 50 is also provided between the control box 11 and the attachment plate 30, and the protrusion portions 31 are also provided at a portion of the attachment plate 30 facing the control box 11. Consequently, water resistance between the control box 11 and the attachment plate 30 is in a state of being guaranteed by the sealing member 50. Particularly, in Fig. 7, the multiple protrusion portions 31 are provided to enclose the attachment plate fastening member 41 to prevent entry of water from the attachment plate fastening member 41.

[0021]

Note that the sealing member 50 is not provided on the wiring hole 30x of the attachment plate 30, and the portion is opened. On the other hand, a waterproof member 51 made of, for example, waterproof silicone or the like is provided between a periphery of the wiring hole 30x of the attachment plate 30 and the reactor unit 20. This makes it possible to surely prevent entry of water from the wiring hole 30x.

[0022]

Next, with reference to Fig. 1 to Fig. 7, an attachment process of the reactor unit 20 will be described. First, the holding jigs 22 of the reactor unit 20 are attached to the attachment plate 30 by using the unit fastening members 42 to sandwich the sealing member 50 between the holding jigs 22 and the attachment plate 30. On this occasion, the sealing member 50 is pressed by the protrusion portions 31 of the attachment plate 30, and is elastically deformed. Thereafter, the waterproof member 51 is coated between the reactor unit 20 and the attachment plate 30 to increase water resistance. Then, the reactor unit 20 is inserted into the opening 11x of the control box 11 from inside, and the attachment plate 30 is attached to the inner surface side of the attachment surface 11A by use of the attachment plate fastening members 41.

[0023]

According to the above-described Embodiment 1, the reactor unit 20 is disposed in the air path 2A to project from the control box 11, and thereby the reactor unit 20 can be efficiently cooled. Moreover, due to pressing of the sealing member 50 by the protrusion portions 31 of the attachment plate 30, it is possible to prevent entry of water and secure the water resistance, and to suppress heat transfer from the reactor unit 20 to the control box 11 to improve heat insulation properties.

[0024]

Fig. 8 is a schematic view showing entry routes of water in the controller in Fig. 7. As shown in Fig. 8, as the entry routes of water, insertion holes for the attachment plate fastening members 41 and the unit fastening members 42 formed in the control box 11 and the gap between the control box 11 and the reactor unit 20 (the holding jigs 22) can be provided. At this time, since the sealing members 50 compressed by the protrusion portions 31 are interposed between the reactor unit 20 and the attachment plate 30 and between the control box 11 and the attachment plate 30, it is possible to prevent entry from the insertion holes. Note that, by using screws having water resistance (for example, coating a screw thread with a chemical having water resistance) as the attachment plate fastening members 41 and the unit fastening members 42, it is further possible to prevent entry of water from the entry routes.

[0025]

Fig. 9 is a schematic view showing a comparative example in which the reactor unit is attached onto the air path outside the control box, and Fig. 10 is a cross-sectional view showing a peripheral portion of a fastening part in the reactor unit in Fig. 9. In Fig. 9 and Fig. 10, a reactor main body 61 has a structure to be contained in an attachment cover 62, and is fastened to the control box 11 at a flange portion of the attachment cover 62 via the sealing member 50. Then, the reactor unit is in a state of being disposed in the air path 2A. However, if the reactor unit is exposed to the air path 2A, various kinds of problems, such as electric leakage or corrosion of metal conductors due to rain water, occur. Therefore, it is necessary to protect the reactor unit from external factors, such as rain water. Moreover, the structure disposes the reactor unit in the air path 2A, but the attachment cover 62 itself that covers the reactor main body 61 becomes high temperature upon being affected by the reactor main body 61. Since the reactor unit is attached to the control box 11, there is a possibility that heat transfer from the reactor unit to the control box 11 is likely to occur.

[0026]

Moreover, it can be considered that the control box 11 has a dual structure of an inside sheet metal (BASE sheet metal) and an outside sheet metal (CASE sheet metal), and the reactor unit is attached onto the outside sheet metal side of the control box 11. In this case, the control substrate or other electrical components are attached to the inside sheet metal, and projection of screws in attaching the electrical components is prevented by the dual structure, and thereby water resistance is guaranteed. Even in this case, the sealing member 50 is inserted between the reactor unit and the outside sheet metal, and thereby water resistance is guaranteed. However, in this structure, since the sealing member 50 is completely crushed, it is difficult to secure water resistance with respect to the entry routes as in Fig. 8. Moreover, since the screw points of the unit fastening members 42 are exposed to the outside, it becomes difficult to secure water resistance with respect to the entry routes in the unit fastening members 42.

[0027]

On the other hand, in an attachment structure of the reactor unit 20 shown in Fig. 7, since the protrusion portions 31 compress the sealing member 50, the water resistance in the sealing member 50 is increased, and thereby entry of water can be securely prevented. Moreover, since the reactor unit 20 is fastened to a control plate via the attachment plate 30 and the sealing member 50, heat generated in the reactor unit 20 has a route of transfer to the control box 11 via the sealing member 50 and the attachment plate 30. In this manner, since the heat generated in the reactor unit 20 is transferred to the control box 11 via the attachment plate 30, effects of heat generation in the reactor unit 20 to other electronic components, such as the control substrate, in the control box 11 can be suppressed. Moreover, in regard to heat transfer from the reactor unit 20 to the control box 11 via air, also, since the wiring hole 30x can be reduced by the attachment plate 30, the effects thereof can be reduced.

[0028]

Embodiment 2

Fig. 11 is a perspective view showing Embodiment 2 of an attachment plate of the controller in the air-conditioning apparatus according to the present invention, and an attachment plate 130 will be described with reference to Fig. 11. Note that, in the attachment plate 130 in Fig. 11, portions having the same configuration as those in the attachment plate 30 in Fig. 7 are assigned with same reference signs, and descriptions thereof will be omitted. The attachment plate 130 in Fig. 11 is different from the attachment plate 30 in Fig. 7 in terms of the shape of a protrusion portion 131.

[0029]

Fig. 12 is a schematic view showing an example of the protrusion portion in Fig. 11. As shown in Fig. 12, in the protrusion portion 131, a tip end 131t has a rounded arc shape and is formed in a taper shape toward the reactor unit 20 side.

As a result, in the tip end 1311 of the protrusion portion 131, an area facing the holding jig 22 and the control box 11 via the sealing member 50 is small as compared to the case of being formed in a flat shape.

[0030]

According to the above-described Embodiment 2, since, due to the tip end 1311 of the protrusion portion 131 having the arc shape, a contact area of the protrusion portions 131 with the control box 11 and the reactor unit 20 can be reduced, the amount of heat transfer from the reactor unit 20 to the control box 11 can be suppressed. Even in this case, similar to Embodiment 1, since the protrusion portions 131 press to compress the sealing member 50, the water resistance can be improved.

[0031]

Embodiment 3

Fig. 13 is a plan view showing Embodiment 3 of an attachment plate of the controller in the air-conditioning apparatus according to the present invention, and an attachment plate 230 will be described with reference to Fig. 13. Note that, in Fig. 13, portions having the same configuration as those in the attachment plates 30 and 130 in Fig. 1 to Fig. 11 are assigned with same reference signs, and descriptions thereof will be omitted. The attachment plate 230 in Fig. 13 is different from the attachment plates 30 and 130 in Fig. 1 to Fig. 11 in terms that guide ribs 241 that guide flow of water are provided.

[0032]

In Fig. 13, below the portions corresponding to the attachment plate fastening members 41 on the attachment plate 230, the guide ribs 241 that guide water dropping from the attachment plate fastening members 41 outward from the wiring hole 30x are provided. In this manner, by disposing the guide ribs 241 below the attachment plate fastening members 41, in case that water steeped from an upper portion of the attachment plate 230, it is possible to guide the water to the outside along the guide ribs 241.

[0033]

For example, though each of the attachment plate fastening members 41 uses a screw having the water resistance, in case that deterioration of the water resistance or the like occurs and thereby water enters along the screw thread and steeps from the upper portion of the attachment plate 30, when the water enters the wiring hole 30x, there is a possibility that the water flows down the wiring 23 to enter the inside of the control box 11. On the other hand, according to the above-described Embodiment 3, since the water does not reach the wiring hole 30x for this reason, it is possible to protect the inside of the control box 11 from water. The arrangement of the guide ribs 241 at this time may be an arrangement by which the water does not reach the wiring hole 30x, and is not limited to the arrangement in Fig. 13. Note that the protrusion portions 131 shown in Embodiment 2 may be used in the attachment plate 230 including the guide ribs 241.

[0034]

The embodiments of the present invention are not limited to the above-described embodiments. For example, arrangement positions and heights of the protrusion portions 31 and 131 are not limited to the above-described embodiments, and are able to be arbitrarily set. Moreover, the case in which the reactor unit 20 is fastened to the attachment plate 30 by use of the holding jigs 22 is exemplified; however, the attachment structure is not considered as long as there is provided a structure in which the reactor unit 20 is fastened to the attachment plate 30. Reference Signs List [0035] I air-conditioning apparatus, 2 housing, 2A air path, 3 fan, 10 controller, 11 control box, 11A attachment surface, II x opening, 12 control substrate, 12A noise filter, 12B rectifier, 12C smoothing capacitor, 12D inverter circuit, 20 reactor unit, 21 reactor main body, 22 holding jig, 23 wiring, 30,130,230 attachment plate, 30x wiring hole, 31,131 protrusion portion, 41 attachment plate fastening member, 42 unit fastening member, 50 sealing member, 51 waterproof member, 1311 tip end, 241 guide rib

Claims

CLAIMS [Claim 1] An outdoor unit of an air-conditioning apparatus, the outdoor unit comprising: a housing in which an air path is formed; a fan attached to the housing and configured to send air into the air path; and a controller disposed at a position adjacent to the air path in the housing, wherein the controller includes a control box containing a control substrate and having an opening in an attachment surface in contact with the air path, a reactor unit electrically connected to the control substrate; an attachment plate fastened onto the opening from an inner surface side of the attachment surface of the control box, and holds the reactor unit to be projected to inside of the air path from the opening of the control box, and a sealing member provided between the attachment plate and the reactor unit, and being made of an elastic body, and wherein the attachment plate includes a protrusion portion pressing the sealing member against a portion facing the reactor unit to elastically deform the sealing member. [Claim 2] The outdoor unit of an air-conditioning apparatus of claim 1, wherein the sealing member is provided between the attachment plate and the control box, and the attachment plate includes a plurality of protrusion portions including the protruding portion at a portion facing the control box. [Claim 3] The outdoor unit of an air-conditioning apparatus of claim 1 or 2, wherein the attachment plate has a wiring hole into which wiring of the reactor unit is inserted, and a waterproof member is provided between a periphery of the wiring hole and the reactor unit. [Claim 4] The outdoor unit of an air-conditioning apparatus of any one of claims 1 to 3, wherein a tip end of the protrusion portion of the attachment plate has an arc shape. [Claim 5] The outdoor unit of an air-conditioning apparatus of any one of claims 1 to 4, wherein the attachment plate is fastened to the control box with an attachment plate fastening member, and a guide rib being configured to guide water dropping from the attachment plate fastening member outward via the opening is provided below a portion where the attachment plate fastening member of the attachment plate is provided.