JP2002048093A - Blower impeller and air conditioner using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the weight of a highly efficient rigid blower impeller with prolonged length, increased dimension, or provided with a thick part in a part or in the whole of a blade so as to provide the blower impeller realizing a stable balance as a rotary body and a cutback of a material and an air conditioner constructed by using it for an energy-saving purpose. SOLUTION: A fine cell structure 10 is formed on the inside when inert gas in a supercritical condition is injected into a molten thermoplastic resin for foaming the resin, and the blower impeller having a skin layer 11 on the surface is formed. In this way, the blower impeller having high physical strength and high efficiency can be provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fan impeller and an air conditioner using the same.

In particular, a blower impeller made of a thermoplastic resin,
The present invention relates to an axial flow fan or a mixed flow fan having a large or partially or entirely thick wall portion, a large or long cross flow fan, and an air conditioner configured by using any of these blower impellers. Things.

[0003]

2. Description of the Related Art As a conventional blower impeller made of a thermoplastic resin, a resin molded product formed by injection molding or extrusion molding or a blower impeller formed by combining them is known.

Further, an axial fan or a mixed flow fan having a large thickness or a part or whole of a blade used for a conventional air conditioner or the like is disclosed in, for example, Japanese Patent Laid-Open No.
Japanese Patent No. 19395 discloses an invention of an axial fan 34 in which a hollow layer 36 is formed in a blade 35 by injecting a high-pressure gas during molding as shown in FIG.
Japanese Patent Application Laid-Open No. 8-113900 discloses an axial or mixed flow fan in which a foamed resin 38 is mounted on a blade 37 as shown in FIG. 17 and the surface of the foamed resin 38 is formed by a cured resin film 39 of a thermosetting resin. It has been disclosed.

A large or long cross flow fan used in a conventional air conditioner or the like is disclosed in Japanese Patent Application Laid-Open No. 4-353293, for example, in which a partitioning plate 41 has a foaming ratio of 5 times as shown in FIG. A conventional crossflow fan 40 comprising the following foamed resin material and a resin material in which a plurality of blades 42 are reinforced with glass fibers is disclosed.

As a conventional air conditioner, there is known an air conditioner using a resin molded product formed by injection molding or extrusion molding or a blower impeller formed by combining them.

[0007]

However, since the above-mentioned blower impeller is formed by combining resin molded products formed by injection molding or extrusion molding or by combining them, for example, a blower capable of saving energy in an air conditioner is provided. Since the length or size of the impeller increases in weight, it imposes a load on the components of the air conditioner, and it is difficult to construct a fan impeller that is optimal for energy saving.

An axial fan is disclosed in Japanese Unexamined Patent Publication No. 4-193.
The axial fan 34 of Japanese Patent Publication No. 95 forms a hollow layer 36 by injecting a high-pressure gas into the blades 35, but it is very difficult to control the flow of the high-pressure gas and the amount of the high-pressure gas injected into each blade 35. Due to the difficulty, it was difficult to form a stable hollow layer 36.

If the amount of the high-pressure gas to be injected is large or the amount of the resin material to be injected is small, the high-pressure gas leaks from a part of the axial fan, so that the hollow layer 36 is limited and the weight is further reduced. However, the balance during rotation is large.

Further, since time for injecting and exhausting a high-pressure gas is required, productivity is poor and cost is high.

Another problem is that the formation of the hollow layer 36 lowers the physical strength of the axial fan.

An axial fan or a mixed flow fan disclosed in Japanese Utility Model Application Laid-Open No. 58-113900 is molded, then a foamed resin 38 is mounted on the blade 37, and then a thermosetting resin is applied to the surface of the foamed resin 38. To form the cured resin film 39,
The productivity is poor and it takes time.

Further, since the general foamed resin 38 is attached as a separate component, the physical strength of the axial flow fan or the mixed flow fan is reduced, and since different materials such as a thermoplastic resin and a thermosetting resin are used, There was a problem that recycling after product disposal was difficult.

Next, a cross flow fan is disclosed in Japanese Unexamined Patent Publication No.
In the conventional cross-flow fan 40 disclosed in Japanese Patent No. 53293, since the material of the partition plate 41 and the plurality of blades 42 are different, the partition plate 41 and the blades 42 are formed as separate parts, the number of parts increases, and the partition plate 41 is formed of a foamed resin material. In this case, the molding time is long, the productivity is low, and the cost is high.

In addition, the use of a foamed resin material for the partition plate 41 has another problem that the physical strength of the blower impeller also decreases.

Alternatively, after forming the foamed resin material of the partition plate 41, it is necessary to form a different material from the resin material of the blades 42, and since the partition plate 41 is formed of the foamed resin material, the molding time is long and the productivity is high. It becomes worse and costs higher.

The foam resin material of the partition plate 41 and the blades 4
The material mixed with the second resin material is also physically unstable, and the range in which the mixed material is mixed is unstable. Therefore, the physical strength of the blower impeller is unstable, and the foamed resin material is used for the partition plate 41. Adopting this also reduces the impact strength of the fan impeller.

Further, since they are made of different materials such as a foamed resin material having an expansion ratio of 5 or less and a resin material reinforced with glass fiber,
There was a problem that recycling after product disposal was difficult.

Further, a cross-flow fan formed by combining resin molded products formed by injection molding or extrusion molding is not required to have a longer or larger cross-flow fan which can save energy of an air conditioner. Heavy cross-flow fan is heavy, which puts a load on the fan motor of the air conditioner. Long cross-flow fan is deformed by its own weight, so the imbalance becomes large. There was a problem that it was difficult to use.

The present invention has been made to solve the above-mentioned problems. First, as for the blower impeller, the present invention provides a long or large blower impeller made of, for example, a thermoplastic resin which enables energy saving of an air conditioner. The purpose is to do.

Next, with respect to the axial flow fan or the mixed flow fan, low noise and high performance can be achieved by increasing the size of the fan or forming a wing-shaped blade cross-section having a part or the whole of a plurality of blades. Since the axial fan or the mixed flow fan can be stably reduced in weight, the load on the fan motor can be reduced.

Also, it has excellent physical strength and good productivity because it does not use dissimilar materials, and it can reduce the number of man-hours for correcting imbalance and reduce the cost by reducing the weight. It is an object to provide an axial fan or a mixed flow fan.

Next, regarding the cross flow fan, since the partition plate and the blades are made of the same material and can be reduced in weight and have excellent physical strength, a long or large-sized high-performance cross flow fan is stopped. A long or large cross-flow fan that can reduce deformation due to its own weight at the time and unbalance during rotation and the like and prevent vibration can be provided.

In addition, the present invention provides a high-performance cross-flow fan which is excellent in recyclability and productivity because it is made of the same material, not dissimilar materials. The purpose is to do.

Another object of the present invention is to provide an air conditioner configured using the above-described blower impeller.

[0026]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention first provides a blower impeller with high temperature and high temperature in a thermoplastic resin material melted in a cylinder at the time of injection molding or extrusion molding. By injecting an inert gas in a supercritical state of pressure, and then performing high-speed injection molding, the inert gas foams in the thermoplastic resin material in the mold,
The molded product of the fan impeller has a fine cell structure inside,
And it becomes a molded article having a skin layer on the surface, and a fan impeller is formed.

With the above structure, a fine cell structure is provided inside the blower impeller made of a thermoplastic resin, and by providing a skin layer on the surface, water or dust can enter the cells inside the blower impeller. In addition, since it has a smooth surface without unevenness, air flows smoothly without causing turbulence on the surface of the blades of the fan impeller.

Further, a long or large blower impeller having excellent physical strength and light weight due to the fine cell layer can be obtained.

Next, for the axial flow fan or the mixed flow fan, a high temperature and high pressure supercritical inert gas is injected into the thermoplastic resin material melted in the cylinder at the time of injection molding. Injection molding is performed at high speed, and the inert gas foams in the thermoplastic resin material in the mold, so that the molded product of the axial flow fan or the mixed flow fan has a fine cell structure inside, In addition, a skin layer is formed on the surface.

According to the above configuration, the axial flow fan or the mixed flow fan made of a thermoplastic resin has a fine cell structure inside, and a skin layer is provided on the surface, so that the axial flow fan or the inside of the axial flow fan can be formed. This prevents the intrusion of water and dust into the cell and provides a smooth surface without unevenness, so that air flows smoothly without turbulence on the surface of the blades of an axial fan or mixed flow fan. The performance such as the air volume and sound of the fan or the mixed flow fan can be maintained.

Also, by having a fine cell structure, the axial flow fan or the mixed flow fan is reduced in weight. For example, in order to realize energy saving of the air conditioner, the size of the axial flow fan or the mixed flow fan of the outdoor unit is increased. It is necessary to increase the efficiency of the axial flow fan or the mixed flow fan by forming a wing-shaped blade cross-section by having a part or the whole part of the blade having a thick part. Then, the weight of the axial fan or the mixed flow fan tends to increase.

Therefore, when the axial fan or the mixed flow fan is installed in the outdoor unit of the air conditioner, the axial fan or the mixed flow fan is supported by the fan motor in a cantilever manner, and the bearing portion of the fan motor is supported. Load increases, a large torque is applied during rotation, and the fan motor or the parts that fix the fan motor are damaged, and the weight of the axial fan or mixed flow fan increases, resulting in a large imbalance during rotation. As a result, vibrations are likely to occur, and the outdoor unit body vibrates, causing problems such as noise.

However, by having a fine cell structure, it is possible to increase the size or reduce the weight of an axial flow fan or a mixed flow fan having a wing-shaped blade cross-section having a partly or entirely thicker blade. Even when incorporated in an outdoor unit, the load on the bearing of the fan motor and the torque during rotation can be reduced by its own weight.

Further, even if the axial flow fan or the mixed flow fan is rotated, the imbalance is small, and the vibration and sound of the outdoor unit are not generated.

The size of the cells foamed by using a supercritical inert gas is fine and uniform, so that the strength is excellent and the weight can be reduced. It is possible to obtain an axial-flow fan or a mixed-flow fan having a wing-shaped blade cross-section having a large-sized or partially or entirely thick blade portion capable of realizing low noise.

Further, it is possible to reduce the number of man-hours for correcting imbalance and to reduce the cost by reducing the weight. Further, since the same material is used instead of a different material, recyclability and productivity are excellent.
It is possible to obtain an axial flow fan or a mixed flow fan having a wing-shaped blade cross section that is lightweight, large in size, or has a blade-shaped cross section partially or entirely having a thick wall portion.

Next, regarding the cross flow fan, the thermoplastic resin melted in the cylinder at the time of injection molding or extrusion molding of the part of the cross flow fan in which the partition plate and the plurality of blades are made of the same thermoplastic resin material. Inject a supercritical inert gas of high temperature and high pressure into the resin material, then perform high-speed injection molding, and foam the inert gas in the thermoplastic resin material in the mold. Thereby, the molded part of the cross flow fan becomes a part having a fine cell structure inside and a skin layer on the surface, and the parts are joined by ultrasonic welding or the like to form a cross flow fan.

With the above structure, a fine cell structure is provided inside the cross flow fan made of a thermoplastic resin, and by providing a skin layer on the surface, water or dust can enter the cells inside the cross flow fan. In addition, the surface of the cross flow fan blades has a smooth surface without unevenness, so that air flows smoothly without causing turbulence, so that the performance of the cross flow fan such as air volume and sound is maintained. Can be.

Further, by having fine cells, the cross flow fan becomes light in weight. Also, in order to achieve energy saving, it is necessary to increase the efficiency of the cross flow fan by increasing the length or size of the cross flow fan, but the cross flow fan tends to be heavier. Therefore, when the cross-flow fan is installed in the indoor unit of the air conditioner, both ends of the cross-flow fan are supported by the boss and the shaft, and when the cross-flow fan becomes heavier when the indoor unit is stopped, bending occurs. When this occurs, the position of the center of gravity moves, and then, when the indoor unit is operated and the cross flow fan is rotated, a large imbalance occurs due to the centrifugal load, which causes the indoor unit to vibrate and cause problems such as noise.

However, by having a fine cell structure, it is possible to reduce the weight of a long or large cross flow fan, and since it does not bend due to its own weight even when incorporated in an indoor unit, it is necessary to rotate the cross flow fan. And there is little imbalance, and no vibration or noise of the indoor unit is generated.

A typical cell made of a foamed resin material is about 2 cells.
The air conditioner is non-uniform at over 00 μm and the physical strength is reduced, but the cell structure foamed using an inert gas in a supercritical state is fine and uniform, has excellent physical properties, and can be reduced in weight. It is possible to obtain a long or large cross flow fan that realizes energy saving.

Further, it is possible to reduce the number of man-hours for correcting the unbalance and to reduce the cost by reducing the weight. Further, since the same material is used instead of dissimilar materials, the recyclability is excellent, the number of parts does not increase, and the unbalance is reduced. Since the number of correction steps is reduced, it is possible to obtain a lightweight, long or large cross-flow fan with excellent productivity.

Next, an air conditioner is constructed by using any one of the blower impellers.

By configuring a long or large blower impeller with the above configuration, an air conditioner that can save energy can be obtained.

[0045]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention provides a base material having a fine cell structure formed by injecting a supercritical inert gas into a molten thermoplastic resin and foaming the same. A blower impeller characterized by comprising a skin layer to be formed.

According to this configuration, conventionally, for example, in order to enable energy saving of the air conditioner, it is necessary to increase the efficiency of the fan impeller by making the fan impeller longer or larger. However, it is difficult to construct a fan impeller that is optimal for energy saving by imposing a load on the components of the air conditioner due to the increase in weight. Size from 20μm to 100
A micrometer is preferable because it has excellent physical strength and can be reduced in weight, but a fine cell formed by injecting and foaming a supercritical inert gas of a blower impeller is 100 μm.
Since it has a fine and uniform cell structure of less than μm and has excellent physical strength and is lightweight, the blower impeller can be made longer or larger, thereby realizing energy saving of the air conditioner.

Also, by having a skin layer on the surface,
Prevents water and dust from entering the cells inside the fan impeller, and since the surface of the blade becomes a smooth surface, air flows smoothly without causing turbulence, maintaining the performance as a fan impeller. Can do things. In addition, it is possible to obtain a light, long or large blower impeller capable of reducing costs by weight reduction.

Another aspect of the present invention relates to an axial fan or a mixed flow fan, in which a thermoplastic resin is foamed by using a supercritical inert gas to have a fine cell structure, and a skin layer is formed on the surface. And an axial flow fan or a mixed flow fan.

According to this structure, conventionally, for example, in order to enable energy saving of the air conditioner, the axial flow fan or the mixed flow fan of the outdoor unit is enlarged, or a part of or the whole of the blade has a thick portion. It is necessary to increase the efficiency of an axial flow fan or a mixed flow fan by forming a blade-shaped blade cross section by having a blade. Or, the weight of the mixed flow fan tends to be heavy, so when the axial flow fan or the mixed flow fan is installed in the outdoor unit of the air conditioner, the axial Depending on the support state, the load on the bearing of the fan motor increases, and a large torque is applied during rotation, causing damage to the fan motor or the parts that fix the fan motor, and the axial flow fan. Because the weight of the fan or the mixed flow fan becomes heavier, the imbalance during rotation increases, and vibrations are likely to occur, causing the outdoor unit to vibrate and cause problems such as noise. It has been difficult to develop an axial or mixed flow fan having a thick wall. However, if the size of the fine cells inside the axial fan or the mixed flow fan is 20 μm to 100 μm, it is desirable because the physical properties are excellent and the weight can be reduced. The fine cell constructed by injecting and foaming a supercritical inert gas is 10
Because it has a fine and uniform cell structure of 0 μm or less, it has excellent physical strength and is lightweight, so even if it is incorporated in an outdoor unit, it can reduce the load on the bearing of the fan motor by its own weight and the torque during rotation. Yes, even when the axial fan or mixed flow fan is rotated, there is little imbalance, no vibration or noise of the outdoor unit is generated, the axial fan or mixed flow fan is enlarged, or some or all of the blades are In this case, the air conditioner can be made energy-saving. In addition, by having a skin layer on the surface, water and dust can be prevented from entering the cells inside the axial flow fan or mixed flow fan, and since the surface of the blade becomes a smooth surface, there is no turbulence The air flows smoothly, and the performance as an axial fan or a mixed flow fan can be maintained.

Further, it is possible to reduce the man-hour for correcting the imbalance and to reduce the cost by reducing the weight. Also, since the same material is used instead of a different material, the recyclability is excellent. It is possible to obtain an axial flow fan or a mixed flow fan having a light weight, a large size, or a partially or entirely thick portion of a blade having excellent properties.

Another aspect of the present invention relates to a cross-flow fan having a fine cell structure formed by foaming a thermoplastic resin with a supercritical inert gas, and having a skin layer on the surface. It is a cross-flow fan that is characterized.

According to this configuration, conventionally, in order to enable the energy saving of the air conditioner, for example, the development of a long or large cross-flow fan for the indoor unit has made the cross-flow fan's own weight heavy. When the cross flow fan is installed in the indoor unit of the air conditioner, both ends of the cross flow fan are supported by the boss and the shaft. If the position moves, and then the indoor unit is operated and the cross flow fan is rotated, a large imbalance will occur due to the centrifugal load, causing problems such as vibration and noise of the indoor unit body. Was difficult to develop.

However, if the size of the fine cells inside the cross flow fan is 20 μm to 100 μm, it is desirable because the physical strength is excellent and the weight can be reduced. The fine cells formed by injecting and bubbling active gas have a fine and uniform cell structure of 100 μm or less and have excellent physical strength and light weight. Even if the cross flow fan is rotated, the imbalance is small even when the cross flow fan is rotated, the vibration and the sound of the indoor unit are not generated, the cross flow fan can be formed in a long or large form, and the energy saving of the air conditioner is realized.

Further, by having a skin layer on the surface,
Prevents water and dust from entering the cells inside the cross flow fan, and the blades have a smooth surface, allowing air to flow smoothly without turbulence and maintaining the performance as a cross flow fan. Can do things.

Further, it is possible to reduce the number of man-hours for correcting the unbalance and to reduce the cost by reducing the weight, and since the same material is used instead of different materials, the recyclability is excellent, the number of parts does not increase, and the unbalance is reduced. Since the number of correction steps is reduced, it is possible to obtain a lightweight, long or large cross-flow fan with excellent productivity.

According to this configuration, conventionally, for example, in order to enable the energy saving of the air conditioner, the length of the fan impeller is increased or the size thereof is increased so that the efficiency of the fan impeller is improved and the fan impeller optimal for energy saving is provided. Although it was difficult to configure the air conditioner, it is possible to obtain an energy-saving air conditioner by configuring the air conditioner using any of the above-described blower impellers.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1) Embodiment 1 of the present invention will be described with reference to FIGS.

FIGS. 1 to 4 show the structure of a turbo fan of an air conditioner using a blower impeller according to an embodiment of the present invention.

The turbo fan 1 has a main plate 2 made of a thermoplastic resin, which is rotationally driven, a ring 3 arranged concentrically on the side of the main plate 2, and a space between the main plate 2 and the ring 3 in the circumferential direction. In the turbo fan 1 provided with a plurality of blades 4 arranged radially, the boss 5 is provided at the center of the main plate 2 so that the boss 5 is fastened to the shaft of the fan motor of the air conditioner to transmit the rotational drive.

The main plate 2 is internally formed by a fine cell structure layer 6 and a surface skin layer 7, and the ring 3 is internally formed by a fine cell structure layer 8 and a surface skin layer 9. In addition, the plurality of blades 4 have a layer 1 having a fine cell structure therein.
0 and the skin layer 11 on the surface.

Layer 6 having fine cell structure of main plate 2, ring 3
The cell size in the fine cell structure layer 8 and the plurality of blades 4 in the fine cell structure layer 10 is uniform at 100 μm or less.

The method for forming the layers 6, 8, and 10 having the fine cell structure and the skin layers 7, 9, and 11 on the surface is, for example, the main plate 2 of the turbofan 1 and the ring 3 disposed concentrically on the side of the main plate 2. Thermoplastic resin melted in the cylinder of an injection molding machine when injection molding a turbo fan 1 comprising a plurality of blades 4 radially arranged at intervals in a circumferential direction between a main plate 2 and a ring 3. A supercritical inert gas at a high temperature and a high pressure is injected into the resin material, for example, carbon dioxide is injected at a critical temperature of 31 ° C. or more and a critical pressure of 73 atm or more, and then injection molding is performed at a high speed. Then, the inert gas is foamed in the thermoplastic resin material in the mold, so that the layers 6, 8 and 10 having a fine cell structure and the skin layers 7, 9 and 11 on the surface are formed inside the turbo fan 1. Can form .

According to the above configuration, conventionally, for example, it is necessary to increase the efficiency by increasing the size of the turbo fan 1 of the air conditioner in order to enable energy saving of the air conditioner, but the own weight of the turbo fan 1 is heavy. Therefore, when the turbofan 1 is incorporated in an air conditioner, the load on the bearing of the fan motor increases, and a large torque is applied during rotation, which causes problems such as overload on the fan motor. Therefore, it was difficult to develop a large-sized turbo fan 1.

However, the weight of the turbo fan 1 can be reduced by 10% or more, and the load on the fan motor due to its own weight and the torque at the time of rotation can be reduced even when incorporated in the air conditioner. Load can be prevented.

By providing skin layers 7, 9 and 11 on the surface, it is possible to prevent water and dust from penetrating into the layers 6 and 8 and 10 having a fine cell structure inside the turbo fan 1 and to improve the surface of the blade. Has a smooth surface, so that air flows smoothly without causing turbulence and the performance as a turbofan can be maintained.

The layers 6, 8 and 10 having a fine cell structure foamed with an inert gas in a supercritical state are fine and uniform, having a size of 100 μm or less, and have excellent physical strength and strength. It is possible to reduce the number of man-hours for correcting imbalance and reduce the cost by reducing the weight, and it is possible to obtain a large and lightweight turbofan 1 with excellent productivity.

In addition to the turbo fan, the same effect can be obtained by increasing the size or length of the sirocco fan, for example.

(Embodiment 2) Embodiment 2 of the present invention will be described with reference to FIGS.

FIGS. 5 to 7 show the structure of an axial fan of an air conditioner according to an embodiment of the present invention.

The axial fan 12 is a thermoplastic resin, for example, a polypropylene resin (hereinafter abbreviated as PP resin), an AS resin, or an acrylonitrile / ethylene propylene / diene / styrene resin (hereinafter A / EPDM /
Calcium carbonate or talc (magnesium silicate), barium sulfate, or glass fiber (hereinafter, GF) to acrylonitrile / styrene acrylate (hereinafter abbreviated to ASA resin)
Or a hub 13 made of one or two kinds of mica (mica) mixed at about 10 to 50% by weight, and an axial flow in which a plurality of blades 14 are provided at a predetermined pitch in the circumferential direction on the outer periphery. By having the boss 15 in the center of the hub 13 with the fan 12, the boss 15 is connected to the shaft of the fan motor of the outdoor unit of the air conditioner to transmit the rotational drive.

The hub 13 has a fine cell structure layer 16 inside.
And a plurality of blades 14 are formed inside by a layer 18 having a fine cell structure and a skin layer 19 on the surface.

The cell size of the layer 16 of the fine cell structure of the hub 13 and the layer 18 of the fine cell structure of the plurality of blades 14 are uniform at 100 μm or less.

The method for forming the layers 16 and 18 having the fine cell structure and the skin layers 17 and 19 on the surface is, for example, by using the hub 13 of the axial fan 12 and the plurality of blades 14 provided at a predetermined pitch in the circumferential direction on the outer periphery. Injection of a supercritical inert gas at a high temperature and a high pressure into a thermoplastic resin material melted in an injection molding machine cylinder at the time of injection molding the axial flow fan 12 made of, for example, carbon dioxide at a critical temperature of 31 ° C. Injection is performed in a critical state of above and at a critical pressure of 73 atm or higher, and then injection molding is performed at a high speed, and an inert gas is foamed in a thermoplastic resin material in a mold, so that the inside of the blower impeller 12 is formed. Thus, the layers 16 and 18 having a fine cell structure and the skin layers 17 and 19 on the surface can be formed.

According to the above configuration, conventionally, in order to enable energy saving of the air conditioner, the axial fan 12 of the outdoor unit is increased in size, or a part or whole of the blades 14 has a thick portion. Although it is necessary to increase the efficiency of the axial fan 12 by forming a wing-shaped blade cross section, the weight of the axial fan 12 tends to increase, and therefore, the axial fan 12 is incorporated in an outdoor unit of an air conditioner. When the fan motor is used, the load on the bearing of the fan motor increases, a large torque is applied during rotation, and vibration is likely to occur due to damage to the fan motor or the parts that fix the fan motor and unbalance during rotation. Since the main body of the outdoor unit vibrates and causes a problem such as noise, it has been difficult to develop the axial fan 12 having a large size or a partially or entirely thick wall portion.

However, the weight of the axial flow fan 12 can be reduced by 10% or more, and the load on the bearing portion of the fan motor and the torque during rotation can be reduced by its own weight even when incorporated in the outdoor unit. There is little imbalance during rotation, and no vibration or noise is generated in the outdoor unit.

By providing skin layers 17 and 19 on the surface, water and dust can be prevented from entering the fine cell structure layers 16 and 18 inside the axial fan 12, and the blade surface can be smooth. Because of the surface, the air flows smoothly without causing turbulence, and the performance as the axial fan 12 can be maintained.

The size of the layers 16 and 18 of the fine cell structure foamed by using an inert gas in a supercritical state is as small as 100 μm or less and is excellent in physical strength, and is excellent in unbalance. The cost can be reduced by reducing the man-hours required for repairing and reducing the weight, and because the same material is used instead of dissimilar materials, the recyclability is excellent. It is possible to obtain a lightweight axial fan 12 having a wing-shaped blade cross-section having a part or whole of the blade 14 having a thick portion. (Third Embodiment) FIGS.
This will be described with reference to FIG.

8 to 13 show the structure of a cross flow fan of an air conditioner according to an embodiment of the present invention. The cross flow fan 20 is a thermoplastic resin, for example, acrylonitrile-styrene resin (hereinafter, referred to as acrylonitrile-styrene resin).
Glass fiber (hereinafter abbreviated as GF) mixed with about 20 to 40% by weight of AS resin or carbon fiber (hereinafter abbreviated as CF) with AS resin
Or a copolymer resin (heat-resistant polystyrene-based resin, hereinafter abbreviated as heat-resistant PS-based resin) formed from styrene and a monomer imparted with heat resistance to glass fiber (hereinafter, referred to as heat-resistant PS-based resin). GF) (about 20 to 40% by weight) and a plurality of blades 22 attached radially at equal or unequal pitches along the outer periphery. It has a substantially cylindrical shape as a whole, and has a boss 23 and a shaft 24 protruding at each end in the axial direction. The boss 23 is fastened to a shaft of a fan motor of an indoor unit of an air conditioner, and the shaft 24 is It is supported by the bearing of the indoor unit of the harmonizer.

A plurality of disk-shaped partition plates 21 are formed inside with a layer 25 having a fine cell structure and a skin layer 26 on the surface.
Further, the plurality of blades 22 have a layer 27 having a fine cell structure therein.
And a skin layer 28 on the surface.

Layer 2 having a fine cell structure of a plurality of partition plates 21
The cell size of the layer 27 having the fine cell structure of the five and the plurality of blades 22 is uniform at 100 μm or less.

The method for forming the layers 25 and 27 having the fine cell structure and the skin layers 26 and 28 on the surface is, for example, such that the disk-shaped partition plate 21 of the cross flow fan 20 is radially arranged at equal pitches or irregularly along the outer periphery. Molded article 29 comprising a plurality of blades 22 attached to the pitch, or molded article 29
When a molded product 30 for insert-molding the boss 23 or a molded product 31 for insert-molding the shaft 24 is injection-molded, a high-temperature and high-pressure Inject a critical state inert gas, for example, inject carbon dioxide in a critical state with a critical temperature of 31 ° C. or higher and a critical pressure of 73 atm or higher.
Injection molding is performed at a high speed, and the inert gas is foamed in the thermoplastic resin material in the mold, so that the cross-flow fan molded article 29, molded article 30, or molded article 31 is formed.
Can be formed with fine cell structure layers 25 and 27 and surface skin layers 26 and 28.

According to the above configuration, conventionally, it is necessary to develop a long or large-diameter form of the cross flow fan 20 of the indoor unit in order to enable energy saving of the air conditioner. When the weight of the cross flow fan 20 becomes heavy and the cross flow fan 20 is installed in the indoor unit of the air conditioner, when the indoor unit is stopped, the cross flow fan 20 is greatly bent by its own weight, and a large imbalance occurs during rotation. Problems such as vibration and noise of the indoor unit main body occurred and it was difficult.

However, 10% of the cross flow fan 20
The above-mentioned weight reduction is possible, and a long or large diameter cross flow fan 20 can be developed. Since the bending due to its own weight does not occur even when the cross flow fan 20 is incorporated in an indoor unit, the cross flow fan 20 is unbalanced even when rotated. And vibration and noise of the indoor unit are not generated.

Also, by providing skin layers 26 and 28 on the surface, water and dust can be prevented from entering the fine cell structure layers 25 and 27 inside the cross flow fan 20 and the surface of the blade is smooth. Since it becomes a surface, air flows smoothly without causing turbulence, and the cross flow fan 20
In addition, the size of the layers 25 and 27 having a fine cell structure is as fine and uniform as 100 μm or less, so that the physical strength is excellent, and the number of man-hours for correcting imbalance is reduced and the weight is reduced. Cost reduction by using the same material instead of dissimilar materials, so it is excellent in recyclability, the number of parts does not increase, and the number of man-hours for correcting imbalance is reduced, so productivity is excellent and lightweight. A long or large cross flow fan 20 can be obtained.

(Embodiment 4) Embodiment 4 of the present invention will be described with reference to FIGS.

FIG. 14 shows the structure of an outdoor unit 32 of an air conditioner constructed using the axial fan 12 according to the second embodiment of the present invention.

FIG. 15 shows a structure of an indoor unit 33 of an air conditioner configured using the cross flow fan 20 according to the third embodiment of the present invention.

In the above configuration, by increasing the size of the axial fan 12 of the outdoor unit 32 of the air conditioner or by partially or entirely thickening the blade 14, a blade-shaped blade cross section is formed. Since the efficiency of the flow fan 12 can be increased, it is possible to obtain an air conditioner that can increase the efficiency of the air conditioner and save energy.

Alternatively, the length or size of the cross flow fan 20 of the indoor unit 33 of the air conditioner can be increased and the efficiency of the cross flow fan 20 can be increased, so that the efficiency of the air conditioner can be increased and energy can be saved. An air conditioner can be obtained.

The blower impeller can be applied to other than the blower impeller described in each of the above embodiments, and the same effect can be obtained.

Further, the present invention can be applied to the number of blades other than the number of blades of the blower impeller in each of the above embodiments, and the same effect can be obtained by using a thermoplastic resin and an additive other than the examples. An inert gas (for example, N2) other than the embodiment can be used and is selected depending on the application.

The size of the cell varies depending on the purpose of weight reduction, form formation, rigidity maintenance, and the like.
Although the blower impeller according to Embodiments 1 to 3 is an air conditioner as an example, the same effect can be obtained by other than the air conditioner.

[0094]

As apparent from the above description, the present invention provides a base material having a fine cell structure formed by injecting a supercritical inert gas into a molten thermoplastic resin and foaming the molten thermoplastic resin. A blower impeller comprising a skin layer formed on a surface of a base material portion. According to this configuration, the size of fine cells inside the blower impeller is 20 μm.
If the thickness is from 100 to 100 μm, the physical properties are excellent and the weight can be reduced. It is desirable that the fine gas formed by injecting and bubbling an inert gas in a supercritical state of a blower impeller into a fine cell of 100 μm or less. With a uniform cell structure, it has excellent physical strength and is lightweight, so that the blower impeller can be made longer or larger, and energy saving of the air conditioner can be realized.

Also, by having a skin layer on the surface,
Prevents water and dust from entering the cells inside the fan impeller, and since the surface of the blade becomes a smooth surface, air flows smoothly without causing turbulence, maintaining the performance as a fan impeller. Can do things.

Further, there is an effect that it is possible to obtain a lightweight, long or large blower impeller which can reduce the cost by reducing the weight.

Further, the present invention relates to an axial fan or a mixed flow fan, wherein a thermoplastic resin is foamed by using a supercritical inert gas to have a fine cell structure and a skin layer on the surface. According to this configuration, the size of the fine cells inside the axial fan or the mixed flow fan is 20 μm to 100 μm.
m is desirable because it has excellent physical strength and can be reduced in weight, and a fine cell formed by injecting and foaming an inert gas in a supercritical state of an axial flow fan or a mixed flow fan is 100 μm or less. Because it has excellent physical strength and light weight by having a fine and uniform cell structure, it is possible to reduce the load on the bearing part of the fan motor by its own weight and the torque during rotation even if it is incorporated in the outdoor unit, In addition, even when the axial fan or the mixed flow fan is rotated, the imbalance is small, the vibration and the sound of the outdoor unit are not generated, and the size of the axial flow fan or the mixed flow fan or the thickness of a part or the whole of the blade is increased. A form having a meat portion becomes possible, and energy saving of the air conditioner is realized.

Also, by having a skin layer on the surface,
Water and dust are prevented from entering the cells inside the axial fan or mixed flow fan, and since the surface of the blade is smooth, air flows smoothly without turbulence, The performance as a flow fan can be maintained.

Further, it is possible to reduce the man-hour for correcting the imbalance and to reduce the cost by reducing the weight. Also, since the same material is used instead of different materials, the recyclability is excellent. This is advantageous in that it is possible to obtain an axial fan or a diagonal fan having a light weight, a large size, or a partially or wholly thick part of the blade with excellent characteristics.

The present invention also relates to a cross-flow fan, characterized in that a thermoplastic resin is foamed with a supercritical inert gas to form a fine cell structure and a skin layer on the surface. According to this configuration, if the size of the fine cells inside the cross flow fan is 20 μm to 100 μm, it is desirable because the physical strength is excellent and the weight can be reduced. Fine cells constructed by injecting and foaming an inert gas in a critical state have a fine and uniform cell structure of 100 μm or less and have excellent physical strength and light weight. The cross flow fan does not bend, the imbalance is small even when the cross flow fan is rotated, the vibration and sound of the indoor unit are not generated, and the cross flow fan is longer. Large form becomes possible to realize energy saving of the air conditioner. In addition, by having a skin layer on the surface, water and dust can be prevented from entering the cells inside the cross flow fan, and since the surface of the blade becomes a smooth surface, air can flow smoothly without causing turbulence. Flow, the performance as a cross-flow fan can be maintained.

Further, it is possible to reduce the number of man-hours for correcting the unbalance and to reduce the cost by reducing the weight, and since the same material is used instead of dissimilar materials, the recyclability is excellent, the number of parts does not increase, and the unbalance is reduced. Since the number of correction steps is reduced, it is possible to obtain a lightweight, long or large crossflow fan with excellent productivity.

Further, according to the present invention, by using the blower impeller for an air conditioner, it is possible to obtain an air conditioner with further improved energy saving during operation of the main body.

[Brief description of the drawings]

FIG. 1 is a perspective view of a fan impeller showing an embodiment of the present invention.

FIG. 2 is a sectional view taken along line AA in FIG.

FIG. 3 is a sectional view taken along line BB in FIG. 1;

FIG. 4 is a sectional view taken along line CC in FIG. 1;

FIG. 5 is a perspective view of an axial fan showing an embodiment of the present invention.

6 is a sectional view taken along line DD in FIG.

FIG. 7 is a sectional view taken along line EE in FIG. 5;

FIG. 8 is a perspective view of a cross flow fan showing an embodiment of the present invention.

FIG. 9 is a perspective view of a molded product including the plurality of blades.

FIG. 10 is a perspective view of a molded product obtained by insert-molding the boss.

FIG. 11 is a perspective view of a molded product in which coaxial insert molding is performed.

FIG. 12 is a sectional view of a main part of a plurality of blades in FIG. 8;

FIG. 13 is a sectional view of a main part of the plurality of partition plates in FIG. 8;

FIG. 14 is a partially cutaway perspective view of an outdoor unit of the air conditioner.

FIG. 15 is a partially cutaway perspective view of an indoor unit of an air conditioner.

FIG. 16 is a partially cutaway perspective view of a conventional axial fan having a hollow portion formed therein.

FIG. 17 is a sectional view of a blade of a conventional axial flow fan or mixed flow fan.

FIG. 18 is a perspective view of a conventional cross flow fan.

[Explanation of symbols]

 Reference Signs List 1 turbo fan 2 main plate 3 ring 4 blade 5 boss 6 layer of fine cell structure inside main plate 7 skin layer of main plate 8 layer of fine cell structure inside ring 9 skin layer of ring 10 fine layer inside blade Layer of cell structure 11 Skin layer of blade 12 Axial fan 13 Hub 14 Blade 15 Boss 16 Layer of fine cell structure inside hub 17 Skin layer of hub 18 Layer of fine cell structure inside blade 19 Blade skin Layer 20 Cross flow fan 21 Partition plate 22 Blade 23 Boss 24 Shaft 25 Layer of fine cell structure inside partition plate 26 Skin layer of partition plate 27 Layer of fine cell structure inside blade 28 Skin layer of blade 29 Partition Molded product composed of a plate and a plurality of blades 30 Molded product for insert molding of boss 31 Molded product for insert molding of shaft 32 Outdoor unit of air conditioner 33 Indoor unit of air conditioner 34 Conventional axial fan 35 Blade 36 Hollow layer 37 Blade 38 Foam resin 39 Cured resin film of thermosetting resin 40 Conventional cross flow fan 41 Partition plate 42 Blade

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Takashi Sugio 1006 Kazuma Kadoma, Kadoma City, Osaka Prefecture Inside Matsushita Electric Industrial Co., Ltd. Terms (reference) 3H033 AA02 AA18 BB02 BB06 BB07 BB08 BB09 CC01 DD06 DD25 DD26 EE00 EE06 EE11 3L049 BB07 BD01 BD02 BD03 BD04

Claims (4)

[Claims] 1. A base material part having a fine cell structure formed by injecting a supercritical inert gas into a molten thermoplastic resin and foaming the base material, and the base material part made of the same material as the thermoplastic resin. A blower impeller comprising: a foam-free skin layer formed on the surface of the blower. 2. The impeller according to claim 1, wherein the impeller is an axial-flow or mixed-flow blower. 3. The blower impeller according to claim 1, wherein the blower is a cross-flow type blower impeller. 4. An air conditioner comprising the blower impeller according to claim 1. Description: