JP2003336893A - Ceiling cassette type air conditioner - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a ceiling cassette type air conditioner wherein easily a space for storing a cosmetic panel fitting in a drain plate is formed without using a piece, and the cost is reduced. <P>SOLUTION: This ceiling cassette type air conditioner is provided with: a heat exchanger 6; the drain plate 7 comprising a drain sheet 12 receiving drain water produced from the heat exchanger and a dew condensation preventing foam member 13 provided by a foam integral molding in the lower surface of the drain sheet; and a decorative panel 23 attached to the drain plate and disposed exposing to a room inside from a ceiling board of the room to be air conditioned. This air conditioner is also provided with: the decorative panel fitting 29 provided in the decorative panel; a side wall 19a and a bottom wall 19b integrally provided in the drain sheet constituting the drain plate, releasing foaming in the foam integral molding of the foam member, and forming the space 20 capable of storing the decorative panel fitting; and a metal fixture 22 attached to the space formed of the side wall and the bottom wall by the foam integral molding of the foam member and supporting the decorative panel by locking the decorative panel fitting. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a ceiling cassette type air conditioner mounted on the ceiling of an air-conditioned room, and more particularly to a drain tray formed by foaming integral molding.

[0002]

2. Description of the Related Art Generally, there is known an air conditioner of a ceiling cassette type in which a main body of the apparatus is buried under the ceiling of an air-conditioned room. This ceiling cassette type air conditioner has a structure in which only the decorative panel is exposed from the ceiling plate, and the occupants do not feel pressure.

Usually, in the ceiling cassette type air conditioner, the decorative panel is attached to the drain tray for receiving drain water generated from the heat exchanger from the lower surface side of the ceiling plate, that is, the air-conditioned room side.

FIG. 8 shows an upside down configuration of a drain tray provided in a conventional ceiling cassette type air conditioner. That is, in the use state, the drain tray a is arranged with the decorative panel mounting side A facing the air-conditioned room side.

The drain tray a is formed of a foam material having a heat insulating property in order to prevent the generation of dew condensation by receiving low temperature drain water generated from a heat exchanger (not shown).

Decorative panel mounting side A of this drain dish a
A plurality of mounting brackets b are provided at predetermined intervals over the entire circumference. The decorative panel c is attached via the mounting bracket b.

FIG. 9 is a perspective view of the mounting bracket b.
The mounting bracket b is in the posture shown here, and the drain tray a in FIG.
Attached to. Each of the mounting brackets b has a rectangular plate body d, and bent portions e are provided at both ends in the width direction of the rectangular plate body d to maintain strength.

Further, an elongated hole portion f is provided along the longitudinal direction at substantially the center of the rectangular plate body d, and one side g of this elongated hole portion f is cut and raised to the inner surface side to form a plate. A claw portion h that is inclined at a predetermined angle with respect to the plate surface of the body d is formed.

Then, the rectangular plate body d in the mounting bracket b
Leg portions i bent in an L shape are integrally provided at both ends in the longitudinal direction. This leg i is the drain plate a
When the foam is integrally molded, the metal fitting is embedded in the foam member, and the mounting bracket b is integrally fixed to the drain tray a.

The mounting bracket b thus constructed is
As shown in FIG. 8, the decorative panel c is attached to the drain tray a by hooking a decorative panel fitting j formed in a hook shape provided on the decorative panel (only a part is shown) c.

To explain further, since the surface of the rectangular plate d of the mounting bracket b is formed flush with the surface of the drain tray a on the decorative panel mounting side A, the rectangular plate d and the leg portion i are formed. A space k for accommodating the decorative panel metal fitting j is required in a portion surrounded by and.

Therefore, conventionally, when the drain tray a is foam-molded, a dedicated piece 1 is fitted in the portion surrounded by the rectangular plate body d and the leg portion i of the mounting bracket b, and the arrow a is shown in FIG. Set in place on the mold as shown.

A foam material is filled around the mounting bracket b and the piece 1 in the mold, but the presence of the piece 1 allows the foam material to escape and so-called foam removal. After the foam molding is completed, the frame 1 is pulled out in the direction indicated by the arrow B, so that the space portion k is formed in the drain dish a while the mounting bracket b remains.

Such a ceiling cassette type air conditioner is provided with a blower, a bell mouth, an electric parts box and the like in addition to the heat exchanger, the drain tray and the decorative panel.

In particular, the bell mouth and the electric component box are also attached to the drain tray through the dedicated attachment fittings, like the decorative panel c. That is, when the drain tray was foam-molded, the dedicated mounting metal fitting was embedded in the foam material and mounted using the mounting screws.

[0016]

However, as in the conventional case, in order to form the above-mentioned space in the drain dish, as many pieces as the number of decorative panel metal fittings are required, and the work for removing the foam must be performed. It was very troublesome.

As a result, there is a problem that not only the number of manufacturing steps of the drain dish increases but also the manufacturing cost increases.

Further, as the number of components mounted on the drain tray, such as the bell mouth and the electrical parts box, increases, the stress applied to the drain tray increases, and the drain tray is likely to be deformed or cracked due to aging. Is likely to occur.

Further, due to deformation caused by stress applied to the drain tray, the clearance between the side surface of the heat exchanger and the side surface of the drain tray cannot be controlled, and drain water generated from the heat exchanger is discharged to the outside of the drain tray. There are problems such as dripping and drain water freezing in a narrow gap to reduce the heat exchange efficiency of the heat exchanger.

An object of the present invention is to provide a ceiling cassette type air conditioner capable of easily forming a space portion for accommodating a decorative panel metal fitting in a drain tray without using a top during foam molding and achieving a low cost. To provide.

[0021]

According to a first aspect of the present invention, a heat exchanger, a drain sheet for receiving drain water generated from the heat exchanger, and dew condensation formed on the lower surface of the drain sheet by foaming integral molding. A ceiling cassette type air conditioner comprising: a drain tray including a foaming member for prevention; and a decorative panel attached to the drain tray and exposed from the ceiling plate of an air-conditioned room to the room. Is integrally provided on the decorative panel fitting provided on the drain sheet and the drain sheet constituting the drain tray, and escapes foaming when the foaming member is integrally foamed to form a space portion capable of accommodating the decorative panel fitting. The foamed member is attached to the wall portion and the space portion formed by the wall portion by foaming integral molding, and the decorative panel metal fitting is hooked to the upper portion so The ceiling cassette type air conditioner and having a mounting bracket for supporting the decorative panel.

According to a second aspect of the present invention, there is provided a heat exchanger, a drain sheet for receiving drain water generated from the heat exchanger, and a foam member for preventing dew condensation provided on the lower surface of the drain sheet by integral foam molding. In a ceiling cassette type air conditioner equipped with a drain dish composed of, a mold integrally formed on the drain sheet constituting the drain dish,
There is provided a ceiling cassette type air conditioner having an attachment part for attaching components such as an electric parts box and a bell mouth.

The invention according to claim 3 is characterized in that a reinforcing rib is integrally provided on the wall portion and the mounting portion of the drain sheet. Located in the ceiling cassette type air conditioner.

According to a fourth aspect of the present invention, a heat exchanger, a drain sheet that accommodates a lower end portion of the heat exchanger and receives drain water generated from the heat exchanger, and a foam integral molding on the lower surface of the drain sheet. In a ceiling cassette type air conditioner provided with a drain plate composed of a foam member for preventing dew condensation, the mold is integrally molded with the drain sheet that forms the drain plate, and abuts against the side surface of the heat exchanger. In addition, the ceiling cassette type air conditioner is provided with a regulating means for ensuring a gap between the drain seat side surface and the heat exchanger side surface.

According to the present invention, since the space portion for accommodating the decorative panel fitting can be formed in the drain tray without using a top during foam molding, the ceiling cassette type air conditioner can be manufactured at low cost. .

[0026]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.

1 to 5 show a first embodiment of the present invention, FIG. 1 is an exploded view of a ceiling cassette type air conditioner, FIG. 2 is an assembly diagram of a ceiling cassette type air conditioner, and FIG. FIG. 4 is a schematic view of the mounting portion between the drain tray and the decorative panel, FIG. 4 is a schematic view of the mounting portion between the drain tray and the electric component box, and FIG.
[Fig. 3] is a perspective view of a mounting bracket.

The ceiling cassette type air conditioner shown in FIG. 1 has a box body 2. This box body 2 has a substantially rectangular shape in plan view, but has an octagonal shape by omitting four corners.
a and a side plate 2b provided on each side of the upper surface wall 2a, and the lower surface of the box body 2 is open.

As shown in FIG. 2, the box body 2 is suspended and fixed to the back of the ceiling by an appropriate means, and the opening portion of the lower surface faces the opening portion 3a provided in the ceiling plate 3. . A heat insulating material 4 is provided in close contact with a predetermined position on the inner surface of the box body 2.

A fan motor 5m constituting the blower 5 is provided inside the box body 2. This fan motor 5m
Is attached and fixed to approximately the center of the upper surface wall 2a, and the rotating shaft 5a protruding downward is oriented in a substantially vertical direction. A fan 5f is fitted on the lower end of the rotary shaft 5a.

The blower 5 rotates the fan motor 5m to suck in air from the lower side of the fan 5f and blow the sucked air in the circumferential direction of the fan 5f.

A heat exchanger 6 having a substantially rectangular frame shape in plan view is arranged around the blower 5. This heat exchanger 6
Is set at a position for receiving the airflow blown from the blower fan 5f, and constitutes a refrigeration cycle together with a compressor, an outdoor heat exchanger, and the like in an outdoor unit (not shown).

A rectangular frame-shaped drain tray 7 is provided on the lower side of the heat exchanger 6. As shown in FIG. 1, the drain tray 7 has protrusions 8 at the four corners, and the protrusions 8 are supported by the heat insulating material 4 so that the box 2
Is fitted into the lower surface opening of the so as to close the opening.

A concave portion 9 is formed on each side of the drain tray 7 by a pair of adjacent protruding portions 8. Thereby, as shown in FIG. 2, the inner surface of the box body 2 and the drain tray 7 are
Vent holes 10 that communicate with each other vertically are formed by the recesses 9 between the respective sides.

The drain tray 7 is provided with a receiving groove 11 over the entire circumferential direction. The receiving groove 11 has an opening surface facing upward, and the lower end of the heat exchanger 6 is housed therein.

As shown in FIGS. 2 and 3, the drain tray 7 is
The drain sheet 12 receives drain water generated from the heat exchanger 6, and a foaming member 13 provided on the lower surface of the drain sheet 12 and having heat insulating properties.

The drain sheet 12 is provided with a plurality of protrusions 14 as restriction means on the upper surface of the bottom of the receiving groove 11 at predetermined intervals in the circumferential direction of the drain sheet 12.

These protrusions 14 are circumscribed on the side surfaces of the lower end portion of the heat exchanger 6, whereby a predetermined gap 50 is secured between the heat exchanger 6 and the receiving groove 11 of the drain sheet 12. .

Further, a plurality of bell mouth mounting portions 15 for mounting a bell mouth 31 as a component to be described later are provided at the inner edge of the lower surface of the receiving groove 11 portion of the drain sheet 12 with respect to the circumferential direction of the drain sheet 12. Are provided at predetermined intervals. Screw holes 16 are provided in these bell mouth attachment portions 15.

Further, the receiving groove 1 of the drain sheet 12
A plurality of panel mounting portions 18 are provided on the bottom surface of one portion.
Are provided at predetermined intervals in the circumferential direction of the drain sheet 12.

These panel mounting portions 18 have four side walls 19a surrounded by a rectangular shape in a plan view, and the bottom wall 1 provided over the end edges of the side walls 19a on the receiving groove 11 side.
9b constitutes a wall portion, and has a space portion 20 defined by the side wall 19a and the bottom wall 19b.

Therefore, the space 20 has an opening surface 21.
Is directed downward, and each opening surface 21 is provided with a mounting bracket 22 described later. The panel mounting part 1
A decorative panel 23 is attached to the panel 8 through the mounting brackets 22.

Further, as shown in FIGS. 2 and 4, a plurality of electric component box mounting portions 17 for mounting the electric component box 34 as a component are mounted on the inner side of the drain sheet 12 in the radial direction. Are provided at predetermined intervals in the circumferential direction. Screw holes 51 are provided in each of the electric component box mounting portions 17.

As the material of the drain sheet 12, a moldable synthetic resin material such as ABS is used, and the above-mentioned protrusion 14, bell mouth mounting portion 15, electrical component box mounting portion 17, and panel mounting portion 18 are used. Is
It is formed integrally with the drain sheet 12.

On the other hand, the foam member 13 is integrally provided on the lower surface of the drain sheet 12 by foam integral molding, as shown in FIGS. That is, the drain sheet 12 molded into a desired shape is set in a mold for foam molding, a liquid foam material is supplied to the lower surface side of the drain sheet 12, and the foam material is foamed to form a drain. The foam member 13 is provided on the lower surface of the sheet 12 in a predetermined shape and thickness.

The opening surface 21 of the panel mounting portion 18 integrally molded with the drain sheet 12, the lower end surface 15a of the bell mouth mounting portion 15, and the electrical component box mounting portion 1 are formed.
The lower end surface 17 a of No. 7 is exposed from the lower surface of the foam member 13.

As shown in FIG. 5, the mounting bracket 22 described above is used.
Has a rectangular plate 24. Side plate portions 25 are integrally bent at both ends of the rectangular plate body 24 in the width direction,
The strength of the mounting bracket 22 is increased.

Further, an elongated hole portion 26 is provided along the longitudinal direction substantially at the center of the rectangular plate 24 in the width direction, and one side 27 of this elongated hole portion 26 is cut and raised to the inner surface side to be machined. A claw portion 28 that is inclined at a predetermined angle with respect to the plate surface is formed.

The legs 2 bent in an L shape are formed at both ends of the mounting plate 22 in the longitudinal direction of the rectangular plate 24.
4a are integrally provided.

As shown in FIG. 3, the mounting bracket 22 is foamed with the pair of side plate portions 25 and the leg portions 24a fitted so as to cover the outer surfaces of the side walls 19a constituting the panel mounting portion 18, respectively. It is set in the mold for molding.

Then, the side plate portion 25 and the leg portion 24
a and the side wall 19a.
The mounting bracket 22 is integrally fixed to the panel mounting portion 18 by being embedded between the panel mounting portion 18 and the panel mounting portion 18.

On the other hand, the decorative panel 23 is provided with a decorative panel fitting 29 at a position facing the mounting fitting 22. The decorative panel fitting 29 is formed in a state in which a hook portion 30 that is bent into a substantially L shape projects from the decorative panel 23.

Then, the hook portion 3 of the decorative panel metal fitting 29 attached to the decorative panel 23 on the claw portion 28 of the mounting metal fitting 22.
0 is hooked, whereby the decorative panel 23 is attached to the lower surface side of the drain tray 7.

The decorative panel fitting 29 is in a state of being hooked on the claw portion 28 of the mounting fitting 22, and the side wall 1
It is adapted to be housed in a space portion 20 defined by 9a and the bottom wall 19b.

As shown in FIG. 2, a bell mouth 31 is provided inside the drain tray 7. The bell mouth 31 expands in diameter as it goes downward, and its lower end forms a flange portion 32 that extends substantially horizontally outward in the radial direction.

As shown in FIG. 3, the flange portion 32 is formed with an insertion hole 32a at a position facing the screw hole 16 formed in the bell mouth mounting portion 15.
The bell mouth 31 is attached and fixed to the drain sheet 12 by inserting the attachment screws 33 into the insertion holes 32a and screwing the attachment screws 33 into the screw holes 16.

As shown in FIG. 2, an electric parts box 34 is provided between the bell mouth 31 and the drain sheet 7. The electric component box 34 is composed of a dish-shaped body arranged with its opening surface facing downward.

An opening 34b is formed in the upper wall 34a of the electric component box 34, and a part of the bell mouth 31 projects from the opening 34b. The lower end of the electrical component box 34 is placed on the upper surface of the flange portion 32 of the bell mouth 31.

As shown in FIG. 4, a mounting hole 35 is formed in the upper surface wall 34a of the electric component box 34 at a position facing the screw hole 51 formed in the electric component box mounting portion 17 of the drain sheet 12. It is provided.

As a result, the mounting hole 35 provided in the electric component box 34 is opposed to the screw hole 51 of the electric component box mounting portion 17, and the mounting screw 36 is screwed into the screw hole 51, whereby the electric component is mounted. The box 34 is attached and fixed to the drain sheet 12.

As shown in FIG. 2, the lower end opening of the box body 2 is closed by the decorative panel 23 attached to the drain sheet 12 as described above. The decorative panel 23 has a substantially rectangular shape in a plan view and is exposed from the ceiling plate 3 to the air-conditioned room. A suction port 37 is provided in the central portion of the decorative panel 23, and a plurality of blowout ports 38 are provided in the peripheral portion.

That is, the room air sucked from the suction port 37 by the blower 5 is guided to the lower end opening of the bell mouth 31 as the primary side air, and the bell mouth 3
1 is guided by 1 to be guided to the blower fan 5f from this upper end opening.

On the other hand, each outlet 38 is provided so as to face the ventilation hole 10 of the drain tray 7, and the air passing through the heat exchanger 6 is used as the secondary side air passing through the outer surface side of the bell mouth 31 as described above. Guided to the outlet 38 through the ventilation hole 10,
The air is blown out from the air outlet 38 into the air-conditioned room.

According to the above-configured ceiling cassette type air conditioner, the drain tray 7 is composed of the drain sheet 12 and the foam member 13 provided on the lower surface of the drain sheet 12, and the foam is released to the drain sheet 12. The side wall 19a and the bottom wall 19b, which are wall portions for the above, are integrally provided.

Therefore, the space portion 20 for accommodating the decorative panel fitting 29 can be formed only by adding the foaming member 13 to the lower surface of the drain sheet 12 by foaming integral molding. Can be reduced, thereby reducing the manufacturing cost.

Further, the bell mouth attachment portion 15 and the electric component box attachment portion 17 are integrally provided on the drain sheet 12, and the components such as the bell mouth 31 and the electric component box 34 are attached to each of them.

Therefore, a metal plate or the like for attachment is not required to attach these components, so that the number of components can be reduced and the number of attachment steps for the drain tray 7 can be reduced.

Further, a projection 14 is provided in the receiving groove 11 portion of the drain sheet 12 so that the side surface of the heat exchanger 6 abuts, and a predetermined portion between the side surface of the heat exchanger 6 and the side surface of the receiving groove 11 is provided. A gap 50 is secured.

Therefore, the clearance between the side surface of the heat exchanger 6 and the side surface of the drain tray 7 can be controlled, and the drain water generated from the heat exchanger 6 can be dropped outside the drain tray or the drain water can be drained in a narrow clearance. Can be completely solved, and the problem that the heat exchange efficiency of the heat exchanger 6 is lowered can be completely solved.

As the material of the drain sheet 12, a moldable synthetic resin material such as ABS was used. Therefore, at the same time when the drain sheet 12 is molded, the bell mouth mounting portion 15, the electrical component box mounting portion 17, the decorative panel mounting portion 18, and the protruding portion 14 can be integrally formed on the drain sheet 12, and the manufacturing process is further improved. Can be reduced.

FIGS. 6 and 7 show a second embodiment of the present invention, and FIG. 6A is a perspective view of a decorative panel mounting portion,
FIG. 6B is a cross-sectional view of the decorative panel mounting portion, FIG.
FIG. 7A is a schematic view of a bell mouth mounting portion, and FIG. 7B is a schematic view of an electric component box mounting portion.

In this embodiment, reinforcing ribs 41, 42 and 43 are integrally provided on the decorative panel mounting portion 18, the bell mouth mounting portion 15 and the electric component box mounting portion 17 formed on the drain sheet 12, respectively. It was

Therefore, even though the drain panel 12 has the components such as the decorative panel 23, the bell mouth 31, and the electrical component box 34 attached thereto, the load of these components causes a relatively large stress to the drain tray 7. However, the deformation due to it can be suppressed.

Furthermore, since it is difficult for cracks to occur in the drain sheet 12 due to aging, the durability of the drain tray 7 can be further improved.

As shown in FIG. 6 (B), the end faces of the ribs 41 formed on the panel mounting portion 18 do not interfere with the mounting of the mounting bracket 22, and the panel mounting portion 1
It is located closer to the bottom wall 19b than the opening surface 21 of No. 8 is.

[0076]

According to the present invention, a space for accommodating a decorative panel fitting can be formed in the foam member of the drain tray simply by foaming the foam material on the lower surface side of the drain sheet, which is low in cost. The effect is obtained.

[Brief description of drawings]

FIG. 1 is an exploded view of a ceiling cassette type air conditioner showing a first embodiment of the present invention.

FIG. 2 is an assembly view of the ceiling cassette type air conditioner according to the first embodiment of the present invention.

FIG. 3 is a schematic view showing a mounting portion of the drain tray and the decorative panel according to the first embodiment of the present invention.

FIG. 4 is a schematic view showing a mounting portion of the drain tray and the electric component box according to the first embodiment of the present invention.

FIG. 5 is a perspective view of a mounting bracket according to the first embodiment of the present invention.

FIG. 6 shows a second embodiment of the present invention, (A) is a perspective view of a decorative panel mounting portion, and (B) is a sectional view of the decorative panel mounting portion.

7A and 7B show a second embodiment of the present invention, FIG. 7A is a schematic view of a bell mouth mounting portion, and FIG. 7B is a schematic view of an electrical component box mounting portion.

FIG. 8 is a schematic view of a conventional drain tray.

FIG. 9 is a perspective view showing a configuration of a conventional mounting bracket.

[Explanation of symbols]

6 ... Heat exchanger 12 ... Drain sheet 13 ... Foamed member 7 ... Drain plate 23 ... Makeup panel 29 ... Decorative panel metal fittings 20 ... Space 19a ... Side wall 19b ... bottom wall 22 ... Mounting bracket 31 ... Bellmouth 34 ... Electrical component box 41, 42, 43 ... Ribs 50 ... gap 14 ... Projection

Claims (4)

[Claims] 1. A drain tray comprising a heat exchanger, a drain sheet for receiving drain water generated from the heat exchanger, and a dew condensation preventing foam member provided on the lower surface of the drain sheet by foam integral molding. A ceiling cassette type air conditioner having a decorative panel attached to the drain tray and exposed from the ceiling plate of the air-conditioned room to a room, comprising: a decorative panel fitting provided on the decorative panel; A wall portion that is integrally provided on the drain sheet that forms the dish and that escapes foam when the foam member is integrally foam-molded and that forms a space that can accommodate the decorative panel fitting, and the wall portion. A mounting bracket that is attached to the space by foaming integral molding of the foaming member and that supports the decorative panel by hooking the decorative panel bracket. Ceiling cassette type air conditioner characterized in that it comprises a. 2. A drain comprising a heat exchanger, a drain sheet for receiving drain water generated from the heat exchanger, and a foam member for preventing dew condensation provided on the lower surface of the drain sheet by integral foam molding. A ceiling cassette type air conditioner equipped with a dish, characterized in that it is integrally molded with the drain sheet constituting the drain dish, and has an attachment portion for attaching components such as an electric component box and a bell mouth. Ceiling cassette type air conditioner. 3. The ceiling cassette type air conditioner according to claim 1, wherein a reinforcing rib is integrally provided on the wall portion and the mounting portion of the drain sheet. Machine. 4. A heat exchanger, a drain sheet for accommodating a lower end portion of the heat exchanger and receiving drain water generated from the heat exchanger, and a lower surface of the drain sheet formed by foaming integral molding to prevent dew condensation. In a ceiling cassette type air conditioner equipped with a drain tray composed of a foaming member for use in a vehicle, the drain seat constituting the drain tray is integrally molded, abuts against the heat exchanger side surface, and the drain seat side surface is formed. A ceiling cassette type air conditioner characterized by comprising a regulation means for ensuring a gap between the heat exchanger and the side surface of the heat exchanger.