JP2005127176A - Turbofan and manufacturing method for turbofan - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive turbofan by constituting a configuration having no regulation in a shape of a blade of the turbofan to facilitate improvement of performance and constituting a simple mold structure while reducing its weight and improving productivity. <P>SOLUTION: Since the blade 5 of the turbofan is made hollow and is attached to a main plate 4, a complicated mold is unnecessary, and design of free blade shape becomes possible to provide the turbofan having high performance. By molding the blade by blow molding or pouring high pressure gas, a wall face of the blade 5 is uniform and its thickness becomes small. By providing a first fitting part 9 in the blade 5 and a second fitting part 11 in a suction ring 10 and fitting them mutually, it can be assembled without fixing by ultrasonic welding and bonding to provide the simple turbofan. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a turbofan used as a fan provided in an air conditioner, for example, and a manufacturing method thereof.

  A conventional turbofan will be described with reference to FIGS. 8 to 11 by taking an air conditioner as an example. FIG. 8 is a schematic diagram of the structure of an air conditioner provided with a ceiling-embedded indoor unit 36. As shown in FIG. 8, the blower circuit in the ceiling-embedded indoor unit 36 includes a suction portion 37, an air filter (not shown). ), A heat exchanger (not shown), a turbo fan (not shown), and an air flow passage flowing through the blow-out portion 38. Therefore, the turbofan is connected to an electric motor (not shown) and is driven to rotate.

  The configuration of this portion will be described in detail with reference to FIGS. The turbo fan 39 includes a tapered portion 2 formed in a horn shape from the outer periphery of the boss 1 engaged with a motor shaft (not shown), and a circular portion 3 extending from the outer periphery in a direction perpendicular to the axial direction of the boss 1. The main plate 4 is composed of a plurality of blades 5 connected to the front end portion of the main plate 4 and provided at an arbitrary interval, and a suction ring 10 installed on the other end portion of the blades 5.

  Further, for the purpose of reducing the noise, the blade 5 employs a cross-sectional wing shape in which the leading end of the main plate 4 is a thin portion 40 and becomes a thick portion 41 toward the axial direction of the boss 1 as shown in FIG. Further, as shown in FIG. 10, in order to reduce the weight of the turbofan, corner R portions 42 are provided at the corners of the blade 5 and the main plate 4, and the thickness of the corner R portions 42 is made uniform. 43 (see, for example, Patent Document 1).

  The main plate 4 and the plurality of blades 5 are integrally injection-molded, and are obtained by ultrasonic welding or bonding to the plurality of blades 5 after forming the suction ring 10 separately.

Further, as shown in FIG. 11, the turbo fan 39 may be configured such that the blade 5 is formed by the cavity 45 of the first movable side mold 44 and the core 47 of the second movable side mold 46 (for example, Patent Document 2).
Japanese Utility Model Publication No. 4-116698 (1st page, FIG. 1) JP-A-7-103184 (3rd, 4th page, FIG. 5)

  However, in the configuration of the conventional turbofan, when the main plate 4 and the plurality of blades 5 are integrally formed by injection molding, since the thin portion 40 and the thick portion 41 of the blade coexist, the resin flow is not uniform, Since it becomes easy to flow into the thick part 41, it is easy to become a short shot. In order to prevent this, the injection pressure and the injection amount are increased, and the variation in the density of the resin becomes large. Therefore, the unbalance generated when the turbo fan rotates is increased. Further, since the resin is injected and filled into the thick portion 41, the cooling time becomes very long and the molding takes time. In addition, since the thick portion 41 is filled with resin, there is a problem that an expensive turbofan is obtained due to the heavy resin weight.

  In addition, the main plate 4 and the plurality of blades 5 that are integrally formed have a problem in assembling such that it takes time and effort to ultrasonically weld or bond the suction ring 10.

  Further, the shape of the blade 5 for improving the performance is substantially perpendicular to the main plate 4 and the thin portion 40 is inclined in the direction opposite to the rotation direction in the middle of the suction ring 10 in the middle of the suction ring 10 and the thick portion 41. It is desirable to provide a twisted portion 12 on the inner peripheral side that falls in the rotational direction.

  In the invention according to Patent Document 2, the blade 5 of the turbo fan 39 is formed by the cavity 45 of the first movable side mold 44 and the core 47 of the second movable side mold 46. Since the shape of the blade 5 formed by the core 47 can only be a shape parallel to the opening direction of the die because it can move in the axial direction of the die from 47, the twisted portions 12 and 13 cannot be formed and the shape of the blade It is impossible to design a blade that is restricted and free, and a high-performance turbo fan cannot be expected. Further, the complicated mold structure of the cavity 45 of the first movable side mold 44 and the core 47 of the second movable side mold 46 has a problem that it is difficult to perform maintenance and inspection and is an expensive mold.

  The present invention solves such a conventional problem, and it is easy to improve the performance by expanding the degree of freedom in the design of the blade shape of the turbofan, and it is lightweight and improves productivity while rotating. The object is to provide an inexpensive turbofan with a simple mold structure that is well balanced.

  In order to solve the above-mentioned problems, the turbofan of the present invention is a turbofan configured by arranging a plurality of blades between a rotationally driven main plate and a suction ring, and the blades are hollowly molded and attached to the main plate. It is characterized by.

  With the above configuration, the blade is hollow-molded separately from the main plate and suction ring and then attached to the main plate, so that it can be easily hollow-molded without the need for a complicated mold structure and can be reduced in weight. Since the restriction on the blade shape is relaxed, the blade shape can be freely designed and a high-performance turbo fan can be obtained.

  Another invention of the present application is characterized in that the blade has a thick part and a twisted part, and at least a part of the thick part is hollow-molded.

  By hollow molding of the blade, a lightweight and thick blade is obtained, and an inexpensive turbofan is obtained.

  Another invention of the present application is characterized in that the main plate side of the blade has a flange portion and the blade is fixed to the main plate by insert molding.

  With the above configuration, when the main plate is molded, the blade can be inserted on the basis of the flange so that the positioning can be easily performed. After the main plate is molded, the main plate and the flange of the blade are fused and integrated into a strong turbofan. Is obtained.

  According to another invention of the present application, the blade is hollowly formed from the side of the main plate, and at the same time, a fitting portion is formed on the side to which the suction ring is attached.

  With the above configuration, the first fitting portion is formed on the suction ring side by providing a hole generated in the hollow molding of the blade on the main plate side, and the blade is provided by providing the second fitting portion on the suction ring side. The suction ring is not fixed by ultrasonic welding or bonding, but it is easy to assemble and obtain an inexpensive turbo fan by simply engaging the first fitting part of the blade and the second fitting part of the suction ring. It is done.

  According to another invention of the present application, in a turbofan configured by arranging a plurality of blades between a rotationally driven main plate and a suction ring, the blades are inserted in a step of forming the main plate after hollow forming the blade. Thus, the manufacturing method is characterized by integrating the main plate and the blade.

  By the above manufacturing method, a hollow layer can be formed in the thick part of the blade, and the wall surface of the blade can be made uniform and thin, so that the molding time is shortened by shortening the cooling time, and the molding of the main plate is Since it has a simple mold structure, the suction ring can be molded in the same mold as the main plate, so that an inexpensive turbofan can be provided.

  As is apparent from the above, according to the turbofan and the turbofan manufacturing method of the present invention, it is possible to reduce the number of molding and assembling steps with a light weight, and to require a complicated mold with a good balance during rotation. Therefore, an inexpensive turbo fan can be obtained. In addition, since the blade shape can be freely designed without being restricted by the mold structure, it is possible to develop a high-performance turbo fan.

  Embodiments of the present invention will be described below with reference to the drawings. In addition, about embodiment of this invention, although the form using the turbo fan used for the ceiling embedded type indoor unit of an air conditioner is demonstrated, the form to which this invention is applied is not limited to this, A fan provided with a thick blade has the same effect.

  The components shown in FIGS. 9 to 11 are denoted by the same reference numerals, and detailed description thereof and description of coupling relationships with other components are omitted.

(Embodiment 1)
First, a first embodiment according to the present invention will be described with reference to FIG. FIG. 1 is an exploded perspective view of an embodiment of the present invention, in which a turbofan 39 has a tapered portion 2 formed in a horn shape from the outer periphery of a boss 1 engaged with a shaft (not shown) of an electric motor, and a boss from the outer periphery. A main plate 4 made of a circular portion 3 and a plurality of blades 5 hollowly formed in the circular portion 3 are attached at an arbitrary interval in a direction perpendicular to the axial direction of one. These blades 5 are mounted so as to be inclined so that the front end portion 6 is located on the inner peripheral side of the main plate 4 and the rear end portion 7 is located on the outer peripheral side, and has a flange 8 on the main plate side. 1, the suction ring 10 has a second fitting portion 11, and the suction ring 10 is constructed on the other end of the blade 5.

  Next, the form of the blade 5 will be described with reference to FIG. FIG. 2C is a cross-sectional shape of the blade 5 on the main plate side, the tip 6 on the inner peripheral side of the main plate 4 is thick, and the rear end 7 on the outer peripheral side of the main plate 4 is thin. FIG. 2D shows a cross-sectional shape on the suction ring side, where the tip end portion 6 falls to the counter-rotation direction side while the wall thickness becomes larger, and the rear end portion 7 falls to the rotation direction side while remaining thin. A blade 5 having a circumferentially twisted portion 12 and a circumferentially twisted portion 13. By adopting the shape of the blade 5 as described above, the blade 5 has a high performance that produces air volume on the main plate 4 side and quiets on the suction ring 10 side.

  FIG. 2E shows a first fitting portion 9 on the suction ring 10 side, which is composed of a rib 14 and a stopper 15 provided at the tip thereof. As shown in FIG. 3, a second fitting of the suction ring is performed. When engaged with the joint portion 11, the suction ring 10 is sandwiched and fixed by the stopper 15.

  The corner portion 16 of the stopper 15 has an R shape to prevent noise. Further, by providing a flange 8 on the main plate 4 side, when the blade 5 is insert-molded when the main plate 4 is molded, the blade 5 can be easily set, and the resin and the flange 8 are melted when the main plate 4 is molded. And become integrated.

  Using the blow molding method to form the blade 5 as described above, a hole 17 generated at that time is provided on the flange side to form a wing shape having a twisted portion, and the wall surface of the hollow layer 18 is It is thin and has a uniform thickness, the molding time is shortened, and the first fitting portion 9 and the flange 8 can be formed.

  Next, a method other than the blow molding will be described with reference to FIG. FIG. 4 is a cross-sectional view of the blade 5 mold and shows a molding flow.

  First, as shown in FIG. 4A, after the movable mold 21 and the fixed mold 20 are closed, the resin melted in the cylinder 22 of the molding machine is injected into the cavity 19 through the spool runner 23. .

Next, as shown in FIG. 4B, a resin 24 whose volume is 30 to 70% of that of the cavity 19 is injected from the flange side 25 of the cavity 19, and 100 kg from the gas injection port 26 provided on the flange side 25. The hollow layer 18 is also formed in the thick part 27 of the blade by injecting a high-pressure gas of / cm ² or more.

  And as shown in FIG.4 (c), since it is the uniform thickness formed in the whole cavity 19 by the thin part 28, cooling time becomes short.

  In normal molding, since the thick portion 27 (showing the thick portion in FIG. 2) is 10 mm or more and the thick portion 27 is formed of resin, the molding time takes about 2 minutes or more. Then, the molding time is significantly shortened to 1 minute or less.

  In the above configuration, the blade 5 can be designed with a high-performance blade shape without restriction of the shape by the mold, is lightweight and has a short molding time, and the blade 5 and the suction ring 10 require a process such as ultrasonic welding. It becomes possible to fix without.

  Next, a turbofan molding process will be described with reference to FIG. FIG. 5 shows a state in which the mold is open. When the flange 8 side of the blade 5 is inserted into the first movable mold 30 so as to face the second movable mold 29, the blade 8 is positioned at the flange 8. The regulation can be performed with high precision, and at the same time, the boss 1 is inserted into the second movable mold 29.

  Thereafter, as shown in FIG. 6, the second movable mold 29 is moved, the mold is closed, and the resin 33 melted in the cylinder 31 of the molding machine is injected and injected through the spool runner 32. Since the flange 8 and the resin 33 are melted, the main plate 4 and the blade 5 become an integrated product 35 and can be taken out from the second movable die 29 as shown in FIG. Further, by simultaneously forming and removing the suction ring 10 with the stationary platen 34 of the molding machine, there is no need for a mold for the suction ring.

  In addition, the turbo fan is assembled and welded by engaging the second fitting part 11 of the suction ring 10 with the first fitting part 9 of the blade 5 immediately after taking out the integrated product 35 and the suction ring 10 at the same time. Alternatively, the bonding process can be omitted.

In the manufacturing method described above, the lightweight blade 5 can be integrated with the main plate 4 with accurate and stable molding, so that a turbofan 39 with good unbalance during rotation can be obtained.

  Further, since the suction ring 10 can be co-taken with the molding die of the main plate 4, a mold for the suction ring 10 is not required, and molding in a separate process is not required, and the suction ring 10 and the blade 5 are welded or bonded. Since a process is unnecessary, an inexpensive turbo fan can be provided.

  Instead of the above blow molding, injection blow molding or DSI (die slide injection) can obtain the same effect. Further, even when the stopper 15 is not fixed in the radial direction, the same effect can be obtained even in the circumferential direction as shown in FIG. 8 or a combination thereof.

  The present invention can be applied not only to air-conditioning equipment but also to turbo fans used in equipment such as blowers.

The exploded perspective view of the turbofan which shows one embodiment of the present invention (A) Perspective view of blade seen from suction ring side of same embodiment (b) Perspective view of blade seen from main plate side of same embodiment (c) Blade cross-sectional view of main plate side of same embodiment ( d) Blade sectional view of the blowing ring side of the same embodiment (e) Main part enlarged view of the first fitting portion on the suction ring side of the same embodiment The perspective view which the 1st fitting part and the 2nd fitting part of the same embodiment engaged (A) Cross-sectional view showing a blade mold of the same embodiment before molding (b) Cross-sectional view of the blade of the same embodiment during molding (c) Blade of the same embodiment Sectional view showing the mold after gas injection Sectional drawing which showed before shaping | molding of the metal mold | die of the same embodiment Sectional view showing the molding of the mold of the same embodiment Sectional view showing the mold of the same embodiment after molding Schematic diagram of a ceiling-embedded indoor unit that is an air conditioner Schematic diagram of turbo fan configuration Sectional drawing which showed the recessed part of the corner corner of the conventional blade and main plate Cross-sectional view of conventional turbofan mold

Explanation of symbols

4 Main plate 5 Blade 8 Flange 9 First fitting portion 10 Suction ring 11 Second fitting portion 12 Inner peripheral side twisted portion 13 Outer peripheral side twisted portion 17 Hole 18 Hollow layer 39 Turbo fan 40 Thin portion 41 Thick wall Part

Claims (5)

The main plate, the suction ring, and a plurality of blades are arranged between the main plate and the suction ring, and the blade is hollow molded and then attached to the main plate. Turbo fan. The turbofan according to claim 1, wherein the blade has a thick part and a twist part, and at least a part of the thick part is hollow-molded. The turbofan according to claim 1, wherein a flange portion is provided on the main plate side of the blade, and the blade is fixed to the main plate by insert molding. The turbofan according to claim 1, wherein the blade is hollow-molded from the side of the main plate, and a fitting portion is formed on the side where the suction ring is attached at the same time. In the step of forming the main plate after the step of forming the blade fixedly disposed between the main plate and the suction ring by hollow molding, the blade is inserted, and the main plate and the blade are integrated. A method of manufacturing a turbofan characterized by comprising:

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