JP2006300431A - Indoor unit drain pan for air conditioner, indoor unit for air conditioner, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an indoor unit drain pan for an air conditioner, an indoor unit for the air conditioner, and its manufacturing method capable of reducing the number of heat insulating members provided on the drain pan, and reducing work manhours for installing the heat insulating members. <P>SOLUTION: The indoor unit 100 for the air conditioner includes a drain pan body 32, and the heat insulating member 31 for the drain pan arranged along inner walls of the drain pan body 32. The heat insulating member 31 for the drain pan is composed of one foaming resin made member. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a drain pan for an indoor unit of an air conditioner, an indoor unit of an air conditioner, and a method for manufacturing the same, and more specifically, a drain pan for an indoor unit of an air conditioner that is used by being attached to an indoor wall surface, and an air conditioner The present invention relates to an indoor unit and a manufacturing method thereof.

In general, drain water, which is moisture condensed in a heat exchanger of an indoor unit of an air conditioner, is collected in a drain pan. Here, since the drain water accumulated in the drain pan is at a low temperature, there is a possibility that condensation occurs on the outer wall of the drain pan. Conventionally, in order to prevent such condensation on the drain pan outer wall, a drain pan having a plurality of heat insulating members on the outer wall is known (for example, see Patent Document 1).
JP 2000-337653 A

  However, since the shape of the outer wall of the drain pan is restricted by the members disposed around it, the outer wall of the drain pan often has a complicated shape. For this reason, it is often difficult to configure the heat insulating member installed on the outer wall with one integrated member. As a result, in the installation of the heat insulating member on the outer wall of the drain pan, it is necessary to install a plurality of heat insulating members at a plurality of positions, which increases the number of heat insulating members and the number of work steps for installing the heat insulating members. There was a point.

  The present invention has been made in order to solve the above-described problems, and it is possible to reduce the number of heat insulating members and reduce the number of work steps for installing the heat insulating members. It aims at providing the drain pan for machines, the indoor unit of an air conditioner, and its manufacturing method.

  The indoor unit drain pan for an air conditioner according to the present invention includes a drain pan main body and a drain pan heat insulating member disposed along the inner wall of the drain pan main body. The heat insulating member for drain pan is formed of an integral foamed resin member.

  According to the drain pan for an indoor unit of an air conditioner of the present invention, by configuring the drain pan heat insulating member as an integral member, the number of heat insulating members can be reduced and the number of work steps for installing the heat insulating member can be reduced. Is possible. As a result, the manufacturing cost of the drain pan is reduced.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and description thereof will not be repeated.

(Embodiment 1)
FIG. 1 is a schematic cross-sectional view showing a configuration of an indoor unit of an air conditioner according to Embodiment 1, which is an embodiment of the present invention. FIG. 2 is a schematic perspective view showing a main part of the indoor unit of the air conditioner according to the first embodiment. FIG. 3 is a schematic perspective view showing the configuration of the drain pan of the first embodiment. FIG. 4 is an enlarged schematic partial cross-sectional view showing the vicinity of the drain pan of FIG. With reference to FIGS. 1-4, the structure of the indoor unit of the air conditioner in Embodiment 1 of this invention is demonstrated.

  Referring to FIG. 1, a housing of an indoor unit 100 of an air conditioner includes a heat exchanger 6 that cools or dehumidifies air by allowing air to pass therethrough, and drain that is moisture condensed in the heat exchanger 6. An air conditioner indoor unit drain pan 3 for collecting water 11 is provided. Specifically, the housing of the indoor unit 100 of the air conditioner includes a rear housing 1 that closes the rear side of the indoor unit 100 of the air conditioner, and a front surface that closes the upper surface side and the front side of the indoor unit 100 of the air conditioner. And a housing 2. The front housing 2 includes a grill portion 21 installed so as to be openable and closable and a panel portion 22 having a suction port 22A. A dustproof filter 8 is disposed along the front housing 2 inside the housing. A heat exchanger 6 is disposed on the side opposite to the front housing 2 when viewed from the dust filter 8. A line flow fan 7 is disposed on the center side of the housing as viewed from the heat exchanger 6. A drain pan 3 having a U-shaped cross-sectional shape is disposed below the heat exchanger 6 disposed along the grill portion 21 of the front housing 2.

  As shown in FIGS. 3 and 4, the drain pan 3 includes a drain pan main body 32 and a drain pan heat insulating member 31 disposed along the inner wall of the drain pan main body 32. That is, the outer wall of the heat insulating member 31 for drain pan and the inner wall of the drain pan main body 32 can be assembled so as to be fitted in a state of being substantially in contact with each other. The heat insulating member 31 for the drain pan is composed of an integral foam resin member, more specifically, an open cell foam resin member. Furthermore, the heat insulating member 31 for drain pan is preferably manufactured by being molded by vacuum forming a foamed resin.

  As shown in FIG. 3, a drain pan heat insulating member drain port 34 is formed on the side surface of the drain pan heat insulating member 31, and a drain pan main body drain port 35 is formed on the side surface of the drain pan main body 32. 2 and 3, when the drain pan main body 32 and the drain pan heat insulating member 31 are combined, the drain pan heat insulating member drain port 34 and the drain pan main body drain port 35 are arranged so as to overlap each other. As a result, the drain pan drain port 3A is configured. Further, one end of a drain hose 33 is connected to the drain pan drain port 3A, and the other end of the drain hose 33 is arranged so as to reach the outdoor.

  Further, as shown in FIG. 1, a blowout port of the indoor unit 100 of the air conditioner is configured between the outer wall side bottom surface of the drain pan 3 and the rear housing 1. Left and right wind direction flaps 5 are disposed at the outlet. Further, the vertical wind direction flap 4 is arranged on the outlet side of the outlet as viewed from the left and right wind direction flaps 5.

  Next, the operation of the indoor unit 100 of the air conditioner in Embodiment 1 will be described. With reference to FIG. 1 and FIG. 2, during the cooling or dehumidifying operation, the line flow fan 7 rotates according to the direction 71 of rotation of the line flow fan, so that outside air (air) is sucked in through the suction port 22A of the panel unit 22 Is sucked into the indoor unit 100 of the air conditioner according to the direction 9. When the sucked air passes through the dust filter 8, foreign matters such as dust are removed from the air. The air from which the foreign matters are removed is further cooled and / or dehumidified by passing through the heat exchanger 6. The cooled and / or dehumidified air passes through the area where the line flow fan 7 is installed, and blows out into the room from the outlet according to the direction 10 of the outlet airflow. At this time, the air direction of the blown-out air is controlled by the left and right wind direction flaps 5 and the up and down wind direction flaps 4.

  During the operation of the indoor unit 100 of the air conditioner described above, in the heat exchanger 6 that is cooled by the refrigerant, condensation occurs due to passage of warm and moist air, and drain water 11 is generated. The drain water 11 drops from the heat exchanger 6 to the drain pan 3 and accumulates in the drain pan 3. As shown in FIG. 2, the accumulated drain water 11 is discharged from the drain pan drain port 3 </ b> A through the drain hose 33 to the outside.

  Here, since the drain water 11 collected in the drain pan 3 has a low temperature, there is a possibility that condensation occurs on the outer wall of the drain pan. However, since the inner side of the drain pan 3 of Embodiment 1 is composed of the heat insulating member 31 for drain pan, which is an open cell foamed resin member having a high heat insulating function, the occurrence of condensation is suppressed.

  In addition, although foamed polystyrene is mentioned as foamed resin which is the raw material of the heat insulating member 31 for drain pans, especially continuous foamed resin, for example, Polyolefin type foamed resins, such as a polypropylene, may be sufficient.

  Conventionally, in order to prevent condensation on the outer wall of the drain pan, a plurality of heat insulating members have been arranged on the outer wall of the drain pan. This is due to the following reasons. In general, foamed polystyrene (resin foamed beads pressure-molded at a high temperature) used as a material for a heat insulating member has a slight gap between the foamed beads. Therefore, when the heat insulating member made of polystyrene foam is disposed on the inner wall side of the drain pan, the drain water gradually permeates into the heat insulating member made of foam polystyrene and the heat insulation performance deteriorates. In order to maintain the predetermined heat insulating performance, it is necessary to increase the thickness of the heat insulating material. However, if this is done, the material cost increases, and therefore the heat insulating member is disposed on the outer wall side of the drain pan. On the other hand, since the shape of the outer wall of the drain pan is restricted by the members arranged around it, it often has a complicated shape. Therefore, it is often difficult to configure the heat insulating member installed on the outer wall with a single integrated member. As a result, in installing the heat insulating member on the outer wall of the drain pan, it is necessary to install a plurality of heat insulating members at a plurality of positions. For this reason, the number of heat insulating members and the number of work steps for installing the heat insulating members are increased, the manufacturing cost of the drain pan is increased, and the manufacturing cost of the indoor unit of the air conditioner is increased.

  On the other hand, according to the structure of the drain pan 3 of the present invention described above, the drain pan heat insulating member 31 is made of an integral foamed resin, so that there is no permeation of moisture into the drain pan heat insulating member 31 and the heat insulating performance is deteriorated. There is no. Therefore, the drain pan heat insulating member 31 can be disposed on the inner wall side of the drain pan main body 32. Further, by configuring the drain pan heat insulating member 31 as an integral member, it is possible to reduce the number of heat insulating members and reduce the number of work steps for installing the heat insulating members. As a result, the manufacturing cost of the drain pan 3 and thus the manufacturing cost of the indoor unit 100 of the air conditioner can be reduced. Furthermore, by configuring the drain pan heat insulating member 31 with an integral foamed resin member, the strength of the drain pan heat insulating member 31 can be improved as compared with a conventional member made of foamed polystyrene. As a result, the heat insulating member can be thinned, the material cost is reduced, and the degree of design freedom is improved.

  Furthermore, the drain pan 3 provided with the heat insulating member 31 for drain pan with low cost and high external accuracy is provided by forming the heat insulating member 31 for drain pan by molding the foamed resin by vacuum molding. be able to.

  Furthermore, the heat exchanger 6 for cooling or dehumidifying the air by allowing the air to pass therethrough, and the above-mentioned air conditioner drain pan for recovering the drain water 11 which is the moisture condensed in the heat exchanger 6 3, the low-cost indoor unit 100 of an air conditioner having the characteristics of the drain pan can be provided.

  Next, the manufacturing method of the drain pan 3 for the indoor unit 100 of the air conditioner and the indoor unit 100 of the air conditioner in the first embodiment will be described. FIG. 5 is a diagram illustrating a method for manufacturing a heat insulating member for a drain pan, which is a main part of the method for manufacturing the indoor unit drain pan for an air conditioner and the air conditioner indoor unit according to the first embodiment. With reference to FIG. 5, an example of the manufacturing method of the drain pan 3 for the indoor unit 100 of the air conditioner and the indoor unit 100 of the air conditioner in the first embodiment will be described.

  With reference to FIG. 5, the apparatus for manufacturing the heat insulating member 31 for the drain pan includes a heater 81 as heating means, an upper molding die 82 and a lower molding die 83 as molding means, and a punching die 84 as punching means. And a pedestal 85 for punching. The upper molding die 82 is formed with an upper molding die convex portion 82A, and the lower molding die 83 is formed with a lower molding die concave portion 83A. Then, by moving the upper molding die 82 in the direction of the upper molding die moving direction 88, the upper molding die convex portion 82A and the lower molding die concave portion 83A can be fitted together and a material sandwiched therebetween can be molded. It is configured as follows. The lower molding die 83 preferably has, for example, a decompression through hole and a vacuum pump connected to the decompression through hole as decompression means for decompressing the inside of the lower molding die recess 83A. . It is preferable that one end of the decompression through hole is connected to the lower molding die recess 83A, and the other end of the decompression through hole is connected to a vacuum pump.

  Next, the manufacturing process of the heat insulation member for drain pans in the case of using a polystyrene sheet which is a foamed resin as a raw material will be described. First, a foaming step is performed in which the polystyrene sheet 80, which is a foamed resin wound up in a roll shape, is pulled out and passed through a region that can be heated by the heater 81 to be foamed and softened. Next, the foamed and softened polystyrene sheet 80 is further pulled out between the upper molding die 82 and the lower molding die 83. Then, by moving the upper molding die 82 in the direction of the upper molding die moving direction 88, the polystyrene sheet 80 sandwiched between the upper molding die convex portion 82A and the lower molding die concave portion 83A becomes the heat insulating member for the drain pan. A molding step is performed to form the shape 31. In the molding process of molding the polystyrene sheet 80 as the foamed resin using the upper molding die 82 and the lower molding die 83 as molding molds, the polystyrene molding is closed by the lower molding die recess 83A and the polystyrene sheet 80. It is preferable to employ vacuum forming including a pressure reducing step for bringing the lower molding die concave portion 83 </ b> A and the polystyrene sheet 80 into close contact with each other by reducing the pressure of the space. In this decompression step, for example, a vacuum pump connected to a through-hole formed in the lower molding die recess 83A is operated to decompress the space closed by the lower molding die recess 83A and the polystyrene sheet 80. Can be implemented. Next, the polystyrene sheet 80 is further pulled out so that the polystyrene sheet 80 molded in the shape of the heat insulating member 31 for the drain pan in the molding step enters the punching base opening 85A. Then, by moving the punching die 84 in the direction of the punching die moving direction 89, the punching process in which the drain pan heat insulating member 31 is punched in accordance with the punching direction 87 (molded polystyrene sheet as a molded foamed resin) By punching 80 using a punching die 84 as a punching die and a punching pedestal 85, a punching step for forming the drain pan heat insulating member 31 is performed. Through the above steps, the heat insulating member 31 for a drain pan integrally formed with an open cell foamed resin (polystyrene) member is manufactured.

  The drain pan of the first embodiment is manufactured by arranging the heat insulating member 31 for drain pan manufactured by the above process along the inner wall of the drain pan main body 32. Here, as the drain pan main body 32, a known one can be adopted. Also, a known method can be adopted as a method for disposing the drain pan heat insulating member 31 on the drain pan main body 32. For example, the drain pan heat insulating member 31 and the drain pan main body 32 are fitted to each other by forming a fitting portion. They may be combined, or may be bonded with an adhesive.

  Furthermore, the indoor unit 100 of an air conditioner can be manufactured using the manufacturing method including the step of forming the drain pan 3 by the method of manufacturing the drain pan 3 for the indoor unit 100 of the air conditioner. Specifically, a known member such as the heat exchanger 6 and the line flow fan 7 and the drain pan 3 according to the first embodiment manufactured by the above-described process are placed in a casing including the rear casing 1 and the front casing 2. By arranging in, the indoor unit 100 of an air conditioner can be manufactured. Members other than the drain pan 3 can be manufactured by a known method. In addition, the air conditioner indoor unit 100 including these members can be assembled by a known method.

  By adopting the above manufacturing process, the heat insulating member 31 for drain pan, which is an integral foamed resin member, can be efficiently manufactured. As a result, the manufacturing cost of the heat insulating member 31 for the drain pan is reduced, and the manufacturing cost of the drain pan 3 and consequently the indoor unit 100 of the air conditioner can be reduced. Furthermore, by adopting a molding process including vacuum molding, it is possible to easily bring the polystyrene sheet 80 and the lower molding die recess 83A into close contact with each other, thereby improving the manufacturing efficiency and suppressing the manufacturing cost. In addition, it is possible to manufacture the heat insulating member 31 for the drain pan with high outer shape accuracy. As a result, it is possible to provide the drain pan 3 and the indoor unit 100 of the air conditioner including the drain pan heat insulating member 31 with low cost and high external accuracy.

(Embodiment 2)
FIG. 6 is an enlarged schematic partial cross-sectional view showing the vicinity of the drain pan in the indoor unit of the air conditioner according to the second embodiment which is an embodiment of the present invention. With reference to FIG. 6, the structure of the indoor unit of the air conditioner in Embodiment 2 of this invention is demonstrated.

  The indoor unit 100 of the air conditioner of Embodiment 2 has basically the same configuration as the indoor unit 100 of the air conditioner of Embodiment 1 shown in FIGS. However, referring to FIG. 6, drain pan 3 in indoor unit 100 of the air conditioner of Embodiment 2 is configured to form a gap between drain pan main body 32 and drain pan heat insulating member 31. This is different from the drain pan 3 of the first embodiment. Specifically, for example, as shown in FIG. 6, the drain pan main body 32 has a drain pan main body protrusion 32 </ b> A, and the outer wall of the drain pan heat insulating member 31 is configured to contact the drain pan main body protrusion 32 </ b> A. Thus, a drain pan gap 37 is formed. The configuration of the drain pan of the second embodiment is not limited to this. For example, the heat insulating member 31 for drain pan has a protruding portion, and the protruding portion may be configured to contact the inner wall of the drain pan main body 32. Good. That is, the drain pan 3 of the second embodiment is not limited to the above-described specific configuration, and may be configured so that a gap is formed between the drain pan main body 32 and the drain pan heat insulating member 31.

  The operation of the air conditioner indoor unit 100 according to the second embodiment is the same as that of the air conditioner indoor unit 100 according to the first embodiment shown in FIGS.

  As described above, the drain pan 3 of the second embodiment has a higher heat insulating performance because the drain pan gap 37 is formed between the drain pan main body 32 and the heat insulating member 31 for the drain pan. As a result, it is possible to provide the drain pan 3 in which the occurrence of condensation on the outer wall of the drain pan 3 is further suppressed. Furthermore, by providing the drain pan 3 of the second embodiment, it is possible to provide the indoor unit 100 of an air conditioner in which the generation of condensation on the outer wall of the drain pan 3 is further suppressed. Moreover, when sufficient heat insulation performance can be secured, the heat insulating member 31 for the drain pan can be made thin, and the material cost can be reduced.

  Next, a method for manufacturing the drain pan 3 for the indoor unit 100 of an air conditioner and the indoor unit 100 of the air conditioner in Embodiment 2 will be described. The manufacturing method of the drain pan 3 for the indoor unit 100 of the air conditioner and the indoor unit 100 of the air conditioner according to the second embodiment is basically the indoor unit of the air conditioner according to the first embodiment described with reference to FIG. This is the same as the method for manufacturing the drain pan 3 for 100 and the indoor unit 100 of the air conditioner. However, since the gap is formed between the drain pan main body 32 and the drain pan heat insulating member 31 as described above, a difference occurs in the manufacturing method. That is, for example, as shown in FIG. 6, when the drain pan main body 32 has a drain pan main body protrusion 32 </ b> A, a recess for forming the protrusion can be provided in the mold for molding the drain pan main body 32. Alternatively, only the drain pan main body protrusion 32 </ b> A may be manufactured as a separate member and attached to the drain pan main body 32. Furthermore, when the heat insulating member 31 for drain pan has a protrusion, a recess corresponding to the protrusion may be further formed in the lower molding die recess 83A of the lower molding die 83.

(Embodiment 3)
7 to 9 are schematic cross-sectional views illustrating the configuration of the heat insulating member for the drain pan in the indoor unit of the air conditioner according to Embodiment 3, which is an embodiment of the present invention. With reference to FIGS. 7-9, the structure of the indoor unit of the air conditioner in Embodiment 3 of this invention is demonstrated.

  The air conditioner indoor unit 100 according to the third embodiment basically has the same configuration as the air conditioner indoor unit 100 according to the first embodiment shown in FIGS. However, the heat insulating member for drain pan of the third embodiment is different from the heat insulating member 31 for drain pan of the first embodiment in that it includes a region where a non-foamed layer is formed on the surface. Specifically, as shown in FIG. 7, for example, the heat insulating member 31 for drain pan has a non-foamed layer 39 as a reinforcing layer formed on the surface on the inner wall side. The non-foamed layer 39 is not only formed of the same material, but also, for example, a polyolefin-based resin can be used. The portion where the non-foamed layer 39 is formed is not limited to the surface on the inner wall side, and may be formed on the surface on the outer wall side as shown in FIG. 8, for example, or the inner wall side and the outer wall side as shown in FIG. It may be formed on both surfaces. Further, the non-foamed layer 39 may be formed on the entire surface of the heat insulating member 31 for the drain pan. Further, the non-foamed layer 39 is not necessarily formed on the entire surface on one side of the inner wall side or the outer wall side, and may be formed only in a region in contact with another member such as the heat exchanger 6.

  The operation of the indoor unit 100 of the air conditioner in the third embodiment is the same as that of the indoor unit 100 of the air conditioner of the first embodiment shown in FIGS.

  As described above, the heat insulating member 31 for drain pan of the third embodiment includes a region where the non-foamed layer 39 as a reinforcing layer having high strength is formed on the surface as shown in FIGS. 7 to 9, for example. As a result, the strength is improved. Therefore, even when the heat insulating member 31 for drain pan contacts with another member, it becomes difficult to break. As a result, an adverse effect on the indoor unit 100 of the air conditioner due to the leakage of the drain water 11 and dripping of the drain water into the room are suppressed. In particular, when the indoor unit 100 of the air conditioner is configured so that the heat exchanger 6 and the inner wall of the drain pan heat insulating member 31 are in contact with each other as described later, a high strength non-strength is formed on the inner wall side of the drain pan heat insulating member 31. Forming the foam layer 39 is effective from the viewpoint of preventing damage to the heat insulating member 31 for drain pan. Furthermore, by using a polyolefin-based resin as the non-foamed layer 39, the chemical resistance of the drain pan 3 to the heat exchanger cleaning agent, cooking oil, and the like is improved. The reinforcing layer may be a layer other than the non-foamed layer 39 as long as the layer is formed of a material having a relatively high strength with respect to the foamed resin member.

  As described above, the drain pan heat insulating member 31 includes the region in which the non-foamed layer 39 is formed on the surface, whereby the highly reliable drain pan 3 can be provided. Moreover, by providing the drain pan 3 of Embodiment 3, the indoor unit 100 of a highly reliable air conditioner can be provided.

  Next, a method for manufacturing the drain pan 3 for the indoor unit 100 of an air conditioner and the indoor unit 100 of the air conditioner in Embodiment 3 will be described. The manufacturing method of the drain pan 3 for the air conditioner indoor unit 100 and the air conditioner indoor unit 100 according to the third embodiment is basically the air conditioner indoor unit 100 according to the first embodiment described with reference to FIG. This is the same as the drain pan 3 and the indoor unit 100 of the air conditioner. However, as described above, since the heat insulating member 31 for drain pan includes the region where the non-foamed layer 39 is formed on the surface, a difference occurs in the manufacturing method. That is, for example, a polystyrene sheet and a non-foaming resin sheet are integrated by applying an adhesive or the like between the sheets and pressing and adhering them with a rotating roller or the like. Thereafter, as in the case of the first embodiment described with reference to FIG. 5, the polystyrene sheet 80 integrated with the non-foamable resin sheet is foamed by passing through a region that can be heated by the heater 81, and A softening foaming step is performed. Next, the foamed and softened polystyrene sheet 80 is further pulled out between the upper molding die 82 and the lower molding die 83. Then, by moving the upper molding die 82 in the direction of the upper molding die moving direction 88, the polystyrene sheet 80 sandwiched between the upper molding die convex portion 82A and the lower molding die concave portion 83A becomes the heat insulating member for the drain pan. A molding step is performed to form the shape 31. In the molding process of molding the polystyrene sheet 80 as the foamed resin using the upper molding die 82 and the lower molding die 83 as molding molds, the polystyrene molding is closed by the lower molding die recess 83A and the polystyrene sheet 80. It is preferable to employ vacuum forming including a pressure reducing step for bringing the lower molding die concave portion 83 </ b> A and the polystyrene sheet 80 into close contact with each other by reducing the pressure of the space. In this decompression step, for example, a vacuum pump connected to a through-hole formed in the lower molding die recess 83A is operated to decompress the space closed by the lower molding die recess 83A and the polystyrene sheet 80. Can be implemented. Next, the polystyrene sheet 80 is further pulled out so that the polystyrene sheet 80 molded in the shape of the heat insulating member 31 for the drain pan in the molding step enters the punching base opening 85A. Then, by moving the punching die 84 in the direction of the punching die moving direction 89, the punching process in which the drain pan heat insulating member 31 is punched in accordance with the punching direction 87 (molded polystyrene sheet as a molded foamed resin) By punching 80 using a punching die 84 as a punching die and a punching pedestal 85, a punching step for forming the drain pan heat insulating member 31 is performed. Through the above steps, the heat insulating member 31 for a drain pan integrally formed with an open cell foamed resin (polystyrene) member is manufactured.

(Embodiment 4)
FIG. 10 is a schematic partial cross-sectional view showing the configuration in the vicinity of the drain pan in the indoor unit of the air conditioner according to the fourth embodiment which is an embodiment of the present invention. With reference to FIG. 10, the structure of the indoor unit of the air conditioner in Embodiment 4 of this invention is demonstrated.

  Referring to FIG. 10, air conditioner indoor unit 100 of the fourth embodiment basically has the same configuration as air conditioner indoor unit 100 of the first embodiment shown in FIGS. 1 to 4. is doing. However, the air conditioner indoor unit 100 according to the fourth embodiment has a gap between the end of the heat exchanger 6 that faces the drain pan 3 for the air conditioner indoor unit 100 and the heat insulating member 31 for the drain pan. The indoor unit of the air conditioner according to the first embodiment is such that the end of the portion facing the drain pan 3 for indoor unit and the heat insulating member 31 for drain pan are arranged in contact with each other at the contact portion 38 so as not to be formed. 100 is different.

  The operation of the air conditioner indoor unit 100 according to the fourth embodiment is the same as that of the air conditioner indoor unit 100 according to the first embodiment shown in FIGS.

  As described above, in the indoor unit 100 of the air conditioner of Embodiment 4, no gap is formed between the end portion of the heat exchanger 6 facing the indoor unit drain pan 3 and the drain pan heat insulating member 31. By being comprised in this, the leaking wind which passes the clearance gap between the lower end of the heat exchanger 6 and the heat insulation member 31 for drain pans can be suppressed. As a result, the amount of air passing through the heat exchanger 6 is substantially increased and the efficiency of cooling or dehumidification is increased, so that the indoor unit 100 of a high-performance air conditioner can be provided. Conventionally, a drain pan having a hard surface and a heat exchanger cannot be installed in contact with each other in order to prevent the occurrence of damage during transportation or handling of the cargo. On the other hand, since the drain pan of this invention is comprised by the member made from a foamed resin, it can be installed in contact with a heat exchanger like this Embodiment 4. FIG.

  Next, a method for manufacturing the indoor unit 100 for an air conditioner in Embodiment 4 will be described. The drain pan for air conditioner indoor unit 100 and the method for manufacturing air conditioner indoor unit 100 according to the fourth embodiment are basically for air conditioner indoor unit 100 according to the first embodiment described with reference to FIG. It is the same as the indoor unit 100 of the drain pan and the air conditioner. However, as described above, the end portion of the heat exchanger 6 facing the indoor unit drain pan 3 and the drain pan heat insulating member 31 need to be in contact with each other.

  The embodiment disclosed this time is to be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The drain pan for an indoor unit of an air conditioner, the indoor unit of an air conditioner, and the manufacturing method thereof according to the present invention include a drain pan for an indoor unit of an air conditioner that is used by being attached to an indoor wall surface, the indoor unit of an air conditioner, and its The present invention can be applied particularly advantageously to the manufacturing method.

It is a schematic sectional drawing which shows the structure of the indoor unit of the air conditioner of Embodiment 1. It is a schematic perspective view which shows the principal part of the indoor unit of the air conditioner of Embodiment 1. FIG. 3 is a schematic perspective view showing a configuration of a drain pan according to the first embodiment. FIG. 2 is a schematic partial cross-sectional view showing an enlarged view of the vicinity of the drain pan of FIG. It is a figure which shows the manufacturing method of the heat insulating member for drain pans which is the principal part of the manufacturing method of the indoor unit drain pan of the air conditioner in Embodiment 1, and the air conditioner. It is a schematic fragmentary sectional view which expands and shows the drain pan vicinity in the indoor unit of the air conditioner of Embodiment 2. 6 is a schematic cross-sectional view showing a configuration of a heat insulating member for a drain pan in an indoor unit of an air conditioner according to Embodiment 3. FIG. 6 is a schematic cross-sectional view showing a configuration of a heat insulating member for a drain pan in an indoor unit of an air conditioner according to Embodiment 3. FIG. 6 is a schematic cross-sectional view showing a configuration of a heat insulating member for a drain pan in an indoor unit of an air conditioner according to Embodiment 3. FIG. It is a schematic fragmentary sectional view which shows the structure of the drain pan vicinity in the indoor unit of the air conditioner of Embodiment 4.

Explanation of symbols

  1 Rear housing, 2 Front housing, 3 Drain pan, 3A Drain pan drain port, 4 Up / down wind direction flap, 5 Left / right wind direction flap, 6 Heat exchanger, 7 Line flow fan, 8 Dust-proof filter, 9 Suction airflow direction, 10 Outlet Direction of air flow, 11 Drain water, 21 Grill part, 22 Panel part, 22A Suction port, 31 Drain pan heat insulating member, 32 Drain pan main body, 32A Drain pan main body protruding part, 33 Drain hose, 34 Drain pan heat insulating member drain port, 35 Drain pan Main body drain, 37 Drain pan gap, 38 Contact part, 39 Non-foamed layer, 71 Direction of line flow fan rotation, 80 Polystyrene sheet, 81 Heater, 82 Upper molding die, 82A Upper molding die convex part, 83 Lower molding die Mold, 83A Lower mold recess, 84 For punching Die, 85 punching base, 85A punching base opening, 87 punching direction, 88 upper molding die moving direction, 89 punching die moving direction, 100 air conditioner indoor unit.

Claims (9)

Drain pan body,
A drain pan heat insulating member disposed along the inner wall of the drain pan body,
The drain pan heat insulating member is a drain pan for an indoor unit of an air conditioner, which is formed of an integral foamed resin member.   The drain pan for an indoor unit of an air conditioner according to claim 1, wherein the heat insulating member for the drain pan is manufactured by vacuum forming a foamed resin.   The drain pan for indoor units of an air conditioner according to claim 1 or 2, wherein a gap is formed between the drain pan main body and the drain pan heat insulating member.   The drain pan for an indoor unit of an air conditioner according to any one of claims 1 to 3, wherein the heat insulating member for drain pan includes a region having a non-foamed layer formed on a surface thereof. A heat exchanger for cooling or dehumidifying the air by passing it through;
The indoor unit of an air conditioner comprising the drain pan for an indoor unit of an air conditioner according to any one of claims 1 to 4 for recovering drain water which is moisture condensed in the heat exchanger. .   In the heat exchanger, the end of the portion facing the drain pan for the indoor unit and the drain pan so as not to form a gap between the end of the portion facing the drain pan for the indoor unit and the heat insulating member for drain pan. The indoor unit of the air conditioner according to claim 5, wherein the indoor unit is disposed in contact with the heat insulating member. A foaming process in which the foamed resin is heated to foam and softened;
A molding step of molding the foamed resin that has been foamed and softened in the foaming step using a molding die;
A method for producing a drain pan for an indoor unit of an air conditioner, comprising: a punching step of forming a heat insulating member for a drain pan by punching out the foamed resin molded in the molding step using a punching die.   The said shaping | molding process is a manufacturing method of the drain pan for indoor units of the air conditioner of Claim 7 including the process of vacuum-molding the said foaming resin foamed and softened in the said foaming process.   The manufacturing method of the indoor unit of an air conditioner provided with the process of forming the said drain pan for indoor units with the manufacturing method of the drain pan for indoor units of the air conditioner of Claim 7 or 8.

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