JP2007122910A - Ion generator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an ion generator in which an ion generating element is sealed easily with less filling material by reducing a process of filling the filling material. <P>SOLUTION: At a side inside a lower case 2 of an ion generator, a substrate receiving part and a groove are formed. In its lower case 2, a drive circuit substrate and an ion generating element which are mutually electrically connected are arranged. In the upper case 11, a recessed part 14 which becomes a resin injection aperture 18 for injecting resin materials, a filled amount adjustment protrusion part 15 for checking the amount of the injected resin materials by visual observation, and a protrusion part 12 for resin fixing that reaches the resin materials filled into the lower case 2 are installed. In the main body of the substrate, a notch corresponding to the recessed part 14 is formed. The filling materials are injected from the resin injection aperture 18 toward the lower case 2. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an ion generator, and more particularly to an ion generator that is sealed with a predetermined filler.

  In an air purifier, in order to realize a clean and comfortable space, indoor air is purified. In order to perform such air purification, an ion generator is mounted on the air cleaner. In recent years, such an ion generator has been commercialized in a form in which a predetermined case and a unit equipped with an ion generating element are integrated.

For example, in the ion generator described in Patent Document 1, as shown in FIG. 18, first, the booster coil 103 is accommodated in a predetermined case 102 and the booster coil 103 is sealed with the filler 109. Then, the circuit board 104 and the ion generating element 108 are sequentially attached at predetermined positions of the case 102, and another filler 110 is filled between the circuit board 104 and the ion generating element 108. In this way, an integrated ion generator 101 is configured.
JP 2003-45611 A

  As described above, in the conventional ion generator 101, the space in which the booster coil 103 is accommodated is first filled with the first filling material 109 to seal the booster coil 103, and the circuit board 104 and the ion are then sealed. A second filling material 110 is filled between the generation element 108. In particular, when the filler 110 is filled for the second time, the peripheral portion of the circuit board 104 is sealed in order to prevent the filler 110 from leaking from the circuit board 104 to the surface on which the component is attached. Treatment is required. For this reason, the filling operation cannot be performed as a continuous operation, and the number of work steps increases.

  In view of the filling operation of the filler in such a conventional ion generator, the present invention reduces the number of steps of filling the filler, and an ion generator that easily seals the ion generating element with less filler. The purpose is to provide.

  The ion generator according to the present invention includes a bottomed bottom case, an ion generating element, a substrate portion, an upper case, and a predetermined inlet for introducing a filler. The ion generating element is fixed to an opening provided in a bottom portion of the lower case, and generates ions toward the outside of the lower case. The substrate unit is disposed above the ion generating element, and is electrically connected to the ion generating element to form a drive circuit for driving the ion generating element. The upper case is attached to the lower case and sandwiches the substrate portion with the lower case to cover the substrate portion.

  The introduction port is formed in the upper case and the substrate portion, a predetermined filler is introduced from the upper case side through the substrate portion, and a connection member for connecting the ion generating element and the substrate portion is connected to the ion generating element. The part is at least sealed.

  According to this configuration, by introducing the filler from the introduction port provided in the upper case and the substrate part in a state where the substrate part for driving the ion generating element is sandwiched between the lower case and the upper case, the filler is introduced once. The ion generating element attached to the lower case can be sealed with the step of introducing the filler, and the substrate portion and the upper case can be fixed to the lower case.

  The upper case preferably includes a first protrusion that protrudes from the upper case toward the lower case and includes a portion that reaches the filler to be introduced and is embedded in the filler.

  Thereby, the front-end | tip part of a 1st projection part is embedded in the resin material, and an upper case can be reliably fixed to a lower case.

  In addition, the first protrusion is separated from the lower case by a predetermined interval that allows the filler to be introduced to be sucked up by capillarity in a portion between the first protrusion and the lower case. preferable.

  Thereby, a filler can be sent between a board | substrate part and a lower case, and a board | substrate part and a lower case can be fixed firmly.

  Furthermore, a key-like portion may be formed in the first protrusion portion at a portion embedded in the filler.

  Accordingly, the upper case can be firmly fixed to the lower case in a state where the key-like portion is caught by the filler.

  On the other hand, the lower case has a substrate receiving portion formed on the side portion to support the substrate portion from below, and a filler formed on the side portion so as to extend from the bottom portion toward the substrate receiving portion. It is preferable to provide a groove portion for sucking up to the substrate receiving portion by capillary action.

  Thereby, the filler sucked up from the groove portion spreads between the substrate portion and the substrate receiving portion, and the substrate portion can be fixed to the lower case with less filler.

Moreover, it is preferable to provide a filling amount adjusting unit for filling a predetermined amount of the filler.
Thus, a predetermined amount of filler can be easily introduced while performing the filling operation by the filling amount adjusting unit without preparing a predetermined filler in advance.

  More specifically, the filling amount adjusting section preferably includes a second protrusion that protrudes toward the lower case formed so as to be exposed at a portion of the introduction port in the upper case.

Thereby, a predetermined amount of filler can be visually filled while filling the filler.
In addition, the filler is preferably filled so as to seal the ion generating element and the portion of the lower case located in the vicinity thereof.

  Thereby, the ion generating element can be fixed to the lower case without using another member.

Furthermore, it is preferable that a moisture-proof material is applied to the substrate portion.
Thereby, a board | substrate part can be protected from dew condensation and the stable operation | movement of an ion generating element can be ensured.

  An ion generator according to an embodiment of the present invention will be described. The ion generator includes a lower case, an ion generating element that generates ions, a drive circuit board unit that drives the ion generating element, and an upper case. Hereinafter, each structure will be described in detail.

  First, as shown in FIG. 1, the lower case 2 has a bottom, and an opening 2a for generating ions toward the outside by mounting an ion generating element on a part of the bottom is formed. A substrate receiving portion 2b for supporting the drive circuit substrate from below is formed inside the side portion of the lower case 2. A groove portion 2c is formed in a part of the substrate receiving portion 2b for sucking upward a resin material as a filler by a capillary phenomenon.

  As shown in FIG. 2, in the drive circuit board portion 7, a step-up transformer 10 that generates a predetermined high voltage on the board body 8, a power connector 9, and the like are attached. The step-up transformer 10 boosts a voltage of about 3 to 200 V to a high voltage of 1 kV or higher capable of corona discharge. The ion generating element 3 is electrically connected to the step-up transformer 10 via a predetermined high withstand voltage electric wire 20. The substrate body 8 is formed with a notch 8a for injecting a resin material.

  As shown in FIG. 3, the ion generating element 3 includes an induction electrode 5 disposed between plate-like dielectric plates 6 and 6, and discharges onto the dielectric plate 6 so as to face the induction electrode 5. An electrode 4 is provided. By applying a high voltage generated by the step-up transformer 10 between the induction electrode 5 and the discharge electrode 4, a corona discharge is generated between the induction electrode 5 and the discharge electrode 4, and positive ions and negative ions are generated. Will do. Depending on the conditions, either positive ions or negative ions or ozone can be generated.

  As shown in FIG. 4, the resin fixing protrusion that protrudes toward the lower case 2 and reaches the resin material filled in the lower case 2 at a predetermined position inside the side of the upper case 11. 12 is provided. Further, the upper case 11 is formed with a recess 14 corresponding to the notch 8 a formed in the substrate body 8. As will be described later, the recessed portion 14 becomes a resin injection opening portion as an introduction port portion together with the notch portion 8a. In addition, a protrusion 15 for filling amount adjustment is provided at the recessed portion 14 for visually confirming the amount of the resin material to be injected. Further, a connector opening 13 for exposing the power connector 9 of the drive circuit board 7 is provided.

  Next, the assembly procedure of the ion generator 1 will be described. First, as shown in FIG. 2, the step-up transformer 10 provided on the drive circuit board 7 and the ion generator 3 are electrically connected in advance by a high-voltage electric wire 20. Next, as shown in FIGS. 5 and 6, the ion generating element 3 connected to the drive circuit board 7 is attached to the opening 2a provided in the upper case 2, and the ion generating element 3 is attached from the opening 2a. Expose. Next, the drive circuit board 7 is placed on the board receiving portion 2 b of the lower case 2. Then, the upper case 11 is placed so as to cover the drive circuit board 7. Thus, as shown in FIGS. 7 and 8, the drive circuit board 7 (not shown) is sandwiched between the upper case 11 and the lower case 2. In this manner, the resin injection opening 18 for filling the resin material is formed by the notch 8a and the recess 14.

  Next, as shown in FIG. 7, a resin material 16 as a filler is injected from the resin injection opening 18. As shown in FIG. 9, the resin material 16 injected from the resin injection opening 18 gradually flows into the ion generating element 3 at the bottom of the lower case 2, and as shown in FIG. The ion generating element 3 is sealed with the resin material 16. At this time, it is preferable to seal so as to cover at least the portion where the high-voltage electric wire 20 is connected to the ion generating element 3 and the bottom portion of the lower case 2 located in the vicinity of the ion generating element 3.

  Further, the injection of the resin material 16 causes the tip portion of the resin fixing protrusion 12 provided in the upper case 11 to be embedded in the resin material 16 that gradually accumulates in the bottom portion of the lower case 2.

  Furthermore, when the resin material 16 gradually accumulates from the bottom portion of the lower case 2 and the resin material 16 reaches the groove portion 2c provided on the inner side of the lower case 2, as shown in FIG. The material 16 is sucked upward. As shown in FIG. 12, the sucked resin material 16a reaches the surface of the substrate receiving surface 2b, and further spreads by capillary action in the gap portion between the drive circuit substrate 7 and the substrate receiving surface 2b. Finally, the filled resin material 16 is dried and solidified at a predetermined temperature.

  By solidifying the portion of the resin material 16 that seals the portion connected to the ion generating element 3 and the bottom portion of the lower case 2 located in the vicinity of the ion generating element 3, the solidified resin material is obtained. The ion generating element 3 is fixed to the lower case 2 via 16. Further, the upper case 11 is fixed to the lower case 2 by solidifying the portion of the resin material 16 in which the tip portion of the resin fixing protrusion 12 is embedded. Furthermore, the portion of the resin material 16a interposed in the gap between the drive circuit board 7 and the board receiving surface 2b is solidified, so that the drive circuit board 7 is fixed to the lower case 2. Thus, the assembly of the ion generator 1 is completed.

  In the ion generator 1 described above, the resin injection opening 14 provided in the upper case 2 and the driving circuit substrate 7 for driving the ion generating element 3 are sandwiched between the lower case 2 and the upper case 11 and the resin injection opening 14 is provided in the upper case 2. By injecting the resin material 16 from the corresponding notch 7a of the drive circuit board 7, the ion generating element 3 attached to the lower case 2 can be sealed by a single injection process. At the same time, the drive circuit board 7 and the upper case 11 can be fixed to the lower case 2.

  Further, by providing the groove 2c in the lower case 2, the resin material 16 is sucked upward by a capillary phenomenon and spreads in a gap portion between the drive circuit board 7 and the board receiving surface 2b. As a result, the drive circuit board 7 can be fixed to the lower case 2 with less resin material 16.

  Furthermore, by providing the resin fixing protrusion 12 on the upper case 11, the tip portion of the resin fixing protrusion 12 is fixed in the resin material 16. Thereby, the upper case 11 can be reliably fixed to the lower case 2 with less resin material 16. Thus, the amount of the resin material 16 to be filled can be reduced, and the weight of the ion generator 1 can be reduced.

  Further, by providing the filling amount adjusting projection 15 on the side wall portion of the resin injection opening 18 (recessed portion 14) of the upper case 11, the filling amount adjusting projection 15 is injected into the lower case 2 with respect to the position of the filling amount adjusting projection 15. A predetermined amount of the resin material 16 can be easily injected while visually confirming the position of the surface of the resin material 16 that is raised.

  In the ion generator 1 described above, as the resin fixing protrusion 12 provided in the upper case 11, the resin fixing protrusion 12 protruding from the side surface portion of the upper case 11 toward the lower case is taken as an example. However, as shown in FIG. 13, the resin fixing protrusion 12 may be provided at a predetermined distance L from the side surface portion of the upper case 11.

  As the distance L, as shown in FIG. 14, the resin material injected into the gap between the resin fixing protrusion 12 and the side surface portion of the lower case 2 with the upper case 11 mounted on the lower case 2. It is preferable that the interval 16 is set so as to be spaced so as to be sucked upward by capillary action. By doing so, the resin material 16a is sucked up from the resin fixing projection 12 in addition to the groove 2c, and the sucked resin material 16a flows into the gap between the drive circuit board 7 and the lower case 2. The drive circuit board 7 can be reliably fixed by the lower case 2.

  Further, as shown in FIG. 15, the resin fixing protrusion 12 may be provided in the upper case 11 so as to face the groove 2 c provided in the lower case 2. Also in this case, the distance L between the substrate receiving portion 2b (groove portion 2c) and the resin fixing projection 12 is set such that the resin material 16 injected into the gap between the resin fixing protrusion 12 and the substrate receiving portion 2b is a capillary phenomenon. It is preferable that the interval is set so as to be sucked upward by. In this case, it is preferable to provide a notch in the substrate body 8 corresponding to the position of the resin fixing protrusion 12.

  According to the inventors, a plurality of grooves having a width of about 0.5 mm and a depth of about 0.5 mm were formed on an ABS (Acrylonitrile Butadiene Styrene) resin plate, and the ABS resin plate was immersed in a urethane resin. Experiments confirmed that the urethane resin was sucked up to an average height of about 9.0 mm from the surface of the urethane resin by capillary action.

  Further, as shown in FIG. 16, a key-shaped portion 12 a may be provided at the tip of the resin fixing protrusion 12. By doing so, the key-like portion 12a is caught on the solidified resin material 16 and the tip portion of the resin fixing projection 12 is prevented from easily coming off from the resin material 16, and the upper case 11 is more easily attached to the lower case 2. It can be firmly fixed.

  Before assembling the ion generator 1, it is preferable to apply a moisture-proof material 17 to the entire drive circuit board 7 as shown in FIG. 17. As the moisture-proof material 17, for example, Humiseal (registered trademark) (HumiSeal) or the like can be applied. By applying the moisture-proof material 17 to the drive circuit board 7, the drive circuit board 7 can be protected from condensation, and a stable operation of the drive circuit can be ensured. The ion generator described above can be widely applied to devices that generate ions, including air cleaners, air conditioners such as air conditioners, humidifiers, and electric fan heaters.

  The embodiment disclosed this time is merely an example, and the present invention is not limited to this. The present invention is defined by the terms of the claims, rather than the scope described above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a perspective view which shows the lower case of the ion generator which concerns on embodiment of this invention. In the same embodiment, it is a perspective view which shows the drive circuit board and ion generating element of an ion generator. FIG. 3 is a cross-sectional view of the ion generating element shown in FIG. 2 in the same embodiment. In the same embodiment, it is a perspective view which shows the upper case of an ion generator. In the embodiment, it is the disassembled perspective view seen from the upper case side for demonstrating the assembly procedure of an ion generator. In the embodiment, it is the disassembled perspective view seen from the lower case side for demonstrating the assembly procedure of an ion generator. In the embodiment, it is the perspective view which looked at the state with which the upper case for demonstrating the assembly procedure of an ion generator was mounted | worn to the lower case from the upper case side. In the embodiment, it is the perspective view which looked at the state with which the upper case for demonstrating the assembly procedure of an ion generator was mounted | worn to the lower case from the side of the lower case. In the embodiment, it is a fragmentary perspective view for demonstrating a mode that the lower case is filled with the resin material. FIG. 9 is a cross-sectional view taken along a cross-sectional line XX shown in FIG. 8 in a state where the lower case is filled with a resin material in the same embodiment. In the embodiment, it is a fragmentary perspective view which shows a mode that resin is sucked up to a groove part. In the embodiment, it is a fragmentary sectional view which shows a mode that resin is sucked up to a groove part. In the same embodiment, it is a fragmentary sectional view which shows the resin fixing protrusion part of the upper case in the ion generator which concerns on a modification. In the embodiment, it is a fragmentary perspective view which shows a mode that the resin material is sucked up in the clearance gap between the resin fixing protrusion part and lower case in the ion generator which concerns on a modification. In the same embodiment, it is a fragmentary top view which shows the arrangement | positioning relationship between the resin fixing protrusion part and groove part of the upper case in the ion generator which concerns on another modification. FIG. 10 is a partial side view showing a resin fixing protrusion of an upper case in an ion generator according to still another modification in the embodiment. In the embodiment, it is a perspective view which shows the modification of the assembly procedure of an ion generator. It is a perspective view which shows the assembly procedure of the conventional ion generator.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Ion generator, 2 Lower case, 2a Opening part, 2b Substrate receiving part, 2c Groove part, 3 Ion generating element, 4 Discharge electrode, 5 Induction electrode, 6 Dielectric substrate, 7 Drive circuit board, 8 Substrate body, 8a Cutting Notch, 9 Power connector, 10 Step-up transformer, 11 Upper case, 12 Resin fixing protrusion, 12a Key-shaped part, 13 Connector opening, 14 Recessed part, 15 Filling amount adjusting protrusion, 16, 16a Resin material, 17 Moisture-proof material, 18 resin material injection opening, 20 high voltage wire.

Claims (9)

A bottomed bottom case,
An ion generating element that is fixed to an opening provided in a bottom portion of the lower case and generates ions toward the outside of the lower case;
A substrate part disposed above the ion generating element and electrically connected to the ion generating element to form a driving circuit for driving the ion generating element;
An upper case that is attached to the lower case and covers the substrate portion by sandwiching the substrate portion with the lower case;
A connection member formed on the upper case and the substrate portion, introducing a predetermined filler from the upper case side through the substrate portion, and connecting the ion generating element and the substrate portion is the ion generating element. An ion generator provided with at least a predetermined inlet for sealing a portion to be connected.   The first protrusion including a portion that is provided in the upper case so as to protrude from the upper case toward the lower case, and that reaches the filler to be introduced and is embedded in the filler. The ion generator according to 1.   The first protrusion is separated from the lower case by a predetermined interval that allows the filler to be introduced to be sucked up by capillarity at a portion between the first protrusion and the lower case. The ion generator according to claim 2.   4. The ion generator according to claim 2, wherein a key-like portion is formed on a portion of the first protrusion portion embedded in the filler. 5. The lower case is
A substrate receiving portion formed on a side surface portion and supporting the substrate portion from below;
A groove portion formed on the side surface portion so as to extend from the bottom portion toward the substrate receiving portion and for sucking up the introduced filler to the substrate receiving portion by capillary action. The ion generator in any one of 1-4.   The ion generator in any one of Claims 1-5 provided with the filling amount adjustment part for filling the predetermined amount of said fillers.   The ion generator according to claim 6, wherein the filling amount adjustment unit includes a second protrusion that protrudes toward the lower case so as to be exposed at a portion of the introduction port in the upper case. .   The ion generator according to claim 1, wherein the filler is filled so as to seal the ion generating element and a portion of a lower case located in the vicinity thereof.   The ion generator according to claim 1, wherein a moisture-proof material is applied to the substrate portion.

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