JP3639060B2 - Box for air conditioning equipment and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to, for example, a box body of an air conditioner outdoor unit and a manufacturing method thereof.
[0002]
[Prior art]
Using an alloyed galvanized steel sheet as a material as shown in FIG. 8 so that it can withstand the bad environment caused by solar radiation and rain water when it is placed outdoors like the outer box of a conventional air conditioner outdoor unit. It was manufactured in the steps of oiling ST4a by painting or showering, press molding processing ST4b such as drawing, welding ST4c, cleaning ST4d, and coating ST4e. In addition, some parts that do not require severe pressing or welding such as drawing are manufactured only by pressing by applying a coated steel plate to the material.
[0003]
[Problems to be solved by the invention]
The outer casing of a conventional outdoor unit for air conditioning needs to be painted to ensure corrosion resistance and design, and oiling is applied to enable rust prevention and drawing of the material before pressing. There was a problem that processing had to be performed and a cleaning step before painting was necessary.
As shown in FIG. 8, the conventional outer box body of an air conditioning outdoor unit is painted after pressing and welding, and thus there is a problem that red rust is easily generated from a portion where coating is difficult to wrap around.
In the case of applying a coated steel plate that has been painted before press working in the outer box of a conventional outdoor unit for air conditioning, there is a drawback that it is extremely difficult to perform resistance welding because the conductivity is remarkably inferior.
Conventional outer casings of air conditioning outdoor units have insufficient heat reflectivity when exposed to direct sunlight. Therefore, there is a problem in that the inside of the outdoor unit becomes high temperature and efficiency in cooling operation decreases.
[0004]
The present invention was made to solve the above problems, and an object of the present invention is to provide a box body for an air conditioning apparatus that can ensure excellent corrosion resistance and design properties equal to or higher than those of conventional ones without painting. And It is another object of the present invention to provide a manufacturing method that enables oil-free drawing and resistance welding necessary for the manufacturing thereof, and can form a box body of an air conditioning device by a very simple process.
Furthermore, it aims at providing the apparatus for an air conditioning which can improve cooling efficiency.
[0005]
[Means for Solving the Problems]
A pneumatic equipment box or a manufacturing method thereof according to the present invention includes a storage box that stores mechanical parts and electrical parts of an air conditioner, and a press forming that includes a throttle in a steel plate that forms at least a part of the storage box. And an outer shell which is joined and assembled without painting by a joining means including welding or screwing, and the steel plate is plated with a highly corrosion-resistant alloy, and an organic top coat is formed on the surface thereof with a film thickness of 1. It is a high corrosion resistance alloy-plated steel sheet coated with a thickness of 3 to 3.0 .
Further, in the case where the outer shell is provided at the bottom of the storage box, a leg portion is attached to the outer shell of the bottom portion, and a high corrosion resistance alloy-plated steel plate having an organic top coat with a predetermined thickness on the surface thereof. It is configured.
[0006]
Moreover, the predetermined film thickness of the organic topcoat is configured with a thickness of 1.3 to 3.0 μm.
[0007]
Further, the high corrosion resistance alloy-plated steel plate has an elongation rate in the tensile test of 40% or more and a plastic strain ratio (Rankford value r) of 1.6 to 2.5.
[0008]
The high corrosion-resistant alloy-plated steel plate has a surface dynamic friction coefficient of 0.17 or less.
[0009]
The high corrosion-resistant alloy-plated steel sheet has a crystal structure of spangle with a dent light arm interval (DAS) of 8 to 12 μm.
[0010]
Further, the high corrosion-resistant alloy-plated steel plate has a blackened surface by physical or chemical treatment.
[0011]
The organic top coat is colored with a paint or the like.
[0012]
A step of producing a bottom plate by subjecting a high corrosion resistance alloy plated steel plate plated with a high corrosion resistance alloy and having a surface coated with an organic top coat to include a drawing; and a compressor on the bottom plate. And a step of fastening a panel to the bottom plate and producing a box body for storing mechanical parts and electrical parts of an air conditioner without painting, wherein the organic top coat is made of the high corrosion resistance alloy-plated steel plate. It is applied to the surface with a thickness of 1.3 to 3.0 μm.
[0013]
Moreover, the said member consists of a volt | bolt which gave Ni-Zn plating, and is joined to the said steel plate with a welding structure .
[0014]
Further, the welding member is made of alumina-dispersed copper as an electrode material , and the electrode tip is welded with a dome-shaped hemispherical structure.
[0015]
In addition, the press molding process is performed by a press process in which oil is not applied to the processed surface .
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1 FIG.
FIG. 1 shows an outer box of an outdoor unit for air conditioning according to Embodiment 1 of the present invention. Reference numeral 1 denotes a bottom plate, which is composed of a drawn portion 1a that has been drawn and formed, two leg portions 1b that are spot-welded at three positions, and three stud bolts 1c that are projection welded to fix the compressor. Has been. Reference numeral 2 is a front panel, 3 is a back panel, 4 is a top panel, each of which is pressed separately, and is screwed to each other between the panels 1, 2, 3, and 4. Housed in the box made up of this panel are mechanical parts such as the fan 5, the motor support 6, the heat exchanger 7, the refrigerant pipe 8, the compressor 9, the partition plate 10, and the electrical parts that control these mechanical parts. It constitutes an outdoor unit of an air conditioner.
[0017]
FIG. 2 shows the main specifications of the high corrosion resistance alloy-plated steel sheet applied to the first embodiment of the present invention. This material is plated with a highly corrosion-resistant alloy after the steel plate is manufactured, and the surface is coated with a resin, and has better heat reflectivity than a general coated steel plate or a mere plated steel plate. The specifications shown in FIG. 2 are examples and do not limit the numerical range described. For example, the Al content of plating may be 0.4 to 60% by weight.
Applying a highly corrosion-resistant alloy-plated steel sheet having a characteristic value within the range shown in the specification example of FIG. 2, for example, oil-free drawing processability and resistance required for the manufacture of the outer box of an air-conditioning outdoor unit Since it can satisfy all of weldability, corrosion resistance without painting, designability, etc., productivity and quality can be secured even if mass production is performed.
The first embodiment of the present invention is an outer box body of an air conditioning outdoor unit manufactured according to the manufacturing process shown in FIG.
[0018]
First, 4 steps of 0.8mm thickness, 335mm width, 770mm length, high corrosion resistance alloy plated steel plate with specifications shown in Fig. 2, drawing, trimming as edge, re-striking as re-press, and piercing as drilling. A bottom plate 1 having a drawing portion 1a shown in FIG. 1 was manufactured. (ST3a) Note that this press working includes drawing, ironing, and the like, in which the gap between the punch and the die is narrower than the material plate thickness.
[0019]
When the aperture is deep, the top coat is organic and the film thickness on one side is preferably 1.3 μm or more. When welding is required, the film thickness is smaller than that of general coating, for example, 3.0 μm or less. For example, if a film thickness of 2.1 μm is specified, a film thickness of 1.7 to 2.5 μm including variations can be obtained.
Next, a press work including edge punching to prevent burrs on the end face was applied to a high corrosion resistance alloy-plated steel sheet having the specification shown in FIG. 2 using a coil material having a plate thickness of 1.0 mm to produce the leg 1b shown in FIG. Next, three stud bolts 1c shown in FIG. (ST3b) Here, as the stud bolt, the one provided with Ni-Zn plating having a small electrode potential difference from the bottom plate material and excellent corrosion resistance was used. Thereby, corrosion resistance is better than conventional bolts such as colored galvanized bolts.
Next, the bottom plate 1 was manufactured by spot resistance welding of the two legs 1b to the bottom plate in three places.
[0020]
Here, as shown in FIG. 7, the electrode for spot welding uses a dome-shaped, alumina-dispersed copper sintered material with a tip diameter of 6mm40R and an outer diameter of 13mm, and the welding current is the same as that of the conventional alloyed hot-dip galvanized steel sheet. Resistance welding was carried out at about 9000 A, about 200% higher than the case, with a pressure of 200 kgf, and with a current-carrying time of 12 Hz. This dome-shaped hemispherical electrode has more stable welding characteristics than other electrode shapes such as a CF type or a flat tip.
[0021]
FIG. 4 is an example showing various properties necessary for simultaneously satisfying resistance weldability and drawing workability as shown in FIG. The specifications shown in FIG. 4 show some of the actual products and comparative products of the highly corrosion-resistant alloy-plated steel plates applied to the production of the bottom plate of the present invention, and the results of evaluating the resistance weldability and drawing workability are shown in FIG. Indicated. From these results, the manufacture of bottom plates that require good weldability and drawing workability with a height of 10 mm or more has characteristics such as elongation of 40% or more, r value of 1.6 or more, Erichsen value of 11.0 mm or more, and dynamic friction coefficient of 0.17 or less. is necessary. Elongation, r value, dynamic friction coefficient, and the like are effective for drawing workability, and the topcoat thickness and plating thickness are effective for resistance weldability. In addition, r value and a dynamic friction coefficient are the states with a topcoat. The r value is a composition strain value, which is obtained by measuring the plate thickness and the plate width when the elongation in the longitudinal direction becomes 20% in the tensile test.
Further, the front panel 2 and the top panel 4 shown in FIG. 1 have a plate thickness of 0.6 mm, and the back panel 3 has a plate thickness of 0.5 mm. Each of the front panel 2 and the top panel 4 is manufactured by applying a high corrosion resistance alloy plated steel plate having the specifications shown in FIG. did.
[0022]
The Erichsen value in FIG. 4 is a test that evaluates the stretch formability by deforming the plate with a punch, and is based on JISZ2247. Originally, the test is performed with sufficient lubricity provided by lard, but in FIG. The test was conducted without lubrication for evaluation including the lubrication ability.
Next, after attaching the heat exchanger 7, propeller fan 5, compressor 9, etc. to the bottom plate, these panels are fastened with screws, plastic parts such as the front cover 2 are fitted, and the outer box of the air conditioner outdoor unit Completed body production. In other words, the high corrosion-resistant alloy-plated iron plate with an organic top coat with a predetermined thickness is used to eliminate the need for painting after press processing, which enables oil-free drawing and resistance welding required for manufacturing. At the same time, the oil ring process, cleaning process, painting process, etc. can be abolished, making it possible to manufacture in a simple process.
[0023]
Embodiment 2. FIG.
In the second embodiment, in FIG. 1, the bottom plate 1 that needs to be welded, that is, the drawn portion 1a, the leg portion, 1b, the stud bolt 1c, and the like are manufactured in the same manner as in the first embodiment, while welding is performed. The other unnecessary panels 2, 3, and 4 were manufactured by pressing a coated steel plate.
These were manufactured and assembled in the same manner as in the first embodiment, and the outer box body of the outdoor unit for air conditioning in the second embodiment was manufactured.
[0024]
Furthermore, if the dendrite arm spacing (DAS) is 8-12 μm as the size of the crystal spangle of the highly corrosion-resistant alloy-plated steel sheet, that is, the crystal flower pattern, for the front panel and top panel of the outer box of the air conditioner outdoor unit A product having a good design can be obtained, and a product having a good balance of corrosion resistance, formability, weldability and the like can be obtained. .
The size of the crystal spangle can be obtained by changing the manufacturing conditions of the steel sheet, such as the composition, the degree of processing, the preheating, and the cooling rate.
[0025]
In addition, a high-corrosion-resistant alloy-plated steel sheet that has been physically or chemically blackened is applied to the front panel or top panel of the outer box of the air conditioning outdoor unit to obtain a design that is attractive in design. In other words, the surface of the steel sheet can be made uneven by micron units by the treatment liquid to enable blackening by irregular reflection, or the topcoat can be blackened by mixing carbon powder or the like.
[0026]
Or you may apply the high corrosion-resistant alloy plating steel plate which gave the organic topcoat colored by mixing paints, such as blue and yellow, in the outer box of the outdoor unit for air conditioning. This makes it possible to produce a product that looks good even without paint.
[0027]
As described above, according to the present invention, an outer case body of an air conditioner outdoor unit can be manufactured by applying a non-coated high corrosion-resistant alloy-plated steel sheet, so that the coating process can be abolished and manufactured at low cost. In addition, the outer box body of an air conditioning outdoor unit to which the present invention is applied can ensure corrosion resistance equivalent to or better than that of the conventional product even without painting, and particularly has excellent corrosion resistance for the gap portion where the wraparound tends to be insufficient with the conventional coated product. As a result, the durability and quality of the product can be improved.
In addition, by applying a highly corrosion-resistant plated steel sheet with an organic top coat, it is possible to perform drawing without oil and to eliminate the oiling process and the cleaning process, so that it can be manufactured at a lower cost.
In the above explanation, an outdoor unit of an air conditioner has been described as an example, but it can be an air conditioner installed in the basement of a building that requires corrosion resistance, a transparent dome with significant solar radiation, or a box of air conditioners installed in a greenhouse, etc. Needless to say, similar effects can be obtained.
[0028]
Further, by appropriately selecting the film thickness of the top coat, the drawing workability and resistance weldability necessary for the production of the present invention can be satisfied at the same time.
Further, by appropriately selecting the size of spangles of the highly corrosion-resistant plated steel sheet, or by blackening or coloring it, an air conditioner box that is more excellent in design can be obtained.
Further, by applying the present invention to the front panel and top panel of the box body, an effect of improving the efficiency of the cooling operation can be obtained by suppressing the temperature rise inside the equipment storage box by improving the heat reflectivity.
[0029]
【The invention's effect】
The present invention includes a storage box for accommodating a mechanical or electrical component of the air conditioner, the steel plates forming at least a portion of the storage box, the bonding means including welding or screwing subjected to press forming that includes an aperture An outer shell that is joined and assembled without painting, the steel plate is plated with a highly corrosion-resistant alloy, and an organic top coat is formed on the surface with a thickness of 1.3 to 3.0 μm. Because it is made of a highly corrosion-resistant alloy-plated steel plate , the box of air-conditioning equipment has excellent corrosion resistance, so it can maintain a good-looking appearance for a long time and improve the performance of storage equipment even when the external environment deteriorates. A highly reliable air-conditioning equipment box can be obtained.
Further, in the case where the outer shell is provided at the bottom of the storage box, a leg portion is attached to the outer shell of the bottom portion, and a high corrosion resistance alloy-plated steel plate having an organic top coat with a predetermined thickness on the surface thereof. Because it is constructed, it prevents corrosion due to dissimilar metals and has excellent corrosion resistance, so it can prevent corrosion of the legs and maintain a good-looking appearance for a long period of time. Is obtained.
[0030]
Moreover, since the predetermined film thickness of the organic top coat is configured with a thickness of 1.3 to 3.0 μm, drawing and welding can be performed without substantially damaging the top coat film thickness. A box of air conditioning equipment with good workability and excellent corrosion resistance can be obtained.
[0031]
In addition, the high corrosion resistance alloy-plated steel plate has an elongation rate in the tensile test of 40% or more and a plastic strain ratio (Rankford value r) of 1.6 to 2.5. Since the elongation is good and deep drawing can be performed, a box of an air conditioning device having a high degree of freedom in shape can be obtained.
[0032]
In addition, since the high-corrosion-resistant alloy-plated steel sheet has a surface dynamic friction coefficient of 0.17 or less, the surface dynamic friction coefficient is low, so that pressing can be performed without applying oil to the surface. Therefore, an economical air-conditioning equipment box that can be manufactured with a small number of work steps can be obtained.
[0033]
In addition, since the high corrosion resistance alloy plated steel plate has a crystal structure with a dent light arm interval (DAS) of 8 to 12 μm, the weldability, formability and corrosion resistance are improved, so that the degree of freedom in processing is increased. A box of air conditioning equipment that is high and has good corrosion resistance can be obtained.
[0034]
Further, since the surface of the highly corrosion-resistant alloy-plated steel plate is blackened by physical or chemical treatment, a box body of an air-conditioning device that has better corrosion resistance and looks good can be obtained.
[0035]
In addition, since the organic top coat is colored with a paint or the like, it is possible to obtain a box for an air-conditioning device that has better corrosion resistance and maintains its appearance for a long period of time.
[0036]
A step of producing a bottom plate by subjecting a high corrosion resistance alloy-plated steel plate plated with a high corrosion resistance alloy and having an organic top coat to the surface thereof to press forming process including drawing, and a compressor on the bottom plate And a step of fastening a panel to the bottom plate and producing a box body for storing mechanical parts and electrical parts of an air conditioner without painting, wherein the organic top coat is made of the highly corrosion-resistant alloy-plated steel plate. Since the surface is made with a thickness of 1.3 to 3.0 [mu] m, the processability is good and it can be manufactured with few processes. can get.
[0037]
In addition, since the member is made of a bolt plated with Ni-Zn and is joined to the steel plate with a welded structure, the member having further increased corrosion resistance is firmly fixed by welding, so that the quality of the product The manufacturing method of the box of the air-conditioning equipment which does not affect the is obtained.
[0038]
In addition, the welding member is made of alumina-dispersed copper, which is an electrode material, and the shape of the electrode tip is welded with a dome-shaped hemispherical structure. A highly reliable method for manufacturing a box of an air-conditioning device can be obtained.
[0039]
Also, the press molding work, because the working surface of the oil is pressing a such is not applied, since the working process during pressing is reduced, the manufacture of the working process less economical box body of the air conditioning equipment A method is obtained.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing an outer box body of an air conditioning outdoor unit according to a first embodiment of the present invention.
FIG. 2 is a diagram showing a specification example of a high corrosion resistance alloy-plated steel plate applied to Embodiment 1 of the present invention.
FIG. 3 is a diagram showing a manufacturing process of the present invention.
FIG. 4 is a characteristic explanatory view showing test results of a practical product of a high corrosion resistance alloy-plated steel sheet applied to the present invention and a comparative product.
FIG. 5 is an explanatory diagram showing the results of trial evaluation for manufacturing the bottom plate of the present invention.
FIG. 6 is an explanatory diagram showing a method for measuring a dynamic friction coefficient.
FIG. 7 is an explanatory view showing an example of an electrode used in the manufacturing method of the present invention.
FIG. 8 is a diagram showing a manufacturing process according to a conventional technique.
[Explanation of symbols]
1 bottom plate, 2 front panel, 3 back panel, 4 top panel, 5 fan, 7 heat exchanger, 9 compressor.

Claims (6)

A storage box for storing mechanical parts and electrical parts of an air conditioner and a steel plate forming at least a part of the storage box are subjected to press forming processing including drawing and joined without painting by a joining means including welding and screwing. An outer shell to be assembled, the steel plate is plated with a highly corrosion-resistant alloy, and an organic top coat is coated on the surface with a thickness of 1.3 to 3.0 μm , and the surface A box body for air conditioning equipment, characterized by being a high corrosion resistance alloy-plated steel plate having a dynamic friction coefficient of 0.17 or less .   In the case where the outer shell is provided at the bottom of the storage box, the leg portion is attached to the outer shell of the bottom portion, and is composed of a highly corrosion-resistant alloy-plated steel plate with an organic top coat having a predetermined thickness on the surface thereof. The box body for an air-conditioning apparatus according to claim 1.   The box body for an air-conditioning apparatus according to claim 1 or 2, wherein the surface of the highly corrosion-resistant alloy-plated steel plate is blackened by physical or chemical treatment.   The box for an air-conditioning apparatus according to claim 1, wherein the organic top coat is colored with a paint or the like. A step of producing a bottom plate by subjecting a high corrosion resistance alloy-plated steel plate plated with a high corrosion resistance alloy and having an organic top coat to the surface to produce a bottom plate, and a compressor attached to the bottom plate The member is made of a bolt with Ni-Zn plating, and is attached to the bottom plate by welding, and a box for fastening the panel to the bottom plate and storing mechanical parts and electrical parts of the air conditioner is manufactured without painting. And the organic top coat is applied to the surface of the high corrosion resistance alloy-plated steel plate with a thickness of 1.3 to 3.0 μm, and the dynamic friction coefficient of the surface is 0.17 or less. A box manufacturing method for air conditioning equipment.   6. The box manufacturing method for an air-conditioning device according to claim 5, wherein the press forming process is performed by pressing without applying oil to the processed surface.

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