JP3702870B2 - 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]
The box body of the air-conditioning equipment according to the present invention is manufactured without painting, and the elongation value of the tensile test is 40% or more so that oil-free press molding is possible, and the r value (plastic strain ratio = Lankford value) The high corrosion-resistant alloy-plated steel sheet having a thickness of 1.6 or more is used, and the dynamic friction coefficient of the coated surface is 0.17 or less.
[0006]
The box of the air-conditioning apparatus according to the second aspect of the present invention has an Al component in the plating composition of the high corrosion-resistant alloy-plated steel sheet used for the top panel of the box and the like in an amount of 0.4 to 60% by weight.
[0007]
A box body of an air-conditioning apparatus according to claim 3 of the present invention is a highly corrosion-resistant alloy-plated steel sheet having an elongation value in a tensile test of 40% or more and an r-value (plastic strain ratio = Rankford value) of 1.6 to 2.5 Is used.
[0008]
The film thickness of the resin film of the box according to the present invention is 1.3 μm to 3.0 μm.
[0009]
The box of the air conditioning apparatus according to the fifth aspect of the present invention has a dendrite arm interval (DAS) of 8 to 12 μm as the size of the crystal spangle of the high corrosion resistance alloy-plated steel sheet.
[0010]
The box body of the air-conditioning apparatus according to the sixth aspect of the present invention employs a high corrosion resistance alloy-plated steel plate that is physically or chemically blackened.
[0011]
The box body of the air-conditioning apparatus according to the seventh aspect of the present invention uses a highly corrosion-resistant alloy-plated steel sheet with a colored organic top coat.
[0012]
According to claim 8 of the present invention, there is provided a method for manufacturing a box body for an air conditioning apparatus, comprising: a step of press forming a high corrosion resistance alloy-plated steel sheet having an organic top coat having a predetermined thickness to manufacture a bottom plate; And a step of fastening the panel after installing the exchanger and manufacturing the box body for storing the mechanical parts and electrical parts of the air conditioner without painting, and the high corrosion resistance alloy-plated steel sheet has an Al component in the plating composition. Is included.
[0013]
According to a ninth aspect of the present invention, there is provided a method of manufacturing a box for an air conditioning device according to the present invention by welding a bolt subjected to Ni-Zn plating and a highly corrosion-resistant alloy-plated steel plate.
[0014]
According to a tenth aspect of the present invention, there is provided a method for manufacturing a box for an air-conditioning apparatus using a welding electrode material made of alumina-dispersed copper and an electrode tip having a dome-shaped hemispherical surface.
[0015]
According to an eleventh aspect of the present invention, there is provided an air conditioning equipment box manufacturing method that is oil-free and press-molded.
[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. This provides better corrosion resistance 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 approximately 9000A, approximately 200% higher than the case, 200 kgf of applied pressure, and 12 Hz energization time. 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】
Since the present invention is configured as described above, the box of the air-conditioning equipment of the present invention can ensure excellent corrosion resistance even when manufactured without coating, and can be manufactured easily and ensure long-term quality even when mass-produced. In addition, it is possible to obtain a product that can maintain a good-looking appearance with excellent heat reflectivity for a long period of time, improve the performance of the storage device, and maintain it without being deteriorated by the external environment.
[0030]
The box of the air-conditioning equipment according to claim 2 can ensure the quality even in mass production.
[0031]
Since the box of the air-conditioning equipment according to claim 3 uses a material having good elongation, deep drawing can be performed while maintaining corrosion resistance.
[0032]
Since the present invention is configured as described above, the organic top coat having lubricity is set to a film thickness that can cope with even a deep drawing, and even when welding is required, the film thickness is smaller than that of general coating. Thus, productivity and quality can be secured even if mass production is performed.
[0033]
The box body of the air-conditioning apparatus according to claim 5 can provide a product having good appearance and good corrosion resistance and moldability without painting.
[0034]
The box body of the air-conditioning apparatus according to claim 6 can provide a good-looking product without painting.
[0035]
The box of the air-conditioning apparatus according to claim 7 can provide a good-looking product without painting.
[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 (7)

Used for a box made without coating that houses mechanical parts and electrical parts of an air conditioner, and a steel plate that forms at least a part of the box and is press-formed. It contains zinc and Al components in the plating composition and has a surface. And a high corrosion-resistant alloy-plated steel sheet coated with a resin having a predetermined film thickness, and an elongation value in a tensile test is 40% or more so that an oil-free press molding process is possible, and an r value (plastic strain ratio = A box body for an air-conditioning apparatus using the highly corrosion-resistant alloy-plated steel sheet having a (Rankford value) of 1.6 or more and a coefficient of dynamic friction of a coated surface of 0.17 or less . Box of the air-conditioning apparatus of claim 1, wherein the Al component in the plating composition of the high corrosion resistant alloy plated steel plate, such as those used in the top Bunnell of the box body is 0.4-60 wt% body. The high corrosion-resistant alloy-plated steel sheet having the r value (plastic strain ratio = Rankford value) of 1.6 to 2.5 and an Erichsen value of 11.0 mm or more in a coated state is used. The box of the air-conditioning apparatus according to claim 1 or 2. The box of an air-conditioning apparatus according to claim 1, wherein the resin film has a thickness of 1.3 μm to 3.0 μm . The box of an air-conditioning apparatus according to claim 1, wherein the crystal spangle of the highly corrosion-resistant alloy-plated steel sheet has a dent light arm interval (DAS) of 8 to 12 µm. The high corrosion-resistant alloy plating steel plate is a box body of the air-conditioning equipment according to claim 1, characterized in that it is blackened by physical or chemical treatment the surface. The height coating resinous corrosion resistance alloy plated steel sheet, the box body of the air-conditioning apparatus of claim 1, wherein the colored treated with paint or the like.

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