JP4507553B2 - Cross flow fan and cross flow fan manufacturing method - Google Patents

Description

  The present invention relates to a crossflow fan and a method for manufacturing the crossflow fan, and more particularly to a crossflow fan characterized by the impeller coupling structure and the coupling method.

  A conventional crossflow fan for an air conditioner will be described with reference to FIGS.

FIG. 14 is a schematic diagram of the structure of the indoor unit of the air conditioner. As shown in FIG. 14, the air blower circuit (the air blower part) of the indoor unit 33 of the air conditioner includes a suction part 34, an air filter 35, and a heat exchanger. 36, the cross flow fan 1, and an air flow passage that flows through the blow-out portion 37. The crossflow fan 1 is connected to a drive shaft 39 of a motor 38 that rotationally drives the crossflow fan 1.
Next, the configuration of the cross flow fan will be described with reference to FIGS. As shown in FIG. 15, the cross flow fan 1 includes a side plate 6 having a shaft 7, a plurality of impellers 2, and a motor side end impeller 8 having a boss 9 as basic components.
FIG. 16A is a configuration diagram illustrating a conventional cross-flow fan assembly manufacturing method described later, and FIG. 16B is an explanatory diagram illustrating a configuration in which the impellers 2 are fitted to each other.
The impeller 2 has a plurality of blades (blades) 3 attached in a ring shape at regular intervals or at irregular intervals in the rotational direction. As shown in FIG. 16 (b), one end portion 3 x is integrally formed with the partition plate 4, and the other end portion 3 y is fitted and fixed to the blade groove 2 a formed in the partition plate 4. It is configured as follows.

  On the other hand, a welding rib (not shown) is inserted in the blade groove 2a in advance, and after one end portion 3y of the blade 3 is fitted to the blade groove 2a, heat welding or ultrasonic welding is performed, A plurality of vehicles 2 are coupled in the rotational axis direction to constitute a cross flow fan.

More specifically, for example, transmission vibration is generated in the axial end surface portion of the blade 3 by applying pressure by applying a vibration to the partition plate 4 by applying a horn (not shown) that transmits vibration of the ultrasonic welder, Heat is generated between the welding ribs (not shown) and the welding ribs are melted, whereby the one end portion 3y of the blade 3 and the blade groove 2a are connected by transmission welding. Thereafter, several impellers 2 are axially welded several times by ultrasonic welding, and then the vanes 3 of the impeller assembly 8 and the vane grooves 2a of the impeller 2 are engaged to transmit welding by ultrasonic welding. The cross flow fan 1 is assembled by combining them.
Further, as a countermeasure against axial runout, as shown in FIG. 16 (a), there is a manufacturing method in which at least two impellers 2 are surrounded by a press surrounding member 40 to correct axial runout. (For example, refer to Patent Document 1).
JP 55-160198 A

However, in the above-described conventional cross flow fan configuration and manufacturing method, a plurality of impellers 2 are sequentially combined and an ultrasonic welding process is required a plurality of times. In a state where the gap with the wheel 2 is 0 or the impeller 2 is pressed down, ultrasonic energy is absorbed by the press surrounding member 40 at the time of ultrasonic welding, so that the gap between the axial end surface of the blade 3 and the welding rib Insufficient ultrasonic energy is transmitted to the surface, resulting in insufficient transmission and welding, resulting in variations in bonding force, and a long welding time.

For this reason, a gap is required between the press surrounding member 40 and the impeller 2, and there is a problem that axial deflection occurs due to the gap.
The present invention solves such a conventional problem, and eliminates the ultrasonic welding process by adopting a structure in which impellers of cross flow fans can be joined by injecting resin, and the end face in the axial direction of the blade By injecting a resin between the blade groove and the blade groove, a strong bond can be obtained, and by eliminating axial runout, the balance during rotation is good and the balance correction process is not required, so an inexpensive cross flow An object of the present invention is to provide a cross flow fan that can provide a fan and that can perform smooth rotation, has good performance, and does not require an annealing process, and that can greatly reduce the cost of electricity, and a method for manufacturing the same.

In order to solve the above-mentioned problems, the crossflow fan of the present invention is configured such that the blades of the impeller engage with the blade grooves of the adjacent impeller partition plate, and the outer peripheral surface of the partition plate has a width substantially equal to the depth of the blade groove. A groove is provided, and a first notch forming a part of the outer peripheral groove is formed on the outer peripheral side of the axial end surface of the engaged blade, and resin is injected into the outer peripheral groove to be coupled. Is.

  With the above configuration, since the plurality of impellers are joined by injecting resin into the outer peripheral groove, the ultrasonic welding process and the annealing process can be eliminated, and an inexpensive cross flow fan can be obtained.

Further, in another invention of the present application, a second notch is provided on the axial end face of the blade, a rib is provided on the partition plate, and the second notch and the rib are engaged with each other in the axial direction of the blade. between the end face and the vane groove is characterized in that the digits set the gap.

  With the above configuration, since the second notch of the blade and the rib of the partition plate are engaged, positioning in the axial direction becomes possible, so that a cross flow fan with good axial length accuracy can be obtained. Multiple impellers are inexpensive and strong because the ultrasonic welding process and annealing process can be abolished while a strong bonding force is obtained by injecting resin between the peripheral groove and the axial end face of the blade and the blade groove. A cross flow fan is obtained.

In another invention of the present application , a wall is provided in the blade groove, and a gap is provided between the axial end surface of the blade and the blade groove by engaging the wall with the axial end surface of the blade . It is characterized by that.

  With the above configuration, since the plurality of impellers are injected with resin between the end face in the axial direction of the blade and the blade groove and stopped by the wall, the cross flow fan capable of stable coupling without flowing out to the central side in the axial direction is provided. can get.

  Another invention of the present application is characterized in that a shape for increasing the coupling area is provided on the end face in the axial direction of the blade.

  With the above-described configuration, the plurality of impellers are filled with resin in a shape that increases the bonding area between the axial end surfaces of the blades and the blade grooves and between the end surfaces of the blades in the axial direction. A cross flow fan with a strong binding force can be obtained.

Further, according to another invention of the present application, the inner peripheral surface of the blade is smaller than the inner diameter of the partition plate, and the width from the inner peripheral surface to the substantially inner diameter of the partition plate at the end surface in the axial direction of the blade is larger than the end surface in the axial direction of the blade. A long rib is provided in a substantially axial direction.

With the above-described configuration, when the blades of the impeller are engaged with the blade grooves, the guide is prevented from being shifted in the normal direction, so that a cross flow fan capable of easily engaging the blades and the blade grooves can be obtained.
According to another invention of the present application, an outer peripheral wall having an outer diameter equal to or smaller than the outer diameter of the outer circumferential groove is provided in at least one blade groove. It is characterized by providing a notch.
With the above configuration, it is possible to prevent the resin from being injected from the outer peripheral groove into the blade groove of the impeller with respect to the blade removed from the impeller assembly, and to remove at least one blade of the impeller assembly. A fan is obtained.
Further, another invention of the present application includes a step of injection molding the impeller described above, a step of engaging the blade with the blade groove, and a step of injecting resin into the outer peripheral groove. Features a manufacturing method.
With the above configuration, a plurality of impellers are joined by injecting resin between the outer peripheral groove or the end face in the axial direction of the blade and the blade groove, and the ultrasonic welding process and the annealing process can be eliminated. The electricity bill can be greatly reduced, and no capital investment or remodeling is required when dealing with new models.

  As is apparent from the above, according to the crossflow fan and the crossflow fan manufacturing method of the present invention, the welding process of the impeller is unnecessary, and the axial runout that occurs during welding is eliminated, so that the balance is corrected. It is possible to obtain an inexpensive cross flow fan because the process is not required and the number of assembly steps can be greatly reduced.

  Moreover, since an annealing process for removing the distortion that has occurred at the time of welding is not required, the electricity cost in the cross-flow fan assembly process can be greatly reduced, and there is almost no axial runout that occurs at the time of welding. Therefore, it is possible to improve performance.

  In addition, since resin is injected between the blade end face in the axial direction and the blade groove, a tightly coupled cross flow fan can be obtained, and the welding and annealing processes are not required, so the cross flow fan assembly for new models is possible. This eliminates the need for capital investment or remodeling, and is economical.

  Embodiments of the present invention will be described below with reference to the drawings. Although the embodiment of the present invention will be described with respect to a crossflow fan used in an indoor unit of an air conditioner, the form to which the present invention is applied is not limited to this, and a plurality of impellers are welded or If it is constituted by adhesion, the same effect is obtained.

  Moreover, the same number is attached | subjected about the component similar to the structure of the crossflow fan shown in FIGS. 14-16, and the description about the detailed description and the connection relationship with another component is abbreviate | omitted.

(Embodiment 1)
First, a first embodiment according to the present invention will be described with reference to FIGS.

  FIG. 1 is an exploded perspective view of an embodiment of the present invention. The cross flow fan 1 is composed of a side plate 6 having a shaft 7, a plurality of impellers 2, and an impeller 8 having a boss 9.

2 is a perspective view from the side of the partition plate 4 of the impeller 2, and FIG. 3 is a perspective view from the side opposite to the partition plate. The partition plate 4 is formed with a blade groove 5 that fits with one end 3 c of the blade 3.

  An outer peripheral groove 10 having a depth of the blade groove 5 is provided on the outer peripheral surface side of the partition plate 4. More specifically, as shown in FIG. 4, the outer peripheral groove 10 is a shape in which a step is provided in a part of the outer periphery on the side where the one end 3 c of the blade 3 of the partition plate 4 having an annular outer peripheral shape is inserted. It is an annular depression that is recessed in the radial direction from the outer periphery.

  Further, the blade groove 5 is formed by cutting up to the outer peripheral groove 10. That is, a part of the blade groove is configured to face the outer peripheral groove 10. The first notch 11 and the axis of the blade 3 which are formed in the axial direction on the outer peripheral portion in the axial direction of the blade 3 when the one end 3c of the blade and the blade groove 5 are engaged are formed in the axial direction. A rib 13 that has a second notch 12 on the end face in the direction and engages with the second notch 12 is provided on the partition plate 4.

  In FIG. 4, the blade groove 5 of the impeller 2 adjacent to the blade 3 and the second notch 12 and the rib 13 are engaged, and a gap 14 is provided between the axial end surface of the blade 3 and the blade groove 5. FIG. 5 is a partial cross-sectional perspective view showing a state, and FIG. 5 is a partial cross-sectional perspective view showing a state in which the resin 15 is injected into the outer peripheral groove 10 and the gap 14 of the cross flow fan 1 in the state of FIG. It is.

  6 and 7 are schematic views showing the manufacturing method of the present invention. As shown in FIG. 6, the impeller injection mold 16, the impeller assembly injection mold 17, and the side plate injection mold. After the impeller 2, the impeller assembly 8, and the side plate 6 are respectively injection molded at 18, the respective blades 3 and the blade grooves 5 are fitted and assembled as shown in FIG.

  FIG. 7B is a cross-sectional view parallel to the axial direction of the cross flow fan 1 of the molds 19a and 19b for injecting resin for joining the impeller. A resin flow path 22 formed by the outer peripheral groove 10 and molds 19a and 19b for injecting resin is provided, and the width of the resin flow path 22 is narrower than the width of the outer peripheral groove 10 of the partition plate 4. A first slide 20 and a second slide 21 that push the cross flow fan 1 in the axial direction are provided on both sides in the direction.

  FIG. 7C is an enlarged view of the main part at the Z portion in FIG. 7B, and shows the relationship between the mold 19 a for injecting resin into the outer peripheral groove 10, the outer peripheral groove 10, and the impeller 2. ing. An annular groove portion 19c is formed in a portion of the mold 19a facing the outer peripheral groove 10, and resin is poured into the annular groove portion 19c and flows so as to fill the outer peripheral groove 10. Then, as shown in FIG. 5, the impeller 2 adjacent in the rotation axis direction is welded and fixed by the annular resin 15.

  By using the cross-flow fan 1 coupling structure as described above, the outer peripheral groove 10 is formed by the first notch of the blade 3 at the outer peripheral portion of the partition plate 4 when the blade 3 and the blade groove 5 are engaged. It is formed. Further, since the second notch 12 and the rib 13 are engaged, a gap 14 is formed between the axial end surface of the blade 3 and the blade groove 5, and the blade groove 5 and the outer peripheral groove 10 are connected. The outer circumferential groove 10 and the gap 14 are connected. Further, the width of the resin flow path 22 is narrower than the width of the outer peripheral groove 10, and the gap 14 does not leak even if the resin is injected by engaging the second notch 12 and the rib 13, Since the blades 3 and the partition plate 4 are joined by injecting the resin 15 into the flow path 22, a plurality of impellers 2 can be joined without requiring ultrasonic welding.

Further, since the resin 15 is injected into the gap 14 through the outer peripheral groove 10 while being pressed in the axial direction by the first slide 20 and the second slide 21, the shaft of the blade 3 is not leaked due to the injection pressure. The end face in the direction and the blade groove 5 are combined, and a strong cross flow fan can be obtained. Further, since an ultrasonic welding process is not required, an annealing process for removing residual stress generated at the time of ultrasonic welding is also unnecessary, and there is no axial runout generated at the time of ultrasonic welding. The process of correcting the balance that occurs during the rotation of the motor becomes unnecessary.

  Therefore, since the ultrasonic welding process, annealing process, and balance correction process, which are the assembly processes of the cross flow fan 1, are not required, an inexpensive cross flow fan can be provided and the annealing process is not required. Electricity costs in the fan assembly process can be greatly reduced. Further, since the second notch 12 of the blade 3 is engaged with the rib 13 of the partition plate 4 while being pressed in the axial direction by the first slide 20 and the second slide 21, the axial positioning is possible. A cross-flow fan with good direction length accuracy can be obtained.

  The same effect can be obtained by providing a protrusion in place of the second notch 12 and providing the partition plate 4 with a groove that engages with the protrusion.

(Embodiment 2)
Next, a second embodiment of the present invention will be described with reference to FIGS. In addition, the same number is attached | subjected about the component similar to Embodiment 1, and the detailed description is abbreviate | omitted.

FIG. 8 is a partial perspective view of the impeller 2 according to the embodiment of the present invention. The outer peripheral groove 10 is provided on the outer peripheral surface of the partition plate 4, and the width in the blade groove 5 is smaller than the width of the tip end surface in the axial direction of the blade. And a wall 24 having the same height as the axial direction of the step 23. FIG. 9 is a cross-sectional view parallel to the axial direction in which the blade 3 and the blade groove 5 are engaged. FIG. 9A is before the resin 15 is injected, and FIG. 9B is the state after the resin 15 is injected. FIG.
With the cross-flow fan coupling structure as described above, the blade 3 engages with the blade groove 5 and is pressed in the axial direction by the first slide 20 and the second slide 21. A position in the axial direction of the blade 3 is determined, and a space 25 formed by the tip surface of the blade in the axial direction, the blade groove 5, the step 23, and the wall 24 is provided, and the blade groove 5 and the outer peripheral groove 10 are connected to each other. Therefore, the outer peripheral groove 10 and the space 25 are connected.

  A resin 15 is injected into the resin flow path 22 and flows from the outer circumferential groove 10 to the space 25, and a wall (standing wall) 24 provided upright on the inner circumferential side of the step 23 and the partition plate 4 with respect to the bottom surface of the blade groove. By stopping the flow, the end face in the axial direction of the blade 3 and the blade groove 5 are combined, and a strong cross flow fan 1 can be obtained. Further, since an ultrasonic welding process is not required, an annealing process for removing residual stress generated at the time of ultrasonic welding is also unnecessary, and there is no axial runout generated at the time of ultrasonic welding. The process of correcting the balance that occurs during the rotation of the motor becomes unnecessary.

Therefore, an ultrasonic welding process, an annealing process, and a balance correction process, which are assembly processes of the cross flow fan 1, are not required, and an inexpensive cross flow fan can be provided.
The same effect can be obtained by providing the wall 24 not on the blade groove 5 but on the blade 3. The same effect can be obtained by providing a step at the tip of the blade 3 in the axial direction instead of the step 23 of the blade groove 5.
(Embodiment 3)
Next, a third embodiment of the present invention will be described with reference to FIGS. 10 and 11 are perspective views of the impeller 2 as viewed from the partition plate side and the side opposite to the partition plate, respectively.

  In the present embodiment, the difference from the first embodiment is that the inner peripheral surface 26 of the blade is smaller than the inner diameter 27 of the partition plate 4, and the inner end surface 27 of the partition plate 4 from the inner peripheral surface 26 on the axial end surface of the blade 3. The long guide ribs 28 are provided in the axial direction of the blades. 11A is a cross-sectional perspective view of the state before the blade 3 and the blade groove 5 are engaged, and FIG. 11B is a cross-sectional perspective view after the engagement.

  According to this embodiment, when the blade 3 and the blade groove 5 are engaged, at least one impeller is rotated, but the guide rib 28 rotates while being in contact with the inner diameter 27 surface of the partition plate. Therefore, the blade 3 and the blade groove 5 can be easily engaged with each other without protruding due to rotation, and the number of assembling steps can be reduced, so that an inexpensive cross flow fan 1 can be obtained. it can.

  A similar effect can be obtained by providing a notch on the inner diameter side of the tip end surface in the axial direction of the blade 3 instead of the guide rib 28 and a guide ring for guiding the notch on the partition plate.

(Embodiment 4)
Next, a fourth embodiment of the present invention will be described with reference to FIG. FIG. 12 is a partial cross-sectional perspective view of the state in which the blade 3 and the blade groove 5 are engaged and the resin 15 is injected. The difference in the present embodiment from the first embodiment is that the resin is applied to the end face in the axial direction of the blade 3. 15 is provided with a recess 29 that increases the bonding area with the Fifteen.

  And according to this embodiment, since the surface where the axial end surface of the blade | wing 3 and the resin 15 contact increases, the cross flow fan 1 with which the coupling | bonding force of the blade | wing 3 and the blade groove | channel 5 is strong can be obtained. .

  In addition, although the said dent 29 was made into the rectangle, even if it is R shape, a triangular shape, etc., if the uneven | corrugated shape is provided, the same effect can be anticipated.

(Embodiment 5)
Next, a fifth embodiment of the present invention will be described with reference to FIG. FIG. 13 is a partial cross-sectional perspective view showing a state where the blade 3 and the blade groove 5 are engaged. In this embodiment, the boss portion of the impeller assembly 8 and the motor drive shaft 39 are easily screwed together. Therefore, at least one of the plurality of blades 3 of the impeller assembly 8 is removed, and an outer peripheral wall 30 having an outer diameter equal to or smaller than the outer diameter of the outer peripheral groove 10 is formed in the blade groove of the impeller 2 that engages with the removed blade. A third notch 31 having an inner diameter equal to or smaller than the inner diameter of the outer peripheral wall 30 is provided on the end face in the axial direction of the blade 3 of the impeller 2 that is provided and engaged therewith.

  According to this embodiment, the resin 15 is stopped by the outer peripheral wall 30 in the blade groove 5 of the impeller 2 that is not engaged because the blade 3 of the impeller assembly 8 does not exist even if the resin 15 is injected. When the impellers 2 are engaged with each other, and the impellers 2 are engaged with each other, the third notch 31 avoids interference with the outer peripheral wall 30, while the blade groove 5 prevents the tip end in the axial direction of the blade 3. 32 is held, it is possible to obtain the cross flow fan 1 having the impeller assembly 8 from which at least one blade 3 is removed and injecting the resin 15 into the outer peripheral groove 10 and joining them.

  In addition, the same effect can be acquired even if it fills with the blade groove | channel engaged with the blade | wing removed from the impeller assembly 8 instead of the outer peripheral wall 30 and the 3rd notch 31. FIG.

1 is an exploded perspective view showing Embodiment 1 of the present invention. The perspective view seen from the partition plate side of the impeller which shows Embodiment 1 of this invention The perspective view seen from the partition plate of the impeller which shows Embodiment 1 of this invention. The partial cross section perspective view which shows the part which combined the impeller which shows Embodiment 1 of this invention The partial cross-sectional perspective view which shows the part which inject | poured resin combining the impeller which shows Embodiment 1 of this invention The perspective view shape | molded with the injection die which shows Embodiment 1 of this invention (A) Perspective view showing the step of combining the impeller, impeller completion and side plate (b) Cross section parallel to the axial direction of the mold cross flow fan for injecting the resin of the present invention (c) FIG. 6 (b) ) Z part main part enlarged schematic diagram of The fragmentary perspective view of the impeller which shows Embodiment 2 of this invention (A) Cross section of cross flow fan before injecting resin showing embodiment 2 of the present invention (b) Cross section of cross flow fan after injecting resin showing embodiment 2 of the present invention (A) The perspective view from the partition plate side of the impeller which shows Embodiment 3 of this invention (b) The perspective view from the partition plate of the impeller which shows Embodiment 3 of this invention from the opposite side (A) Cross-sectional perspective view before engagement of blade and blade groove according to Embodiment 3 of the present invention (b) Cross-sectional perspective view after engagement of blade and blade groove according to Embodiment 3 of the present invention The fragmentary sectional perspective view which shows the state which the blade | wing and blade groove | channel which show Embodiment 4 of this invention engaged, and inject | poured resin The fragmentary sectional perspective view which the blade and the blade groove which showed Embodiment 5 of this invention engaged. Schematic diagram of indoor unit of air conditioner Cross-flow fan schematic diagram Schematic diagram showing the countermeasures against shaft runout of a conventional crossflow fan

DESCRIPTION OF SYMBOLS 1 Crossflow fan 2 Impeller 3 Impeller 4 Partition plate 5 Impeller groove 6 Side plate 8 Impeller assembly 10 Outer peripheral groove 11 First notch 12 Second notch 13 Rib 14 Crevice 15 Resin 19 Mold 20 for injecting resin 20 First slide 21 Second slide 22 Resin flow path 23 steps 24 wall 25 space 27 inner diameter of partition plate 28 guide rib 29 dent 30 outer peripheral wall 31 third notch

Claims (7)

A blade of an impeller configured by arranging a plurality of blades in an annular shape engages with a blade groove of a partition plate of an adjacent impeller, and an outer peripheral groove having a width substantially equal to the depth of the blade groove is formed on the outer peripheral surface of the partition plate. A first notch forming a part of the outer peripheral groove is provided on the outer peripheral side of the axial end face of the provided and engaged blades, and a resin is injected into the outer peripheral groove to be coupled and fixed. Cross flow fan. A second notch formed on the end face in the axial direction of the blade, a rib on the partition plate, the end face and the vane of the second notch and the axial direction of the blade by engaging the rib cross flow fan according to claim 1, wherein the digits set a gap between the grooves. A wall is provided in the blade groove, and a gap is provided between the axial end surface of the blade and the blade groove by engaging the wall with the axial end surface of the blade. The crossflow fan according to claim 1. 2. The crossflow fan according to claim 1, wherein a shape for increasing the coupling area is provided on an end face in the axial direction of the blade. The inner peripheral surface of the blade is smaller than the inner diameter of the partition plate, and a rib extending from the inner peripheral surface to the substantially inner diameter of the partition plate at the end surface in the axial direction of the blade is longer in the axial direction than the end surface in the axial direction of the blade. The crossflow fan according to claim 1. An outer peripheral wall having an outer diameter equal to or less than the outer diameter of the outer peripheral groove is provided in at least one of the blade grooves, and a third notch is provided on the outer peripheral portion of the end surface in the axial direction of the blade engaged with the outer groove, not larger than the inner diameter of the outer peripheral wall. The crossflow fan according to claim 1. As in the case of forming the crossflow fan according to any one of claims 1 to 6, the step of injection molding the impeller and the step of connecting the impeller by engaging the vane and the blade groove adjacent to each other in the axial direction. And a method of manufacturing a cross flow fan, comprising a step of injecting a resin into the outer peripheral groove.

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