JP6113962B2 - Resin panel and air conditioner equipped with the same - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a synthetic resin panel formed by injecting resin into a mold, and specifically, a front panel and a cover panel mounted on an air conditioner cabinet, a display panel for home appliances, and an instrument panel. In addition, the present invention relates to a resin panel used as a clock dial or the like.

Conventionally, as a method of forming a resin panel, a method of injecting a resin into a mold having a cavity formed in the shape of the resin panel and taking out the resin panel from the mold after cooling is frequently used. For example, in the case of molding a substantially rectangular resin panel, in order to inject resin into the cavity, in order to efficiently fill the cavity with resin, it corresponds to one end of the both ends of the resin panel in the short direction in the cavity. It is desirable to provide a gate at a position where the resin is injected and to inject the resin from the gate toward the other end.

  By the way, conventionally, as a resin panel, in order to improve the intensity | strength of a panel, the structure by which the side wall was formed in the edge part of a plate-shaped panel main body is used. For example, as a resin panel, FIG. 2 of Patent Document 1 is a front panel formed in a horizontally long shape in an air conditioner, and has a cross section in which side walls are formed at an upper end portion and a lower end portion, that is, both ends in a short direction. U-shaped ones are listed.

  In order to mold the front panel having the above-described configuration, a gate is provided at the position of the front end portion of the side wall formed at one end portion of the upper end portion and the lower end portion, which are both ends in the short direction of the front panel, and the other end portion. A method of injecting resin toward the surface can be employed. Specifically, when the front panel 11 of the air conditioner is molded as a resin panel, as shown in FIG. 9, a gate is provided at the position of the tip of the upper side wall 14a formed at the upper end of the front panel, and the lower end It is possible to inject resin toward

Since the front panel 11 formed by the above method is cut at the gate portion and separated from the runner , the gate mark G remains at the gate formation position on the upper side wall 14a. By the way, in the molding method, the resin flow tends to be disturbed in the vicinity of the gate. In particular, the resin flow direction changes abruptly at the connection portion between the upper side wall 14a and the panel body 13, and therefore the resin flow is more disturbed. Residual stress is likely to occur during the cooling process.

  Therefore, when the thickness of the panel body 13 of the resin panel and the thickness of the upper side wall 14a on which the gate is formed are the same, the strength of the upper side wall 14a becomes insufficient, and the left and right ends of the front panel 11 are There is a problem that cracks are likely to occur on the upper side wall 14a in the vicinity of the gate mark G when a force is applied in a bending direction so as to approach each other. In addition, sinking, unevenness, flow marks, and the like may occur from the side wall portion near the gate mark G to the front side of the panel body 13 due to a sudden change in the flow rate of the resin, and this also impairs the appearance.

JP 2011-64343 A

  As means for solving the above problem, it is conceivable to increase the strength of the upper side wall 14a by increasing the thickness of the upper side wall 14a having the gate mark G as shown in FIGS. However, with this means, although the strength of the upper side wall 14a is improved, the change in the flow rate of the resin becomes more rapid, and there is a problem that appearance defects such as sink marks, unevenness, and flow marks increase on the front side of the panel body. .

  Therefore, in the present invention, in view of the above, even if a bending force is applied to the resin panel, it is possible to suppress the occurrence of cracks in the side wall near the gate mark, and to cause the appearance failure on the front side of the panel body. It is an object to provide a resin panel that can be reduced and an air conditioner using the resin panel.

  In order to achieve the above object, according to the present invention, in the resin panel having a gate mark at the time of molding, the resin panel has a U-shaped cross section including a panel main body and a side wall formed at an end of the panel main body. The gate trace is located at a tip in the height direction of the extending portion, the extending portion extending in a height direction from the side wall in a part of the side wall. .

  According to the said structure, the intensity | strength of a side wall can be improved by extending an extending part in the height direction of a side wall. That is, the presence of the extended portion itself increases the rigidity of the side wall, thereby suppressing the occurrence of cracks in the side wall.

  In addition, even when appearance defects such as sink marks, unevenness, and flow marks occur, the appearance defects can be retained in the region of the extending portion and the side wall portion to suppress the appearance failure from reaching the panel body portion. It becomes possible. In the resin panel, side walls are formed at both ends in at least one direction out of two vertical and horizontal (or up, down, left, and right) directions of the panel body, and an extending portion is provided on one of the opposing side walls across the panel body. As long as it is formed, side walls may be formed at one end or both ends in the other direction of the panel body.

  The extending portion may be formed so that the width on the side close to the side wall is widened. This prevents stress from concentrating on the connecting part (boundary part) between the extended part and the side wall when a force is applied to the resin panel to bend like a bow, thereby suppressing the occurrence of cracks. Can do. That is, by forming the extended portion, as described above, the generation of cracks in the vicinity of the gate is suppressed, and the width of the boundary between the extended portion and the side wall is increased by increasing the width toward the side wall. It is possible to suppress cracking. Moreover, you may form an extending part in the same thickness as a side wall. Thereby, when resin flows into the side wall portion from the extending portion portion in the cavity during molding, it is possible to suppress the occurrence of poor appearance by suppressing the change in the flow rate of the resin.

  A plurality of extending portions may be formed at the front end of the side wall at intervals in the length direction of the side wall. Thereby, even if it is an elongate rectangular resin panel, the intensity | strength of a resin panel can be improved and it becomes possible to fill resin in a cavity efficiently.

  The above-mentioned resin panel is less likely to cause appearance defects such as sink marks, unevenness, and flow marks, and even if an appearance defect occurs, it remains in the region of the extending portion and the side wall portion, and the appearance defect extends to the panel body portion. Can be suppressed. That is, appearance defects can be substantially reduced. Therefore, the air conditioner in which the resin panel is mounted on the cabinet as the front panel can suppress the occurrence of cracks and poor appearance on the front panel.

  As described above, the resin panel of the present invention is formed in a U-shaped cross section including a panel main body and a side wall formed at the end of the panel main body, and a part of the side wall is formed in a height direction from the side wall. Since the gate trace is located at the tip in the height direction of the extended section, even if the resin panel is curved, cracks on the side wall near the gate trace are unlikely to occur. In addition, it is possible to reduce the occurrence of poor appearance on the front side of the panel body.

The perspective view of the indoor unit of the air conditioner which shows embodiment of this invention The perspective view which looked at the front panel of Drawing 1 from the upper part AA sectional view of FIG. Enlarged view of the circled portion of FIG. Top view showing upper wall and extension The figure which shows the 2nd aspect of an extending part The figure which shows the 3rd aspect of an extending part The figure which shows the 4th aspect of an extending part A perspective view showing a front panel of a conventional air conditioner BB sectional view of FIG. Enlarged view of the circled part in FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this embodiment, the front panel of an air conditioner is produced as a resin panel according to the present invention, and this front panel is attached to the air conditioner. 1 is an external perspective view of an indoor unit of an air conditioner according to the present invention as viewed from above, FIG. 2 is an external perspective view of a front panel used in the indoor unit of FIG. 1, and FIG. FIG. 4 is an AA cross-sectional view, and FIG. 4 is an enlarged view of a portion surrounded by a circle in FIG.

  As shown in FIG.1 and FIG.2, the front panel 1 as a resin panel of this invention is attached to the front surface of the cabinet 2 of an indoor unit so that rotation is possible. The front panel 1 is formed in a substantially rectangular shape so that the longitudinal direction of the front panel 1 is parallel to the horizontal direction X of the indoor unit, and the short side direction of the front panel 1 is parallel to the vertical direction Y of the indoor unit. Is mounted on the front surface of the cabinet 2.

  The front panel 1 includes a panel body 3 and side walls 4 formed so as to surround the entire periphery of the panel body 3. The side wall 4 has an upper side wall 4a, a lower side wall 4b, a right side wall 4c, and a left side wall 4d at the upper end portion, the lower end portion, the right end portion and the left end portion of the front panel 1 with the front panel 1 mounted on the cabinet 2, respectively. Is formed.

  As shown in FIGS. 2, 3, and 4, an extending portion 5 extends from a front end of the upper side wall 4 a in the height direction of the upper side wall 4 a on a part of the upper side wall 4 a of the front panel 1. A gate mark G for injecting resin into the cavity when the front panel 1 is molded is left at the tip of the extended portion 5. The extending portion 5 has the same thickness as that of the upper side wall 4a. Further, the width closer to the side wall is increased, in other words, the width is gradually increased toward the upper side wall 4a.

  That is, as shown in FIG. 5, the extending portion 5 is formed to have a trapezoidal shape (hereinafter simply referred to as a trapezoidal shape) when viewed from above the front panel 1. By interposing the extending portion 5 having such a shape between the gate and the upper side wall 4a, the occurrence of cracks in the upper side wall 4a in the vicinity of the gate mark G and appearance defects such as sink marks, unevenness, and flow marks can be prevented. While suppressing generation | occurrence | production, the crack of the boundary part of an extending part and a side wall can also be suppressed.

Since the front panel 1 is still connected to the runner 6 when the mold is filled with resin, the runner 6 is cut at the gate portion when the front panel 1 is removed from the mold. Therefore, the gate trace G is left as a cut surface of the runner 6 at a part of the tip of the extended portion 5.

  As shown in FIG. 2, the extending portions 5 are formed at three positions at intervals in the length direction of the upper side wall 4 a at the tip of the upper side wall 4 a. Thus, the intensity | strength of the upper side wall 4a can be raised more by forming the extending part 5 in multiple numbers.

  Furthermore, even if appearance defects such as sink marks, unevenness, and flow marks occur, it is possible to keep the appearance defects in the region of the extending portion 5 and the upper side wall 4a and suppress the appearance failure from reaching the panel main body portion. it can. In particular, in the present embodiment, the extension portion 5 is formed on the upper surface of the front panel 1, so that the extension portion 5 is not touched when attached to the indoor unit, and the extension portion 5 has a poor appearance. Even in this case, the aesthetic appearance is not substantially lost.

  An air inlet 7 is formed by the front panel 1 and the cabinet 2 on the upper surface of the indoor unit. Therefore, as the height of the upper side wall 4a of the front panel 1 increases, the opening area of the suction port 6 decreases, and there is a possibility that the amount of air sucked and thus the heat exchange efficiency may be affected. The height of the upper side wall 4a is not increased as a whole, but the extending portion 5 is partially provided, so that a reduction in the opening area of the suction port 6 can be minimized.

  FIG. 6 is a diagram showing another aspect of the extending portion 5. As illustrated, the extending portion 5 can be formed not only in a trapezoidal shape but also in a square shape (hereinafter simply referred to as a square shape) when viewed from above the front panel 1. However, in the case of this embodiment, when a force that bends the bow so that the left and right ends of the front panel 1 are brought close to each other as indicated by white arrows is applied to the front panel 1, the direction indicated by the black arrows, Stress tends to concentrate on the connecting portion (boundary portion) between the side wall 4a and the extending portion 5.

  On the other hand, when the extending portion 5 is formed in a trapezoidal shape, as shown in FIG. 5, the connecting portion between the upper side wall 4a and the extending portion 5 is an inclined surface, so that stress is dispersed and cracking occurs. Can be suppressed. Therefore, compared with the case where the extending part 5 is formed in a square shape, cracks are less likely to enter.

  In addition, in order to suppress the crack in the boundary part with a side wall in a square-shaped extension part, the connection part (boundary boundary) between the upper side wall 4a and the extension part 5 so that the width | variety near the side wall may become wide. The portion may be smoothly connected. For example, the licking portion 8 is provided as shown in FIG. 7, or the R portion 9 is provided as shown in FIG.

  Although the embodiments of the present invention have been described above, the scope of the present invention is not limited to these embodiments, and various modifications can be made without departing from the spirit of the invention.

DESCRIPTION OF SYMBOLS 1 Front panel 2 Cabinet 3 Panel main body 4 Side wall 4a Upper side wall 5 Extension part 6 Runner 7 Suction port G Gate trace

Claims (5)

In the resin panel having a gate mark at the time of molding, the resin panel is formed in a U-shaped cross section including a panel main body and a side wall formed at an end of the panel main body. It has an extending part extending in the height direction from the side wall in a part in the length direction, and the extending part is left in a state of being connected to the side wall even after molding as a part of the panel, A resin panel, wherein the gate mark is located at a tip in a height direction of the extending portion. The resin panel according to claim 1, wherein the extending portion is formed so that a width on a side close to the side wall is widened. The resin panel according to claim 1, wherein the extending portion is formed to have the same thickness as the side wall. The resin panel according to any one of claims 1 to 3, wherein a plurality of the extending portions are formed at the front end of the side wall at intervals in the length direction of the side wall. An air conditioner in which the resin panel according to any one of claims 1 to 4 is mounted on a cabinet as a front panel.

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