JPH06123449A - Outdoor device of air conditioner - Google Patents

Abstract

PURPOSE:To make a small-sized outer frame of each of electrical parts, make the number of lines minimum and short distance so as to improve a workability in connecting operation and further to reduce noise by a method wherein the electrical parts constituting an inverter are arranged in a multi-layer structure. CONSTITUTION:A first layer of a multi-layer structure is of heat radiation fins 6, a second layer is formed at a flat part of it, and an inverter module 4 having these first and second layer is closely contacted with a substrate 17 as well as a rectifier 5 with screws 16. A third layer is the formed substate 17 for an electrical power and fixed to the thermal radiation fins 6 with screws 16 through a spacer 18. A power factor improving capacitor 7, a DC power source smoothing capacitor 8, a noise filter 11 and an input/output terminal 19 and the like are mounted on the power formed substrate 17. A fourth layer is a printed circuit board 22 and this is fixed to the power formed substrate 17 with an inter-board support 21. A micro-computer 23, a sensor terminal 24 and a control power source transformer 25 and the like are mounted on the printed circuit board 22 so as to constitute a control circuit. These electrical component parts of the inverter are stored in an electrical part case 2 and fixed to a side surface of the thermal radiation fins 6.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an outdoor unit for an air conditioner, and mainly to an outdoor unit equipped with an inverter.

[0002]

2. Description of the Related Art In recent years, since air conditioners have excellent controllability at room temperature, they have been made into inverters, and outdoor units equipped with electrical components of the inverters have become the mainstay. In the case of inverters, in addition to the conventional internal / external connection terminals, power supply circuits, capacitors, relays, etc., electrical components such as power factor correction circuits, rectifiers, noise filters, inverter modules, control circuits, radiating fins, etc. are required. . Therefore, the electrical components become complicated and large, and the method of mounting the electrical components of the inverter and the method of storing the inverter in the outdoor unit are important in determining the size, cost, reliability, etc. of the product.

FIG. 10 shows a conventional air conditioner, which comprises an indoor unit 100 and an outdoor unit 101, which are connected by a refrigerant pipe 102. The outdoor unit 101 includes an inverter 103, a compressor 104, a heat exchanger 105, a blower fan 106, and a motor 107.
And the heat exchanger 105 is the heat exchanger 10 of the indoor unit 100.
8 and the refrigerant pipe 102 form a refrigeration cycle. The heat exchanger 108 of the indoor unit 100 radiates the heat of the outside air into the room during heating with a refrigerant as a medium, and conversely releases the outside air into the room during cooling to perform air conditioning for cooling and heating. The drive control of the compressor 104 is performed, and the compressor 10 is controlled according to the difference between the room temperature and the set temperature.
The number of rotations of 4 is controlled. FIG. 11 shows a configuration of an outdoor unit and a storage arrangement of an inverter device in a conventional air conditioner. In FIG. 11, 109
Is an outdoor unit outer casing, 107 is a fan motor, 106 is a blower fan, 105 is a heat exchanger, 103 is an inverter,
Reference numeral 110 is a partition plate, and 104 is a compressor. In the figure, the outdoor unit partitions the heat exchanger chamber 111 housing the blower fan 106 and the heat exchanger 105 and the compressor chamber 112 by a vertical partition plate 113. The inverter 103 makes its bottom contact the upper part of the partition plate 113. Compressor 1
It is installed in the upper section of 04.

FIG. 12 shows the structure of a conventional inverter. In the figure, reference numeral 1 denotes an internal / external connection terminal which is screwed to the front bottom portion of an electric case 2 made of an iron plate. Reference numeral 3 is a reactor, which is screwed to the electrical equipment case 2. An inverter module 4 is fixed in close contact with the radiating fin 6 together with the radiating fin 6, and the radiating fin 6 is screwed to the electrical component case 2. At that time, the heat radiation fins 6 are arranged at positions facing the circumferential side portions of the blower fan 106, and cool the heat generating elements such as the inverter module 4 and the rectifier 5 by the airflow generated by the rotation of the blower fan 106. Reference numeral 7 denotes a capacitor, which forms a power factor correction circuit in a circuit configuration with the reactor 3 and is vertically arranged in parallel with the smoothing capacitor 8 in the electrical component case 2. A control board 9 is fixed to the electrical equipment case 2 on the pattern side via an insulating frame 10 made of resin.

A noise filter 11 is a printed circuit board 12.
The printed circuit board 12 is fixed to the upper surface of the electrical component case 2 by forming a circuit. Reference numeral 13 is an iron lid of the electric case.

FIG. 13 shows a circuit configuration of the inverter, and the same reference numerals as those in FIG. 12 indicate the same electric parts. Figure 1
The inverter circuit shown in FIG. 3 is composed of a power supply circuit 14 including a noise filter 11, a reactor 3, capacitors 7, 8 and a rectifier 5, an inverter module 4 and a control circuit 9, and connecting terminals between terminals of individual electric parts. They are electrically joined together by using the attached lead wires 15, and these lead wires 15 have wire diameters and coating thicknesses corresponding to the respective current capacity and voltage.

Those similar to the above-mentioned conventional examples are introduced in Japanese Patent Publication No. 3-99136, Japanese Patent Application No. P03-178985 and the like.

[0008]

Since the outdoor unit and the inverter of the conventional air conditioner are constructed as described above, there are the following problems.

(1) Since the electric parts constituting the circuit of the inverter are separated from each other, the lead wires are enormous and diversified, and the reliability of the connecting portion is lowered, and the wiring work is complicated. As a result, processing costs increase. Further, since the control circuit malfunctions due to the inductive and electrostatic noise generated from the lead wire, the number of noise countermeasure components increases.

(2) The shape of the electrical case is complicated,
When the electrical components that make up the circuit of the inverter are housed and fixed in the electrical case, the workability deteriorates and the assembly processing cost rises.

(3) The electrical case has a complicated shape,
Moreover, since the shape does not match the shape of the electric component, the space factor in the case is poor, and the mounting structure has a lot of space. Therefore, the total size of the inverter becomes large, and in the conventional example, the volume of the inverter becomes about 8.6 l, which affects the volume and weight of the entire outdoor unit of the air conditioner. In the conventional example, the volume is about 103 l, and when installing the outdoor unit in a general household, there is a problem in the product of the air conditioner such that the installation space is wide and the installation work requires a long time. .

The present invention has been made in order to solve the above-mentioned problems, and the size of the outer frame of the electric components mounted on the inverter is made small and the number of wirings is made the minimum and the shortest.
Improve work and reduce noise. Furthermore, it is intended to downsize the outdoor unit and reduce the cost.

[0013]

A refrigeration cycle component such as a compressor, an outdoor heat exchanger, an outdoor blower and a noise filter, a power factor improving circuit, a rectifier, a smoothing capacitor, a power transistor, and a radiation fin in a unit body. In an outdoor unit of an air conditioner that accommodates an inverter composed of a constituent circuit such as a control circuit wiring board, the heat dissipation parts such as a rectifier and a power transistor are arranged on the second layer in the structure of the inverter by disposing a radiating fin on the first layer. Is placed in close contact with the heat radiation fin, a wiring board that constitutes a power supply circuit including a noise filter, a rectifier, a power factor correction circuit, a smoothing capacitor, etc. is placed on the third layer, and a control circuit wiring board is placed on the fourth layer. And connect the electrical connections of the second and third layers at the lead terminals of the rectifier and power transistor, or connect with the lead wires. The second unit and the third layer are connected by a vertical connector between boards or a lead wire, and the above-mentioned object is achieved by an outdoor unit of an air conditioner that houses an inverter having a structure in which the heat radiation fin and the electric case are fixed. To achieve.

[0014]

As described above, by arranging the electric components forming the inverter in a multi-layer structure, the space factor inside the inverter is increased to achieve miniaturization, reduction in the number of wirings and noise, and at the same time, a compact inverter. The outdoor unit of the air conditioner can be made lighter and more compact by mounting it on the outdoor unit of the air conditioner.

[0015]

EXAMPLES Examples of the present invention will be described below. FIG. 1 shows the structure of an inverter according to the present invention, and FIG. 2 is a perspective view showing the layer structure of the inverter. The same 1 symbol is the same 1
Indicates a thing. In the figure, the first layer of the multi-layer structure is made up of aluminum radiating fins 6, and the inverter module 4 and the rectifier 4, which form the second layer on the flat portion, are brought into close contact with each other with screws 16.

In the third layer, the power molding substrate 17 is fixed with the radiation fins 6 and the screws 16 via the spacers 18. A power factor improving capacitor 7, a DC power source smoothing capacitor 8 and a noise filter 1 are provided on the power molding substrate 17.
1, an input / output terminal 19, an inter-board connector 40, and an inter-board support 21 are mounted. The fourth layer is a printed wiring board 22 and is fixed to the power molding wiring board by an inter-board support 21. A microcomputer 23, a sensor terminal 24, a control power supply transformer 25, etc. are mounted on the printed wiring board 22 and soldered to form a control circuit. The electric assembly of the inverter having the above-mentioned multilayer structure is housed in the electric case 2 and fixed to the side surface of the heat radiation fin 6 with the screw 16.

Next, each layer structure and the electrical joining method will be described. A first embodiment will be described with reference to FIG. The same code is
The same thing is shown. In the figure, the radiation fin 6 of the first layer is
This is for cooling the heating elements such as the inverter module 4 and the rectifier 5 in the second layer, and the ventilation duct 26 is provided in the fin portion to enhance the cooling effect. The power molding board 17 of the third layer is a circuit that mainly constitutes the power supply circuit 14 of the inverter, and requires a current capacity of 20 A or more. Therefore, in this embodiment, a molded substrate capable of passing a current of up to 30 A is used as the power molded substrate 17. The structure of the power molding substrate 17 will be described with reference to FIGS. FIG. 4 shows an example of the circuit pattern 27, which is made of copper or conductive metal, and has a pattern width of, for example, 4 mm in order to reduce the resistance so as not to generate heat even when a large current is applied. As described above, the pattern thickness is set to 0.5 mm or more. The circuit pattern 27 is covered with an injection molding resin 28. FIG. 5 shows a cross-sectional structure of the molded substrate, in which the end portion of the circuit pattern 27 is bent to provide the connection terminal 19 protruding from the molded resin layer 28, and a large electric component such as the capacitor 8 is provided. A rib 29 for fixing the is formed. At the portion where the rib 29 is formed, a terminal 30 of an electric component such as the capacitor 8 is formed.
The through holes 31 into which the terminals are fitted are provided, and the terminals 30 and the circuit pattern 27 are soldered by the solder lands 32a formed by opening the lower molding resin layer 28 around these through holes. Further, the terminals 34 of the electric component 33 arranged on the back surface of the power molding board 17 are soldered to the solder lands 32b provided on the front surface of the molding resin layer 28. In the embodiment of FIG. 3, the electrical connection between the layers is made using the solder lands 32 of the power molding board 17. That is, the lead terminals 33 a and 33 b of the inverter module 4 and the rectifier 5 are soldered to the surface solder lands 32 b of the power molding board 17. Moreover, electric parts such as a noise filter mounted on the power molding board 17 are soldered to the solder lands 32a provided on the back surface.

It should be noted that the power molding board 17 can obtain the same function even if it is formed of a conventional printed wiring board. The fourth layer is a printed wiring board 22 on which electronic components such as the microcomputer 20 are mounted and soldered to form a control circuit. The fixing is performed by the inter-substrate support 21 which is formed integrally with the injection-molded resin 119 during the molding. Further, for electrical connection with other layers, the lead wire 15 connects between the input / output terminal 34a soldered on the printed wiring board and the input / output terminal 34b provided on the other layer. At this time, the lead wire 15 is formed on the power molding board 17 and the printed wiring board 22 by the opening 3
Lead wire 1 by wiring through 5, 36
It can be shortened because there is no need to draw around 5.

Next, a second embodiment is shown in FIG. The layer structure and the electric components to be mounted in this embodiment are the same as those in the first embodiment described with reference to FIG. 3, but the method for electrically connecting the layers is different. The same reference numerals indicate the same things. Below, FIG.
Will be described.

Reference numeral 37 is a power printed wiring board on which a photocoupler, a capacitor, a drive circuit 38 and the like are mounted. The lead terminals 33a of the inverter module 4 and the connection terminals 39, which are on the extension of the circuit pattern of the power molding board 17 and project outward from the molding resin 28, are soldered to the solder lands of the power printed wiring board 37 to form lead wires. Make electrical connection without The printed wiring board 22 forming the control circuit is connected by fitting the inter-board connector 40 soldered at a predetermined position.

According to the inverter device unitized with the multi-layer structure as described above, the space area becomes small, and if the layers are joined by the connector and the soldering, the number of lead wires is also greatly reduced. An example of the dimensions of the electrical equipment case of such an inverter device is as follows: width 140 mm × 150 mm × 2
It is 00 mm and the volume is 4.1 liters, which is a wiring-less structure.

FIG. 7 shows an embodiment of an outdoor unit of an air conditioner in which the above-mentioned inverter device 103 is incorporated, and parts corresponding to those in FIG. 11 are designated by the same reference numerals.

In this embodiment, similarly to the conventional example shown in FIG. 11, the inverter device 103 is arranged above the compressor 104. According to this, since the volume of the inverter device 103 of the present invention is about 1/2, the width is narrower and the volume is 20% to 30% compared to the outdoor unit of FIG. 10 using the conventional inverter device. It gets smaller.
FIG. 8 shows the compressor 104 including a propeller fan 106 and a motor 1.
7 shows another embodiment of the outdoor unit of the air conditioner according to the present invention, which is arranged below 07 and the inverter device 103 is arranged beside the compressor 104. FIG. 9 is a perspective view of this embodiment, and 114 is a whole surface cover. In this embodiment, since each device is arranged as described above, the height direction is higher, but the width is narrower and the occupation area of the installation place is smaller than that of the embodiment shown in FIG. can do. By the way, in this example, the width was 600 mm, the height was 650 mm, the depth was 650 mm, and the volume was 72 liters, which was about 70% of the conventional value.

The present invention is not limited to the circuit example shown in FIG. 13, and the arrangement of the electric components in each layer is not limited to that shown in FIGS. 1 and 2.

[0025]

As described above, according to the present invention,
Large-sized electric components can be arranged three-dimensionally by applying the multilayer structure mounting method and the power-molded board, so that a high-density type inverter with a small space area and a volume reduced to about 1/2 can be obtained. In addition, the number of wirings can be greatly reduced by using soldering and electrical connection between the boards for electrical connection of each layer, and this has made it possible to reduce the number of assembly processing to about 2/3 that of the conventional method. Noise generated from other wirings can be reduced. By installing this inverter in the outdoor unit of the air conditioner, the width and width of the unit can be greatly reduced compared to the conventional one, even if the depth and height of the unit are the same as those of the conventional one. The degree of freedom of arrangement at the time of installation is increased, and there are great effects such as reduction of the occupied area of the air conditioner and reduction of installation work.

[Brief description of drawings]

FIG. 1 is a perspective view of an inverter device of the present invention.

FIG. 2 is a perspective view showing a layer structure of an inverter device of the present invention.

FIG. 3 is a cross-sectional view of a first embodiment of the inverter device of the present invention.

FIG. 4 is a diagram showing a circuit pattern of a power molding substrate.

FIG. 5 is a cross-sectional structural diagram of a power molding substrate.

FIG. 6 is a cross-sectional view of a second embodiment of the inverter device of the present invention.

FIG. 7 is a view showing an outdoor unit of the air conditioner according to the first embodiment of the present invention.

FIG. 8 is a diagram showing an outdoor unit of an air conditioner according to a second embodiment of the present invention.

FIG. 9 is a perspective view of an outdoor unit of an air conditioner according to a second embodiment of the present invention.

FIG. 10 is a perspective view of a conventional air conditioner.

FIG. 11 is a diagram showing an outdoor unit of a conventional air conditioner.

FIG. 12 is a development view of a conventional inverter device.

FIG. 13 is a circuit diagram of a conventional inverter device.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Internal / external connection terminal, 2 ... Electrical case, 3 ... Reactor, 4 ... Inverter module, 5 ... Rectifier, 6 ... Radiating fin, 7 ... Power factor improving capacitor, 8 ... Smoothing capacitor, 9 ... Control board, 10 ... Insulation frame, 11 ... Noise filter, 12 ... Printed circuit board, 13 ... Lid, 14 ... Power supply circuit, 15 ... Lead wire, 16 ... Screw, 17 ... Power molding board, 18 ... Spacer, 19 ... Input / output terminal, 20 ... Board Connector, 21 ... Board support, 22 ... Printed wiring board, 23 ... Microcomputer, 24 ... Sensor terminal, 25 ... Control power transformer, 26 ... Ventilation duct, 27 ... Pattern circuit, 28 ... Molded resin, 29 ... Fixing rib , 30 ... through-hole,
31 ... Lead terminal, 32 ... Solder land, 33 ... Terminal,
34 ... Connection terminal, 35 ... Opening part, 36 ... Molded board opening part, 37 ... Power printed board, 38 ... Drive circuit,
39 ... Connection terminal, 40 ... Board connector, 10 ... Indoor unit, 101 ... Outdoor unit, 102 ... Refrigerant piping, 103 ... Inverter, 104 ... Compressor, 105 ... Heat exchanger, 106 ...
Blower fan, 107 ... Motor, 108 ... Indoor heat exchanger,
109 ... Case, 110 ... Partition plate, 111 ... Heat exchanger room, 113 ... Compressor room, 114 ... Panel.

Claims (6)

[Claims] 1. A refrigeration cycle component such as a compressor, an outdoor heat exchanger, an outdoor blower and a noise filter, a power factor correction circuit, a rectifier, a smoothing capacitor, a power transistor, a radiation fin, and a control circuit wiring in a unit body. In an outdoor unit of an air conditioner that accommodates an inverter composed of a circuit such as a board, the inverter has a structure in which a heat radiation fin is arranged in the first layer and a heat generating component such as a rectifier and an inverter module is arranged in the second layer. , A wiring board having a power supply circuit composed of a noise filter, a rectifier, a power factor correction circuit, a smoothing capacitor, etc. is arranged on the third layer, and a control circuit wiring board is arranged on the fourth layer. Two
The electrical connection of the third and third layers is soldered at the lead terminals of the rectifier and power transistor, or with a connector with a lead wire, and the second and third layers are connected with a vertical connector between the boards or a lead wire. An outdoor unit for an air conditioner, characterized in that an inverter having a structure in which the radiation fin and the electric case are fixed is housed. 2. The outdoor unit for an air conditioner according to claim 1, wherein the heat dissipating fins of the inverter are arranged so as to face a side portion of a blower propeller fan. 3. The outdoor unit for an air conditioner according to claim 1, wherein the radiation fins of the inverter are arranged in series with a side portion of the blower propeller fan, and the ventilation fins are provided with ventilation ducts. Inverter device. 4. The outdoor unit for an air conditioner according to claim 1, wherein the second-layer wiring board of the inverter has a thick wiring conductor capable of flowing a large current and a power supply circuit pattern having a connection tab terminal to the outside. An inverter device comprising a power-molded substrate covered with an injection-molded resin. 5. The power-molded substrate according to claim 4,
An inverter device characterized in that a molded resin is formed so that a connection portion between a circuit pattern and a mounted component is exposed, and a molded substrate having a structure in which soldering lands are provided on wiring conductors on both surfaces of the substrate is incorporated. 6. The power-molded substrate according to claim 4,
A molding resin is formed so that the connection portion between the circuit pattern and the mounted component is exposed, and a portion of the molding board having a structure in which soldering lands are provided on the wiring conductors on both sides of the board is opened, and the opening is formed. An inverter characterized by arranging a printed wiring board on which electric circuit components are mounted, and incorporating a molded board having a structure in which lead terminals provided on the printed board and soldering lands of the wiring conductor are connected by soldering. apparatus.