JPH1151416A - Casing member for air conditioner and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate manufacture of the chamber, or the like, of an air conditioning indoor unit while enhancing torsional strength and to reduce the cost by sharing the trimming die or bending die for component. SOLUTION: The air conditioning casing member comprises a plurality of linear frames 1 having substantially identical cross-section orthogonal to the longitudinal direction, and a plurality of corner plates 2 for connecting the frames arranged at the corners of a chamber. The frame 1 and the corner plate 2 are provided, respectively, with coupling means 8, 9 to be engaged each other. The frame 1 and the corner plate 2 are coupled according to the frame work of the chamber and a foamable resin thermal insulating material is foamed on the periphery using a die thus integrating the frame 1 and the corner plate 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air conditioner such as a casing for an air-conditioning indoor unit surrounding the periphery of an indoor unit or the like embedded in a ceiling of an air conditioner, or a chamber for forming an air outlet or a suction port. It relates to a casing member for use.

[0002]

2. Description of the Related Art As one of the above-mentioned air-conditioning casings, an air-conditioning chamber is disposed, for example, between an air-conditioning indoor unit installed on a ceiling of the room and an indoor panel, supports a filter and the like, and has an air outlet. It has a complicated shape in which an air inlet, an air flow path for passing fresh air, and the like are defined.

Conventionally, such a chamber is manufactured by combining sheet metal parts formed in various shapes, screwing these sheet metal parts together, and affixing a heat insulating material for preventing dew condensation to the required places. However, there is a problem that it takes time and a lot of time to assemble.

[0004] Further, since the sheet metal parts of the chamber have various shapes that are not uniform, a die cost for manufacturing the parts is high. Therefore, there is also a disadvantage that the torsional strength is weak.

[0005]

SUMMARY OF THE INVENTION The present invention addresses the above-mentioned situation and facilitates the fabrication of casing members such as chambers by performing foam molding at the same time as assembling the components, and at the same time, increases the torsional strength. It is an object of the present invention to improve and further reduce the cost of the mold by unifying the components.

[0006]

That is, the feature of the air-conditioning casing member of the present invention which meets the above-mentioned object is that an air flow path such as an air outlet or a suction port is defined near an indoor unit of an air conditioner. An air-conditioning casing member such as a chamber having a plurality of linear frames having substantially the same cross section orthogonal to the longitudinal direction, and a plurality of corner plates provided at the corners of the casing member and connecting these frames. The frame and the corner plate are respectively engaged with each other to form engagement means for connecting the two, and the frame and the corner plate are connected to the skeleton shape of the casing member, and a foamed resin heat insulating material is provided around the frame and the corner plate. This is where the foamed resin heat insulating material, the frame and the corner plate are integrated by foam molding.

Further, the method of manufacturing a casing member according to the present invention includes a plurality of linear frames having substantially the same cross section perpendicular to the longitudinal direction, and a plurality of linear frames provided at the corners of the casing member and connecting these frames. Using a corner plate, the frame and the corner plate are engaged with each other to form engagement means for connecting the two, and a forming mold for a foamed resin heat insulating material having a cavity in the shape of the casing member is formed. Then, in the mold, the frame and the corner plate are connected to the skeleton shape of the casing member, or the frame and the corner plate previously connected to the skeleton shape of the casing member are inserted into the mold,
Thereafter, the foamed resin heat insulating material is formed by foam molding, thereby integrating the foamed resin heat insulating material with the frame and the corner plate.

In the casing member or the method of manufacturing the same according to the present invention, the engaging means includes a slit formed in a part of the frame, and a claw formed in the corner plate and engaged with the slit. It is also possible to configure with a member.

On the other hand, another feature of the air-conditioning casing member of the present invention is that a plurality of air-conditioning casing members such as an indoor unit casing surrounding an indoor unit of an air conditioner from outside have substantially the same cross section orthogonal to the longitudinal direction. And a top plate disposed on the upper part of the casing member and connecting the frames, and engaging means for engaging the frame and the top plate with each other to connect the two. Then, the frame and the top plate are connected to the skeleton shape of the casing member, and a foamed resin heat insulating material is foamed around the frame resin to integrate the foamed resin heat insulating material, the frame, and the top plate. is there.

Further, in the method for manufacturing an air-conditioning casing member according to the present invention, a plurality of linear frames having substantially the same cross section perpendicular to the longitudinal direction are provided, and a ceiling member is provided above the casing member and connects these frames. Using a plate, the frame and the top plate are engaged with each other to form engagement means for connecting the two, and a forming mold for a foamed resin heat insulating material having a cavity in the shape of the casing member is formed. In this mold, the frame and the top plate are connected to the skeleton shape of the casing member, or the frame and the top plate previously connected to the skeleton shape of the casing member are inserted into the mold,
Thereafter, the foamed resin heat insulating material is formed by foam molding, thereby integrating the foamed resin heat insulating material with the frame and the top plate.

In the casing member or the method of manufacturing the same according to the present invention, the engaging means includes a slit formed in a part of the frame and a claw formed in the top plate and engaged with the slit. It is also possible to configure with a member. Further, as a cross section orthogonal to the longitudinal direction of the frame of these casing members, for example,
A letter shape can be adopted. Note that the configuration in which the cross sections orthogonal to the longitudinal direction are substantially the same means that the frame is provided with a slit hole or the like, and even if the slit hole or the like is shown in the cross section, the frame has a U-shaped cross section or the like. If they have the same outer shape, it is interpreted that the cross sections are almost the same. Also, even if the tip portion is tapered or the like, as long as the same punching die and bending die can be shared as described later,
Similarly, it is understood that the cross sections are almost the same.

[0012]

In the above-mentioned air-conditioning casing member and the method of manufacturing the same according to the present invention, the casing member can be assembled by engaging the frame with the claw member of the corner plate or the top plate and integrally molding with the foamed resin heat insulating material. The number of screwing points can be greatly reduced compared to the past, and since the foamed resin heat insulating material is integrally molded, there is no need to attach heat insulating material as in the past, making it extremely easy to manufacture casing members. It is possible to do it.

Similarly, the torsional strength of the casing member can be improved by integral molding of the foamed resin heat insulating material. Further, even though the frames have different lengths, the same cross-sectional shape is used. It is possible to use only one type of punching die and bending die, so that the cost of producing the component parts can be greatly reduced by sharing the dies of these frames.

[0014]

BRIEF DESCRIPTION OF THE DRAWINGS FIG.
An embodiment of the present invention will be described.

FIG. 1 is an exploded perspective view of a frame and a corner plate showing an air-conditioning chamber which is one of casing members as an embodiment of the present invention, and FIG.
The chamber of this embodiment includes a plurality of frames 1 having a U-shaped cross section (may be an L-shape) and four corner plates 2 to 5 provided at the corners of the chamber and connecting these frames 1. Have.

At the corners of the side wall 6 and the bottom wall 7 of the frame 1, a number of slit holes 8 for engagement are formed in pairs on the left and right side walls 6, as shown in FIG. As shown in FIG. 3, the frame 1 is made of a rod-shaped metal material whose cross section orthogonal to the longitudinal direction has substantially the same shape except for a tapered portion at the tip. This means that long plate materials with different lengths are formed by the same punching die, and these are bent in the same bending die into a U-shaped cross section,
Alternatively, frames 1 of various lengths can be obtained by cutting long ones bent and raised in a U-shaped cross section with the same mold.
Can be produced.

On the other hand, as shown in FIGS. 5 to 8, each of the corner plates 2 to 5 has a claw member 9 which engages with the slit hole 8 of the frame 1 to connect the corner plate to the frame 1 as shown in FIG. It is erected from the main body at an appropriate place as described above. The claw member 9 has a T-shape. When the claw member 9 is inserted from the side into the slit hole 8 of the frame 1 shown in FIGS. . Various types of engagement between the slit hole and the claw member are conceivable. For example, one of them is a claw member in which the head 9a 'is engaged by the longitudinal movement of the frame 1 as shown in FIG. It is also possible to employ 9 'and slit holes 8'. Conversely, it is also possible to form the claw members 9 and 9 ′ in the frame 1 and the slit holes 8 and 8 ′ in the corner plate 2.

The frame 1 and the corner plates 2 to 5 are connected to the skeletal shape of the chamber as shown in FIGS. 1 and 2, and this is connected to a molding die for a foamed resin heat insulating material having a cavity in the shape of a chamber ( (Not shown), and the above resin is foamed, whereby the foamed resin heat insulating material 12, each frame 1 and each corner plate 2 to 5 are integrated as shown in FIG. In this case, assembling the frame 1 and each of the corner plates 2 to 5 is performed by placing the corner plates 2 to 5 on each corner of the mold and positioning the same, and inserting the claw member 9 into the slit hole 8 from inside. This can be done simply and efficiently, but it is also possible to assemble the frame 1 and the corner plates 2 to 5 outside the mold and then insert them into the mold.

The frame 1 and each of the corner plates 2 to 5 are formed with a large number of projections 10 and communication portions 11, whereby the foamed resin heat insulating material 12 and the frame 1 and the corner plates 2 to 5 are formed. Can be strengthened. The chamber thus formed is further strengthened by fixing the opposite side of each of the corner plates 2 to 5 of the frame 1 with another corner plate or a fixing metal as necessary. 2 and FIG.
Reference numeral 15 shown in FIG. 1 denotes a holding member, which connects the upper portions of adjacent frames 1 by inserting claws 17 into slits 16 of the frame 1 as shown in FIG.

In the air-conditioning chamber and the method of manufacturing the same according to the embodiment of the present invention, the engagement between the frame 1, the claw members 8 of the corner plates 2 to 5 and the slit holes 9, and the integration of the foamed resin heat insulating material 12 are performed. Since the chamber can be assembled by molding, it is possible to significantly reduce the number of screwed parts than before, and since the foamed resin heat insulating material is integrally molded, there is no need to attach heat insulating material as in the past, This makes it possible to make the chamber very quickly and easily.

Similarly, the torsional strength of the chamber can be improved by integrally forming the foamed resin heat insulating material 12, and the frame 1 has the same cross-sectional shape as described above. It is possible to use only one type of mold and bending mold, and thus it is possible to use the molds of these frames 13 in common, thereby greatly reducing the cost of producing the component parts.

FIG. 11 is an exploded perspective view showing a casing for an air conditioner indoor unit according to another embodiment of the present invention. When used, the top is on top. In other words, this casing surrounds the air-conditioning indoor unit (not shown) from the outside, and has a plurality of linear frames 13 whose longitudinal cross sections are substantially U-shaped and substantially the same, and an upper portion of the casing (in the figure, And a top plate 14 connected to the frame 13.

Each of the frames 13 has a T-shaped slit hole 8 as in the previous embodiment, and the top plate 14 has a T-shaped slit hole 8 which engages with the slit hole 8. Claw members 9 are formed (see FIG. 3). Then, the slit hole 8 and the claw member 9 are engaged with each other,
As shown in FIG. 11, the frame 13 and the top plate 14 are connected to the skeleton shape of the casing for the indoor unit, and a foamed resin heat insulating material is foamed around the periphery of the casing by a metal mold.
As shown in FIG.
3 and the top plate 14 are integrated. The casing formed in this manner is further strengthened by fixing the opposite side of each top plate 14 of the frame 13 with another fixing bracket or the like as necessary.

Thus, in the casing for the air-conditioning indoor unit and the method of manufacturing the same according to the embodiment of the present invention, the frame 1
Since the casing can be assembled by the engagement of the claw member 8 and the slit hole 9 of the top plate 14 with the slit hole 9 and the integral molding of the foamed resin heat insulating material, the number of screwed portions can be greatly reduced as compared with the related art. Since the foamed resin heat insulating material is integrally formed, it is not necessary to attach a heat insulating material as in the conventional case, and thus, the casing can be manufactured very quickly and easily.

Similarly, the torsional strength of the casing can be improved by integrally molding the foamed resin heat insulating material.
Further, since the frame 13 has the same cross-sectional shape as described above, it is possible to use only one type of punching die and bending die of the frame, and thus, the die of these frames 13 is shared. As a result, it is possible to greatly reduce the cost of producing the components.

The embodiment of the present invention has been described above.
As the above-mentioned foamed resin heat insulating material, foamed polystyrene (styrene) is generally used, but foamed polyurethane resin or the like can also be used. Although the corner plate, frame, or top plate is made of sheet metal in this example, it can be made of a synthetic resin or the like. Other than the groove may be employed.

[0027]

As described above, the air-conditioning casing member and the method of manufacturing the same according to the present invention are provided on a plurality of linear frames having substantially the same cross section perpendicular to the longitudinal direction, and on a part of the casing member. A plate member for connecting these frames, forming engagement means for engaging the frame and the plate member with each other to connect the two, and forming the frame and the plate member into a frame shape of the casing member. The foamed resin heat insulating material and the frame and the plate material are integrated by foaming and molding the foamed resin heat insulating material around the periphery by means of a mold. Since the casing member can be assembled by integral molding with foamed resin insulation material, the number of screwing points can be greatly reduced compared to the past, and Since the fat heat insulating material is integrally formed, it is not necessary to attach a heat insulating material as in the related art, thereby making it possible to manufacture the casing member very quickly and easily. Since the torsional strength of the casing member can be improved by integral molding of the material, and since the above-mentioned frame has substantially the same cross-sectional shape, it is possible to create a component using a single die or bending mold for the frame. It has many effects of greatly reducing costs.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a frame and a corner plate showing an air conditioning chamber according to an embodiment of the present invention.

FIG. 2 is an assembly view of the same.

FIG. 3 is a perspective view showing a slit hole for engagement and a claw member.

FIG. 4 is a perspective view showing a shape of a frame.

FIG. 5 is a perspective view showing a first corner plate.

FIG. 6 is a perspective view showing a second corner plate.

FIG. 7 is a perspective view showing a third corner plate.

FIG. 8 is a perspective view showing a fourth corner plate.

FIG. 9 is a perspective view showing another example of the engagement slit and the claw member.

FIG. 10 is a perspective view showing a chamber after molding a foamed resin heat insulating material.

FIG. 11 is an exploded perspective view showing a casing for an air-conditioning indoor unit according to the embodiment of the present invention.

FIG. 12 is a perspective view showing a casing for an air-conditioning indoor unit after molding a foamed resin heat insulating material.

FIG. 13 is a cross-sectional view showing a holding member and a frame.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Frame 2-5 Corner plate 6 Frame side wall 7 Frame bottom wall 8, 8 'Slit hole 9, 9' Claw member 9a, 9a 'Head 10 Convex part 11 Communication part 12 Foam resin insulation material 13 Frame 14 Top plate 15 Holder Hardware 16 Slit 17 Claw

Claims (12)

[Claims] A plurality of linear frames having substantially the same cross section orthogonal to the longitudinal direction in an air-conditioning casing member that defines an air flow path such as an air outlet and a suction port near an indoor unit of an air conditioner. And, provided at a corner of the casing member, having a plurality of corner plates connecting these frames, forming engagement means for engaging the frames and the corner plates respectively to connect the two, The frame and the corner plate are connected to the skeleton shape of the casing member, and the foamed resin heat insulating material is foamed around the frame member to integrate the foamed resin heat insulating material with the frame and the corner plate. Air conditioning casing member. 2. The air-conditioning casing according to claim 1, wherein said engaging means comprises a slit formed in a part of said frame, and a claw member formed in said corner plate and engaging with said slit. Element. 3. An air-conditioning casing member surrounding an indoor unit of an air conditioner from outside, wherein a plurality of linear frames having substantially the same cross section perpendicular to the longitudinal direction are provided, and these frames are provided on an upper portion of the casing member. A top plate to be connected, the frame and the top plate are engaged with each other to form engagement means for connecting the two, and the frame and the top plate are connected to the frame shape of the casing member. A casing member for air-conditioning, wherein the foamed resin heat insulating material is foam-molded around the periphery to integrate the foamed resin heat insulating material with the frame and the top plate. 4. The air-conditioning casing according to claim 3, wherein said engaging means comprises a slit formed in a part of said frame, and a claw member formed in said top plate and engaging with said slit. Element. 5. An air-conditioning casing member according to claim 1, wherein the frame has a U-shaped or L-shaped cross section orthogonal to the longitudinal direction. 6. A plurality of linear frames having substantially the same cross section orthogonal to the longitudinal direction in an air-conditioning casing member that defines an air flow path such as an air outlet and an air inlet near an indoor unit of an air conditioner. And a plurality of corner plates provided at the corners of the casing member and connecting these frames, forming engagement means for engaging the frames and the corner plates with each other to connect the two, and Forming a molding die for a foamed resin heat insulating material having a cavity in the shape of the casing member, and connecting the frame and the corner plate to the skeleton shape of the casing member in the mold; Manufacturing an air-conditioning casing member, wherein the foamed resin heat insulating material, the frame and the corner plate are integrated by foam molding of Method. 7. A plurality of linear frames having substantially the same cross-section orthogonal to the longitudinal direction in an air-conditioning casing member that defines an air flow path such as an air outlet or a suction port near an indoor unit of an air conditioner. And, disposed at the corner of the casing member, using a plurality of corner plates connecting these outlets, forming engagement means for engaging the frame and the corner plate with each other to connect the two, A molding die for a foamed resin heat insulating material having a cavity in the shape of the casing member is formed, and the frame and the corner plate connected to the skeleton shape of the casing member are inserted into the mold, and then the foaming is performed. A casing member for air-conditioning, wherein the foamed resin heat insulating material is integrated with the frame and the corner plate by foaming the resin heat insulating material. Manufacturing method. 8. The air conditioner according to claim 6, wherein said engaging means comprises a slit formed in a part of said frame, and a claw member formed in said corner plate and engaging with said slit. Of manufacturing casing member for use. 9. An air-conditioning casing member surrounding an indoor unit of an air conditioner from outside, wherein a plurality of linear frames having substantially the same cross section perpendicular to the longitudinal direction are provided, and these frames are disposed above the casing member. A molding die for a foamed resin heat insulating material having a top plate to be connected, engaging means for engaging the frame and the top plate with each other to connect the two, and having a cavity in the shape of the casing member. Is formed in the mold, the frame and the top plate are connected to the skeleton shape of the casing member, and then the foamed resin heat insulating material is foamed to form the foamed resin heat insulating material, the frame and the top plate. And a method for manufacturing an air-conditioning casing member. 10. An air-conditioning casing member surrounding an indoor unit of an air conditioner from the outside, wherein a plurality of linear frames having substantially the same cross section orthogonal to the longitudinal direction are disposed above the casing member, and these frames are connected. A molding die for a foamed resin heat insulating material having an engagement means for engaging the frame and the top plate with each other and connecting the two to each other, and having a cavity in the shape of the casing member. Then, the frame and the top plate connected to the skeleton shape of the casing member are inserted into the mold, and then the foamed resin heat insulating material is foamed to form the foamed resin heat insulator, the frame and the ceiling. A method for manufacturing an air-conditioning casing member, comprising integrating a plate. 11. The method according to claim 9, wherein the engaging means comprises a slit formed in a part of the frame, and a claw member formed in the top plate and engaging with the slit.
0. A method for manufacturing an air conditioning casing member according to item 0. 12. The method for manufacturing an air-conditioning casing member according to claim 6, wherein a cross section orthogonal to the longitudinal direction of the frame is U-shaped or L-shaped.