TW201937119A - Manufacturing method and manufacturing mold for air conditioner - Google Patents

Abstract

The present invention provides a manufacturing method for an air conditioner (C) that comprises an indoor unit (Ci) provided with a drain pan (7) having a drain hole (7 h) for discharging condensed water generated by cooling or dehumidifying operation, said method involving a first mold (17) and second mold (18) for forming the drain hole (7h) of the drain pan (7), wherein when the first mold (17) moves after the formation of the drain hole (7h), the first mold (17) overlaps a portion of the abutting area of the first mold (17) and second mold (18).

Description

Manufacturing method of air conditioner and manufacturing mold

The present invention relates to a method for manufacturing an air conditioner and a manufacturing mold.

Conventionally, in a cold room or a dehumidification operation of an air conditioner, the condensed water generated by the indoor unit is discharged as described in Patent Document 1.
Specifically, the drain pan receives condensed water in the indoor unit and is discharged to the outside through a hose connected to a drain hole of the drain pan.

The drain pan is formed of resin using a resin mold.
[Prior technical literature]
[Patent Literature]

Patent Document 1: Japanese Patent Application Laid-Open No. 2017-227398 (Figure 3A, Figure 3B, paragraph 0022, etc.)

[Technical problem to be solved by the invention]

However, in the case where the drainage hole is formed by a resin mold, if the conventional mold structure is used, the hole may be blocked if the molding is defective. At this time, water will overflow from the drain pan of the indoor unit, and water leakage from the indoor unit occurs.

Here, when the drainage pan is poorly formed and the resin enters the drainage hole, the resin is removed by manual entry.
Therefore, if the drain pan is poorly formed and the removal process by a human hand is not sufficiently performed, there is a possibility that water leakage from the indoor unit may occur.

The present invention has been made in view of the foregoing circumstances, and an object thereof is to provide a method for manufacturing an air conditioner and a mold for manufacturing a drain pan with high reliability.

[Technical solution to solve the problem]

In order to solve the aforementioned problems, a first method for manufacturing an air conditioner according to the present invention is a method for manufacturing an air conditioner. The air conditioner includes an indoor unit. The indoor unit includes a drain pan. Drainage holes for condensed water generated by cold room or dehumidification operation; characterized in that: the first mold and the second mold are used to form the drainage holes of the drainage pan; after the drainage holes are formed, the first mold When moving, the first mold overlaps a part of the abutting portion between the first mold and the second mold.

A second manufacturing mold for an air conditioner according to the present invention is a manufacturing mold for an air conditioner. The air conditioner is provided with an indoor unit, and the indoor unit is provided with a drain pan. The drain pan is provided for discharging a cold room or a dehumidification operation. The drain hole of the generated condensed water is provided with a first mold and a second mold for forming the drain hole of the drain pan, and is configured to move the first mold after the drain hole is formed. In this case, the first mold overlaps a part of the abutting portion between the first mold and the second mold.

[Effect of the invention]

According to the present invention, it is possible to provide a method and a manufacturing mold for an air conditioner capable of forming a drain pan with high reliability.

Hereinafter, embodiments of the present invention will be described in detail with appropriate reference to the drawings.

FIG. 1 shows an indoor unit Ci and an outdoor unit Co of the air conditioner C according to the embodiment of the present invention.
The air conditioner C according to the embodiment includes an indoor unit Ci and an outdoor unit Co.

A refrigeration cycle is connected inside the outdoor unit Co and the indoor unit Ci through a pipe 14 through which a refrigerant flows.

The indoor unit Ci is installed indoors and performs indoor air conditioning.
The outdoor unit Co is installed outdoors, and the main mechanical components of the refrigeration cycle are accommodated in the outdoor unit Co.

The inside of the outdoor unit Co is divided into a ventilation room Co1 and a machine room Co2 by a partition plate (not shown).
In the blower room Co1, an outdoor heat exchanger 2 is housed on the front side, and an outdoor fan 3 is housed on the back side.

The outdoor heat exchanger 2 is provided in a shape bent in an L shape when viewed from above toward the inner and outer peripheral portions of the blower room Co1 on the left and rear portions. An outdoor fan 3 is disposed in front of the outdoor heat exchanger 2 to transmit air to the outdoor heat exchanger 2 from the rear of the outdoor unit Co (arrow α10 in FIG. 1).

A pressure accumulator (not shown), a compressor, an expansion valve, and a four-way valve constituting a refrigeration cycle are connected inside the machine room Co2 through a pipe 14.
On the upper right side of the outdoor unit Co, an electric box 4 that controls a fan motor, a compressor, and the like that drives the outdoor fan 3 is disposed.

A schematic cross-sectional view of the indoor unit Ci is shown in FIG. 2. FIG. 3 is a perspective view in which a part of the indoor unit Ci is cut out.
In the indoor unit Ci, an indoor heat exchanger 5 is provided on the outer peripheral portion, and an indoor fan 6 is provided on the central portion. In addition, the indoor unit Ci further includes a drain pan 7, a frame base 8, a screen 9a, 9b, a front panel 10, left and right wind direction boards 11, and an up and down wind direction board 12.

The indoor heat exchanger 5 includes a plurality of fins f and a plurality of heat transfer tubes g passing through the fins f. The indoor heat exchanger 5 includes a front indoor heat exchanger 5a and a rear indoor heat exchanger 5b.
The indoor heat exchanger 5 exchanges heat between the refrigerant flowing through the heat transfer tube g and the indoor air that is sent into the room (arrow α11 in FIG. 2) from the outside through the indoor fan 6.

The indoor fan 6 is a fan that sends indoor air to the indoor heat exchanger 5 by being driven by a fan motor, and is installed near the indoor heat exchanger 5. The indoor fan 6 is, for example, a cylindrical cross flow fan.
The indoor fan 6 includes a plurality of fan blades 6a, a partition plate 6b provided with the fan blades 6a, and an indoor fan motor (not shown) as a drive source.

The drain pan 7 receives the condensed water from the indoor heat exchanger 5 and the piping 14 and is arranged below the front indoor heat exchanger 5a.
The frame base 8 is a strength member provided with equipment such as the indoor heat exchanger 5 or the indoor fan 6.

The filter screen 9a is provided on the front side of the indoor heat exchanger 5 to remove dust from the air traveling toward the front air intake port h1. The filter screen 9b is provided on the upper side of the indoor heat exchanger 5 to remove dust from the air traveling through the upper air intake port h2.

The front panel 10 is a decorative panel provided so as to cover the front screen 9a, and is rotatable toward the front side about a shaft (not shown) at the lower end portion.
The left and right wind direction plates 11 (see FIG. 2) are members for adjusting the flow of the air blown into the room in the left-right direction as the indoor fan 3 rotates. The up-and-down wind direction plate 12 is a member for adjusting the up-and-down flow of the air which is blown out into the room as the indoor fan 3 rotates.

FIG. 4 is a cross-sectional view showing the periphery of the drainage hole 7h of the drainage pan 7. FIG.
A drain hole 7h is formed in the drain pan 7 as a drain hole. A drain pipe 13 is connected to a drain hole 7h of the drain pan 7. The drain pipe 13 is configured by, for example, a flexible hose or pipe, but is not limited thereto.

The water received by the drain pan 7 is discharged to the outside through the drain pipe 13.
The system is configured so that not only the condensed water but also the refrigerant leaked from the indoor heat exchanger 5 and the pipe 14 is guided into the drain pan 7. The drain pan 7 is for preventing the condensed water and the like from leaking to the outside of the indoor unit Ci when the condensed water or leaked refrigerant generated by the indoor heat exchanger 5 or the piping 14 is received. The wall 7k is formed in a bottomed disk shape having an opening above.

The drain pan 7 is a resin injection molder.
In the drain pan 7, a front support portion 7s1 and a side support portion 7s2 for supporting the drain pan 7 inside the indoor unit Ci are formed so as to extend forward, downward, and rearward, respectively.

5A to 5C are sectional views showing a forming process of the drain pan 7.

As shown in FIG. 5A, the drain pan 7 is formed using the A mold 16, the B mold 17, and the C mold 18 for resin molding.
The A mold 16 is formed by shaping the front lower portion of the drain pan 7. The A mold 16 is formed into a shape in which a front support portion 7s1 and a side support portion 7s2 of the drain pan 7 are formed.

The B mold 17 is formed by forming the internal shape of the drain pan 7 and a part of the drain hole 7h. Here, the B mold 17 is formed with a drain pan internal shape portion 17a, and a drainage hole protruding from the drain pan internal shape portion 17a toward the lower rear portion partially forms a convex portion 17b. The convex part 17b is partially formed in the drainage hole, and when the B mold 17 is removed after forming, the abutment surface 7h1 of the B mold 17 and the C mold 18 is moved (arrow α29 in FIG. 6). The drainage hole partially forms a convex portion 17b, and if it is a shape that partially protrudes inside the drainage hole 7h, it may be a semi-cylindrical shape or another shape.

The C mold 18 is formed by shaping the rear portion of the drain pan 7. The C mold 18 has a shape in which the rear portion of the drain pan 7 is formed, and a core pin 18p for fixing the drain hole 7h as a discharge hole is fixed. The core pin 18 p is formed with a drainage hole partially formed with a concave portion 18 p 1 and a B mold abutment portion 18 p 2 that abuts the B mold 17 in a shape that abuts the convex portion 17 b of the drainage hole of the B mold 17. The core pin 18 p will be described as a part of the C mold 18.

The drainage hole, which is a part of the B mold 17, is formed into a form in which the convex portion 17 b is bitten into the C mold 18 (core pin 18 p).
The formation of the drain pan 7 is performed as follows.

First, as shown in FIG. 5A, A mold 16 and B mold 17 and C mold 18 are combined (arrow α20 in FIG. 5A). In this way, a cavity 7C in the shape of the drain pan 7 is formed between the A mold 16 and the B mold 17 and the C mold 18.
Next, as shown in FIG. 5B, the cavity 7C between the A mold 16 and the B mold 17 and the C mold 18 is filled with resin from a resin filling port (not shown).

Thereafter, as shown by arrows α21, α22, and α23 of FIG. 5C, the A mold 16 and the B mold 17 and the C mold 18 are removed, respectively. In this way, the drain pan 7 is formed.

Here, when the molding is defective, the resin may enter between the abutting surface 7h1 of the B mold 17 and the C mold 18, and the drain hole 7h may be blocked.

FIG. 6 is an enlarged cross-sectional view of the vicinity of the drainage hole 7h when the A mold 16, the B mold 17, and the C mold 18 are removed after injection molding when the drainage pan 7 is poorly formed.
As shown in FIG. 6, by the movement of the B mold 17 after molding (arrow α22 in FIG. 6), the drainage hole of the B mold 17 can be partially formed with a convex portion 17 b to penetrate through the resin entering the butting surface 7h1. Part j1 (arrow α29 in FIG. 6). Therefore, the drainage hole 7h will be completely closed, and the development of water leakage can be suppressed.

According to the foregoing configuration, if the drainage hole 7h is poorly formed and the removal process by a human hand is not sufficiently performed, the drainage hole 7h will not be completely blocked.
Therefore, it is possible to provide an air conditioner having an indoor unit capable of suppressing the occurrence of water leakage caused by the clogging of the drain hole 7h.

＜ Modifications ＞
FIG. 7A shows a state in which the vicinity of the drainage hole 7h of the drainage pan 7 of the modification is formed, and FIG. 7B illustrates injection molding when the drainage pan 7 is poorly formed, and the A mold 26, B mold 27, and C mold 28 are removed An enlarged sectional view of the vicinity of the drainage hole 7h.

As shown in FIG. 7A, in the modification, the butting portion 27h1 of the B mold 27 and the C mold 28 is formed outside the drain hole 7h. The other structures are the same as those of the embodiment, and therefore, the symbols of the 20th paragraph are added for illustration.
In the modified example, the drainage hole 7h of the drainage pan 7 is formed so that the drainage hole which is a part of the B mold 27 partially forms a convex portion 27b and bites into the C mold 28 (core pin 28p).

When the molding is defective, the resin may enter between the abutting surface 27h1 of the B mold 27 and the C mold 28, and the drainage hole may be blocked for 7h.
However, as shown in FIG. 7B, when the A mold 26, the B mold 27, and the C mold 28 are removed (the arrows α31, α32, and α33 in FIG. 7B) after forming, the B mold 27 is moved (FIG. 7A) (Arrow α32 in FIG. 7B), a convex portion 27b can be partially formed in the drainage hole of the B mold 27 to penetrate a part of the resin j2 entering the abutting surface 27h1 (arrow α32 in FIG. 7B).

Therefore, even when the abutting portion 27h1 of the B mold 27 and the C mold 28 is formed outside the drainage hole 7h, the drainage hole 7h will be completely closed, and the development of water leakage can be suppressed.

≪Other embodiments≫
1. Although the case where the mold formed in the vicinity of the drainage hole 7h of the drain pan 7 is comprised by three is demonstrated, it is good also as a structure which uses four or more molds for shaping | molding.

2. The structure described in the foregoing embodiment is merely an example of the present invention, and various specific forms can be adopted within the scope of the patent application.

7, 27‧‧‧ Drain pan

7h, 27h‧‧‧‧Drain hole

17, 27‧‧‧B mold (the first mold)

7h1, 27h1 ‧‧‧ butt face (butt)

18, 28‧‧‧C mold (second mold)

18p, 28p‧‧‧ core pin (2nd mold)

C‧‧‧air conditioner

Ci‧‧‧ indoor unit

[Fig. 1] A perspective view showing an indoor unit and an outdoor unit provided in an air conditioner according to an embodiment of the present invention.

Fig. 2 is a schematic cross-sectional view showing an indoor unit.

[Fig. 3] A perspective view in which a part of the indoor unit is cut away.

[Fig. 4] A cross-sectional view around a drainage hole of a drainage pan.

5A A cross-sectional view of a forming process of a drain pan.

5B A cross-sectional view of a forming process of a drain pan.

5C A cross-sectional view of a forming process of a drain pan.

[Fig. 6] An enlarged cross-sectional view of the vicinity of the drainage hole when the A mold, the B mold, and the C mold are removed after injection molding when the drainage tray is poorly formed.

7A is a cross-sectional view showing a state in which the vicinity of a drainage hole of a drainage pan in a modification is formed.

[Fig. 7B] An enlarged cross-sectional view of the vicinity of the drainage hole when the A mold, the B mold, and the C mold are removed after injection molding when the drainage tray is poorly formed according to a modification.

Claims (4)

A method for manufacturing an air conditioner. The air conditioner is provided with an indoor unit. The indoor unit is provided with a drain pan. The drain pan is provided with a drainage hole for draining condensed water generated by a cold room or dehumidification operation. : A first mold and a second mold for forming the drainage holes of the drainage tray; The butt joint between the first mold and the second mold is formed in a stepped shape, After the drainage hole is formed, when the first mold moves, the first mold overlaps a part of the abutting portion between the first mold and the second mold. The method for manufacturing an air conditioner according to claim 1, wherein: A part of the abutting portion is disposed inside or outside the drainage hole. A mold for manufacturing an air conditioner. The air conditioner is provided with an indoor unit. The indoor unit is provided with a drainage pan. The drainage pan is provided with a drainage hole for draining condensed water generated by a cold room or a dehumidification operation. : A first mold and a second mold for forming the drainage holes of the drainage tray; The butt joint between the first mold and the second mold is formed in a stepped shape, And it is comprised so that, when the said 1st mold moves after the said drainage hole is formed, the said 1st mold overlaps a part of the said butt joint part of the said 1st mold and the said 2nd mold. The mold for manufacturing an air conditioner according to claim 3, wherein, A part of the abutting portion is disposed inside or outside the drainage hole.