US20110214443A1 - Air conditioner - Google Patents
Air conditioner Download PDFInfo
- Publication number
- US20110214443A1 US20110214443A1 US13/039,058 US201113039058A US2011214443A1 US 20110214443 A1 US20110214443 A1 US 20110214443A1 US 201113039058 A US201113039058 A US 201113039058A US 2011214443 A1 US2011214443 A1 US 2011214443A1
- Authority
- US
- United States
- Prior art keywords
- heat sink
- substrate holder
- air passage
- disposed
- air conditioner
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000758 substrate Substances 0.000 claims description 91
- 239000012778 molding material Substances 0.000 claims description 16
- 238000005057 refrigeration Methods 0.000 description 15
- 238000009833 condensation Methods 0.000 description 13
- 230000005494 condensation Effects 0.000 description 13
- 238000001816 cooling Methods 0.000 description 13
- 238000010438 heat treatment Methods 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 230000020169 heat generation Effects 0.000 description 8
- 238000005192 partition Methods 0.000 description 5
- 239000003507 refrigerant Substances 0.000 description 4
- 230000005855 radiation Effects 0.000 description 3
- 238000009434 installation Methods 0.000 description 2
- 239000004065 semiconductor Substances 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F7/00—Ventilation
- F24F7/007—Ventilation with forced flow
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F1/00—Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
- F24F1/0007—Indoor units, e.g. fan coil units
- F24F1/0059—Indoor units, e.g. fan coil units characterised by heat exchangers
- F24F1/0063—Indoor units, e.g. fan coil units characterised by heat exchangers by the mounting or arrangement of the heat exchangers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B29/00—Combined heating and refrigeration systems, e.g. operating alternately or simultaneously
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F2221/00—Details or features not otherwise provided for
- F24F2221/34—Heater, e.g. gas burner, electric air heater
Definitions
- a conventional air conditioner is disclosed in JP-A-H8-152179.
- This air conditioner is configured as an integrated type in which an indoor section that is disposed indoors is installed at its front portion, and an outdoor section that is disposed outdoors is installed at its back portion.
- a compressor that operates a refrigeration cycle is disposed.
- an outdoor heat exchanger that is connected to the compressor is disposed, and an outdoor fan that cools the outdoor heat exchanger is provided so as to face the outdoor heat exchanger.
- a suction port is open on the front surface of the indoor section, and a blowoff port is open at a position above the suction port.
- an air passage is formed that is constituted by a blower duct connecting the suction port and the blowoff port to each other, and a blower fan is provided inside the air passage.
- an indoor heat exchanger is disposed that is connected to the compressor via a refrigerant pipe.
- a PTC (positive temperature coefficient) heater is disposed.
- the compressor Upon the start of a cooling operation, the compressor is driven to operate the refrigeration cycle.
- the indoor heat exchanger functions as an evaporator on a low temperature side of the refrigeration cycle
- the outdoor heat exchanger functions as a condenser on a high temperature side of the refrigeration cycle.
- the outdoor fan is driven to cause the outdoor heat exchanger to exchange heat with the outside air thereby to radiate heat.
- the blower fan is driven to cause air inside a room to flow into the air passage through the suction port and the air cooled by heat exchange with the indoor heat exchanger to be sent out into the room through the blowoff port. Thus, cooling of the room is performed.
- the compressor Upon the start of a heating operation, the compressor is driven to operate the refrigeration cycle.
- the indoor heat exchanger functions as the condenser on the high temperature side of the refrigeration cycle
- the outdoor heat exchanger functions as the evaporator on the low temperature side of the refrigeration cycle.
- the outdoor fan is driven to cause the outdoor heat exchanger to exchange heat with the outside air thereby to absorb heat.
- the blower fan is driven to cause air inside a room to flow into the air passage through the suction port, which is then heated by heat exchange with the indoor heat exchanger.
- the driving of the PTC heater the air inside the air passage is further heated. The air thus heated is sent out into the room through the blowoff port, and thus heating of the room is performed.
- the PTC heater is made up of a heat generation element having PTC characteristics and electrodes sandwiching the heat generation element therebetween, and a voltage is applied between the electrodes to drive the PTC heater.
- the heat generation element is heated to a temperature higher than its Curie point, the resistance value thereof increases rapidly, leading to a decrease in the current value and heat generation amount of the heat generation element. This stabilizes the heat generation amount of the PTC heater, so that hot air at a predetermined temperature can be easily generated, and the occurrence of overheating can be prevented.
- JP-A-2003-59623 discloses a method of controlling the driving of a PTC heater, in which an electric current flowing through the PTC heater at start-up is monitored in order to prevent the electric current from exceeding a tolerable current level based on a power supply capacitance. That is, by a control circuit employing a triac element, duty control of the PTC heater is performed so that, at start-up, the PTC heater is driven with the duty ratio thereof increased gradually. This can prevent an overcurrent from occurring at the start-up of the PTC heater.
- the present invention includes: an air passage that is formed in a cabinet so as to connect a suction port and a blowoff port to each other, which are open on a surface of the cabinet; a blower fan that is disposed inside the air passage so as to extend in a longitudinal direction; a heat exchanger that is disposed so as to be opposed to the suction port and exchanges heat with air flowing in through the suction port; a heater that is disposed between the blower fan and the heat exchanger in order to heat air flowing in through the suction port and is shorter in a longitudinal direction than the blower fan; a control element that controls the heater and is disposed outside the air passage adjacently to the air passage; and a heat sink that is in close contact with the control element and is disposed between the blower fan and the heat exchanger, on an outside of the heater in the longitudinal direction.
- the control element is disposed outside the air passage adjacently to the air passage, and in order to avoid heat radiation of the heater, the heat sink in close contact with the control element is disposed between the blower fan and the heat exchanger, on the outside of the heater in the longitudinal direction.
- the control element is cooled by an airflow flowing through the air passage via the heat sink.
- the control element that controls the heater is disposed adjacently to the air passage and the heat sink is disposed inside the air passage, and thus the control element can be cooled by an airflow flowing through the air passage via the heat sink. This eliminates the need to install a fan for cooling the control element, and thus power consumption and cost can be reduced and the safety of the air conditioner can be improved.
- the heat sink is disposed on the outside of the heater that is shorter than the blower fan, and thus the temperature rise of the control element due to heat radiation of the heater can be suppressed. Moreover, air heated by heat exchange with the heat sink is sent out from an end portion of the air passage, and thus the efficiency of a heating operation can be improved.
- the heat sink is disposed in a dead space between the blower fan and the heat exchanger, on the outside of the heater in the longitudinal direction, and thus the air conditioner can be prevented from increasing in size due to the installation of the heat sink.
- the heater is formed by a PTC heater, and the control element is formed by a triac element. According to this configuration, duty control of the PTC heater is performed by the triac element, and thus the occurrence of an overcurrent at the start-up of the PTC heater is prevented.
- the circuit substrate is disposed in the cup-shaped substrate holder, and the control element mounted on the circuit substrate is brought into close contact with the heat sink via the window portion.
- the molding material is filled in the substrate holder, so that the circuit substrate is molded and the control element disposed at the window portion is also molded.
- the molding material is filled, it is possible to prevent dew condensation water from being deposited on the circuit substrate and the control element.
- the air conditioner configured as above may have the following configuration. That is, the heat sink has a guide groove that is recessed therein so as to extend in one direction, and the substrate holder has a fitting portion to be fitted into the guide groove. Further, the width between both side walls of the guide groove is set to be greater at least part of a region between the side walls than at an open surface of the guide groove, and through fitting between the guide groove and the fitting portion, the substrate holder is guided to be slid in the one direction. According to this configuration, the fitting portion of the substrate holder is inserted in a sliding manner from one direction into the guide groove of the heat sink, after which the circuit substrate is disposed in the substrate holder, and the control element is mounted to the heat sink.
- the air conditioner configured as above may have the following configuration. That is, an engaging protrusion is provided on the opposed surface of the substrate holder, and an engaging hole is provided in the heat sink, which is engaged with the engaging protrusion so that positioning of the heat sink and the substrate holder relative to each other is performed.
- the fitting portion of the substrate holder is slid from one direction into the guide groove of the heat sink, and the engaging protrusion is engaged with the engaging hole, by which positioning of the substrate holder is performed.
- the control element is fastened to the heat sink with a screw, and a groove portion into which the control element is fitted is recessed in the heat sink.
- the control element is installed by being fitted into the groove portion of the heat sink and then is fastened thereto with a screw. At this time, the groove portion prevents the control element from being rotated due to the screw being firmly screwed down.
- an opening portion is formed on one of wall surfaces of the air passage in the longitudinal direction, and a heat sink holder is provided that has an arm portion made of an elastic body and used to sandwich two circumferential surfaces of the heat sink, which are opposed to each other, and is mounted to the one of wall surfaces of the air passage by being fitted into the opening portion.
- the heat sink holder is fitted into the opening portion and mounted to the wall surface of the air passage by, for example, being fastened thereto with a screw.
- FIG. 1 is a perspective view showing an air conditioner according to an embodiment of the present invention.
- FIG. 2 is a cross-sectional side view showing the air conditioner according to the embodiment of the present invention.
- FIG. 3 is a front view showing the air conditioner according to the embodiment of the present invention.
- FIG. 4 is a perspective view showing an intermediate wall of the air conditioner according to the embodiment of the present invention.
- FIG. 7 is a cross-sectional side view showing a heat sink and a substrate holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state where they are fitted to each other.
- FIG. 9 is a cross-sectional top view showing the heat sink and the substrate holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in the state where they are fitted to each other.
- FIG. 10 is a perspective view showing a wiring state of the control circuit unit of the air conditioner according to the embodiment of the present invention.
- FIG. 11 is a front view showing the heat sink and a heat sink holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state before they are fitted to each other.
- FIG. 12 is a front view showing the heat sink and the heat sink holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state where they are fitted to each other.
- FIGS. 1 , 2 , and 3 are a perspective view, a cross-sectional side view, and a front view showing an air conditioner according to one embodiment, respectively.
- FIGS. 1 and 3 show a state without an exterior cover 30 (see FIG. 2 ).
- An air conditioner 1 is configured as an integrated type including an indoor section 2 that is disposed indoors and an outdoor section 4 that is disposed outdoors adjacently to the indoor section 2 .
- a suction port 21 is provided in a front portion of the indoor section 2
- an outdoor heat exchanger 42 is provided in a front portion of the outdoor section 4 .
- a front side refers to a suction port 21 side
- a back side refers to an outdoor heat exchanger 42 side.
- a right side and a left side of the air conditioner 1 refer to the right side and the left side thereof in a view facing the suction port 21 from the front, respectively.
- the indoor section 2 and the outdoor section 4 are installed on a bottom plate 3 , and a partition wall 5 is provided so that the indoor section 2 on the front side and the outdoor section 4 on the back side are separated from each other.
- the indoor section 2 constitutes a cabinet 20 surrounded on its outer side by the bottom plate 3 , the partition wall 5 , and the exterior cover 30 .
- an electrical equipment box 31 containing electrical equipment is provided at a right end portion in the cabinet 20 .
- the outdoor section 4 constitutes a cabinet 40 surrounded on its outer side by the bottom plate 3 , the partition wall 5 , and an exterior cover (not shown).
- a compressor 41 that operates a refrigeration cycle is disposed at an end portion on the right side.
- the outdoor heat exchanger 42 that is connected to the compressor 41 via a refrigerant pipe 47 is disposed.
- An outdoor fan 43 formed by a propeller fan is disposed at a center portion in the lateral direction in a view facing the outdoor heat exchanger 42 and cools the outdoor heat exchanger 42 .
- the outdoor fan 43 and the outdoor heat exchanger 42 are disposed in a housing 44 that is supported by the partition wall 5 via a bracket 45 .
- the housing 44 constitutes a duct that guides an airflow from the outdoor fan 43 to the outdoor heat exchanger 42 .
- the suction port 21 is open on the front surface of the exterior cover 30 covering the indoor section 2 , and a blowoff port 22 is open at a position above the suction port 21 .
- an air passage 23 is provided that connects the suction port 21 and the blowoff port 22 to each other.
- the rear surface and side surfaces of the air passage 23 are constituted by an intermediate wall 24 mounted on the bottom plate 3 .
- a wall of the air passage 23 below and in the vicinity of the blowoff port 22 is constituted by a duct member 29 that can be mounted and demounted when the exterior cover 30 is removed.
- a louver 26 that can change a direction in which air is blown out through the blowoff port 22 is mounted to the duct member 29 .
- a blower fan 25 formed by a cross-flow fan is provided so as to extend in the lateral direction.
- an indoor heat exchanger 27 that is connected to the compressor 41 via the refrigerant pipe 47 is disposed so as to be opposed to the suction port 21 .
- the indoor heat exchanger 27 is provided in the longitudinal direction of the blower fan 25 so as to have substantially the same width as that of the blower fan 25 .
- a drain pan 32 is disposed below the indoor heat exchanger 27 that collects dew condensation water from the indoor heat exchanger 27 and drains it to the outside.
- the drain pan 32 extends to below a control circuit unit 50 , which is described later, and collects dew condensation water produced from the control circuit unit 50 .
- a heater unit 28 is disposed between the blower fan 25 and the indoor heat exchanger 27 . As described later, the heater unit 28 is held by an angle 80 fastened with a screw to a side surface portion 24 a (see FIG. 4 ) of the intermediate wall 24 . The indoor heat exchanger 27 and the heater unit 28 are covered above by the duct member 29 . When the screw used for mounting the angle 80 is unscrewed and the duct member 29 is removed, the heater unit 28 can be mounted and demounted from above.
- the heater unit 28 is formed by lamination of a PTC heater 28 a made up of a semiconductor element and electrodes sandwiching the semiconductor element therebetween and a fin 28 b of a honeycomb structure.
- the PTC heater 28 a is shorter in the longitudinal direction than the blower fan 25 , and inside the air passage 23 , a space portion 33 is formed on the right side of the PTC heater 28 a . In the space portion 33 , a terminal portion 28 c of the heater unit 28 is disposed.
- the control circuit unit 50 including a triac element 52 that controls the PTC heater 28 a is disposed behind the terminal portion 28 c .
- duty control of the PTC heater 28 a is performed so that, at start-up, the PTC heater 28 a is driven with the duty ratio thereof increased gradually. This can prevent an overcurrent from occurring at the start-up of the PTC heater 28 a.
- FIG. 4 shows a perspective view of the intermediate wall 24 .
- the intermediate wall 24 has the side surface portion 24 a constituting each of side walls of the air passage 23 , and an opening portion 24 b is provided on a right-side one of the side surface portions 24 a .
- the control circuit unit 50 is mounted to the opening portion 24 b astride the inside and outside of the air passage 23 .
- a heat sink 70 (see FIG. 5 ) is disposed inside the air passage 23
- a substrate holder 60 is disposed on the outside of the air passage 23 .
- FIGS. 7 , 8 , and 9 are a cross-sectional side view, a front view, and a cross-sectional top view showing a state where the substrate holder 60 and the heat sink 70 are fitted to each other, respectively.
- the heat sink 70 is formed by extrusion molding of aluminum, and a plurality of the fins 71 are provided in a protruding manner on one surface of the heat sink 70 .
- a guide groove 73 is provided so as to extend in the vertical direction.
- the guide groove 73 is formed by a croze whose both side walls are inclined and that thus is trapezoidal in cross section, and the width between the side walls of the guide groove 73 is set to be greater at part of a region between the side walls than at an open surface of the guide groove 73 .
- Part of the side walls of the guide groove 73 may be formed in a squared U-shape in cross section so that the width between the side walls is made greater at part of the region between the side walls than at the open surface.
- a groove portion 72 squared U-shaped in cross section is recessed so as to extend in the vertical direction.
- a screw hole 74 is provided, and at a lower portion thereof, an engaging hole 75 is recessed.
- a window portion 64 is open at an upper portion of an opposed surface 60 a thereof, which is opposed to the heat sink 70 .
- a fitting portion 61 to be fitted into the guide groove 73 is provided in a protruding manner at a plurality of positions.
- an engaging protrusion 63 is provided in a protruding manner.
- a plurality of L-shaped ribs 62 are provided on the inner circumferential surface of the substrate holder 60 .
- the fitting portions 61 of the substrate holder 60 are inserted from below into the guide groove 73 of the heat sink 70 .
- the substrate holder 60 thus is guided by the guide groove 73 to be slid upward, and at a time when the engaging protrusion 63 is engaged with the engaging hole 75 , positioning of the heat sink 70 and the substrate holder 60 relative to each other is achieved. This eliminates the need to fasten the substrate holder 60 to the heat sink 70 with a screw, and thus the substrate holder 60 can be easily fixed.
- the triac element 52 is fitted into the groove portion 72 of the heat sink 70 , the triac element 52 is prevented from being rotated due to the screw 57 being firmly screwed down. This can prevent the terminal 52 b of the triac element 52 from being warped to be broken. Furthermore, at the time of firmly screwing down the screw 57 , the circuit substrate 51 is not fixed to the substrate holder 60 , which can more reliably prevent the terminal 52 b of the triac element 52 from being warped to be damaged.
- a concave portion 51 a from which the through hole 52 a is exposed is formed by cutting out a portion of the circuit substrate 51 , which is opposed to the through hole 52 a .
- the triac element 52 is fixed with the screw 57 via the concave portion 51 a . This can reduce the amount of two-dimensional protrusion of the triac element 52 from the circuit substrate 51 .
- the substrate holder 60 can be reduced in size and thereby allows the control circuit unit 50 to be reduced in size, and the amount of a molding material 58 used, which is described later, can be reduced.
- the molding material 58 made of a resin such as urethane is filled in the substrate holder 60 .
- the circuit substrate 51 and the triac element 52 are molded, and thus the circuit substrate 51 is fixed.
- part of the molding material 58 which flows along a gap between the periphery of the window portion 64 and the heat sink 70 , is prevented by surface tension from flowing out to the periphery of the substrate holder 60 .
- a shielding material that prevents the molding material 58 from flowing out may be provided at the periphery of the substrate holder 60 .
- the triac element 52 is disposed at an upper portion in the substrate holder 60 . If voids are formed in the molding material 58 , dew condensation water on the surface of the molding material 58 may reach the triac element 52 . In such a case, since the triac element 52 is disposed at the upper portion in the substrate holder 60 , the possibility that dew condensation water reaches the triac element 52 can be reduced to a greater degree than in the case where the triac element 52 is disposed at a lower portion in the substrate holder 60 .
- FIG. 10 is a perspective view showing a state where the circuit substrate 51 is fixed by filling the molding material 58 .
- a lead 59 extending from the circuit substrate 51 is taken out through an opening portion 65 that is open on the lower surface of the substrate holder 60 .
- the lead 59 is bent into a U-shape below the substrate holder 60 and is guided upward by a holding portion 66 that is provided on a side surface of the substrate holder 60 .
- the lead 59 is connected to the inside of the electrical equipment box 31 (see FIG. 3 ) via an opening portion (not shown) provided at an upper portion of the electrical equipment box 31 .
- dew condensation water produced in the substrate holder 60 and allowed to slip along the lead 59 drips from a lower end of the lead 59 onto the drain pan 32 (see FIG. 3 ) and thus is collected. This can prevent the entry of dew condensation water into the electrical equipment box 31 .
- the opening surface of the substrate holder 60 is closed with the lid portion 68 .
- a housing portion 68 a is recessed so as to be opposed to the opening portion 65 of the substrate holder 60 and to extend in the vertical direction.
- the lead 59 is disposed in the housing portion 68 a , which allows the lead 59 to be bent at an increased radius of curvature. This can prevent breakage of the lead 59 . Furthermore, this can also prevent the lead 59 from being displaced in the lateral direction.
- FIGS. 11 and 12 are front views showing a state before the heat sink 70 and the heat sink holder 78 are fitted to each other and a state where they have been fitted to each other, respectively.
- the heat sink holder 78 is made of a resinous molded article, and at each of two portions thereof, which are upper and lower portions of the heat sink holder 78 , an arm portion 78 a that constitutes an elastic body is provided in a protruding manner so as to extend in one direction.
- the arm portion 78 a is formed in an L-shape in cross section and has a standing portion 78 c that is to lie along the reference surface 70 a of the heat sink 70 .
- a nail portion 78 b is formed so as to be opposed to the standing portion 78 c.
- the heat sink 70 is inserted between both the arm portions 78 a while causing the arm portions 78 a to be bent elastically during the insertion.
- the standing portion 78 c comes to lie along the reference surface 70 a of the heat sink 70
- the nail portion 78 b provided at the tip end of the arm portion 78 a is engaged with the fins 71 .
- the arm portions 78 a thus sandwich therebetween two surfaces of the heat sink 70 , which are opposed to each other in the vertical direction, and thereby holds the heat sink 70 .
- the heat sink holder 78 is fitted into the opening portion 24 b (see FIG. 4 ) of the intermediate wall 24 . Then, a screw is inserted into a through hole 78 d provided at each of upper and lower ends of the heat sink holder 78 and into a through hole (not shown) provided on the periphery of the opening portion 24 b and screwed to be secured to a screw portion 80 a (see FIG. 3 ) of the angle 80 .
- the control circuit unit 50 is mounted to the intermediate wall 24 .
- the substrate holder 60 containing the triac element 52 is disposed outside the air passage 23 adjacently to the air passage 23 .
- the heat sink 70 in close contact with the triac element 52 protrudes into the air passage 23 and is disposed between the blower fan 25 and the indoor heat exchanger 27 , on the outside of the PTC heater 28 a in the longitudinal direction.
- a common screw is used for mounting the angle 80 and the control circuit unit 50 to the intermediate wall 24 , and thus the number of components used can be reduced.
- the use of the arm portions 78 a allows the heat sink 70 to be easily held and thus eliminates the need for a screw for fitting the heat sink 70 and the heat sink holder 78 to each other, so that the number of components used can be reduced.
- the arm portions 78 a are fitted onto the inner circumferential surface of the opening portion 24 b while covering the upper and lower surfaces of the guide groove 73 , and thus it is possible to prevent air from leaking from the air passage 23 via the guide groove 73 .
- the compressor 41 upon the start of a cooling operation, the compressor 41 is driven to operate the refrigeration cycle.
- the indoor heat exchanger 27 functions as an evaporator on a low temperature side of the refrigeration cycle
- the outdoor heat exchanger 42 functions as a condenser on a high temperature side of the refrigeration cycle.
- the outdoor fan 43 is driven to cause the outdoor heat exchanger 42 to exchange heat with the outside air thereby to radiate heat.
- the blower fan 25 is driven to cause air inside a room to flow into the air passage 23 through the suction port 21 and the air cooled by heat exchange with the indoor heat exchanger 27 to be sent out into the room through the blowoff port 22 . Thus, cooling of the room is performed.
- the compressor 41 Upon the start of a heating operation, the compressor 41 is driven to operate the refrigeration cycle.
- the indoor heat exchanger 27 functions as the condenser on the high temperature side of the refrigeration cycle
- the outdoor heat exchanger 42 functions as the evaporator on the low temperature side of the refrigeration cycle.
- the outdoor fan 43 is driven to cause the outdoor heat exchanger 42 to exchange heat with the outside air thereby to absorb heat.
- the blower fan 25 is driven to cause air inside a room to flow into the air passage 23 through the suction port 21 , which is then heated by heat exchange with the indoor heat exchanger 27 .
- the air flowing through the air passage 23 is further heated.
- the blower fan 25 and the indoor heat exchanger 27 are formed so as to extend further to the lateral sides than the PTC heater 28 a . This can increase a heat exchange area of the indoor heat exchanger 27 .
- air flowing through the space portion 33 on the lateral side of the PTC heater 28 a cools the triac element 52 via the heat sink 70 . At this time, the air flowing through the space portion 33 exchanges heat with the heat sink 70 and thus is heated.
- the air heated by the indoor heat exchanger 27 and the PTC heater 28 a is sent out into the room through the blowoff port 22 , and thus heating of the room is performed.
- the compressor 41 may be deactivated so that air is heated by the PTC heater 28 a alone.
- an integrated air conditioner capable only of cooling based on the operation of a refrigeration cycle may be modified so that a heating operation by the PTC heater 28 a is enabled.
- the triac element 52 that controls the PTC heater 28 a is disposed adjacently to the air passage 23 and the heat sink 70 is disposed inside the air passage 23 , and thus the triac element 52 can be cooled by an airflow flowing through the air passage 23 via the heat sink 70 .
- This eliminates the need to install a fan for cooling the triac element 52 and thus power consumption and cost can be reduced and the safety of the air conditioner 1 can be improved.
- the heat sink 70 is disposed on the outside of the PTC heater 28 a that is shorter than the blower fan 25 , and thus the temperature rise of the triac element 52 due to heat radiation of the PTC heater 28 a can be suppressed. Moreover, air heated by heat exchange with the heat sink 70 is sent out from an end portion of the air passage 23 , and thus the efficiency of a heating operation can be improved.
- the heat sink 70 is disposed in a dead space between the blower fan 25 and the indoor heat exchanger 27 , on the outside of the PTC heater 28 a in the longitudinal direction, and thus the air conditioner 1 can be prevented from increasing in size due to the installation of the heat sink 70 .
- the substrate holder 60 is formed in a cup shape and has the window portion 64 open therein for inserting the triac element 52 thereinto, and by the molding material 58 filled in the substrate holder 60 , the circuit substrate 51 and the triac element 52 are molded.
- the molding material 58 is filled, it is possible to prevent dew condensation water from being deposited on the circuit substrate 51 and the triac element 52 .
- the guide groove 73 is so formed that the width between both the side walls thereof is greater at least part of the region between the side walls than at the open surface of the guide groove 73 , and the substrate holder 60 has the fitting portion 61 to be fitted into the guide groove 73 , so that the substrate holder 60 can be easily fitted to the heat sink 70 . Furthermore, since there is no need for a screw for fitting the substrate holder 60 to the heat sink 70 , it is possible to reduce a phenomenon in which, during a cooling operation, dew condensation occurs in the substrate holder 60 due to heat conduction via the screw.
- the engaging protrusion 63 is provided in the substrate holder 60
- the engaging hole 75 is provided in the heat sink 70 , so that through engagement between the engaging protrusion 63 and the engaging hole 75 , positioning of the heat sink 70 and the substrate holder 60 relative to each other can be easily performed, and thus assembling workability can be improved.
- the triac element 52 is fitted into the groove portion 72 recessed in the heat sink 70 and is fastened in that state with the screw 57 , and thus the triac element 52 is prevented from being rotated due to the screw 57 being firmly screwed down. This can prevent the terminal 52 b of the triac element 52 from being warped to be broken.
- the heat sink holder 78 has the arm portion 78 a that is made of an elastic body and used to sandwich the two circumferential surfaces of the heat sink 70 , which are opposed to each other, and is mounted by being fitted into the opening portion 24 b on a wall surface of the air passage 23 , so that the heat sink 70 can be easily held by the heat sink holder 78 .
- air flowing through the air passage 23 is heated by the PTC heater 28 a that is controlled by the triac element 52 in close contact with the heat sink 70 .
- Heating may be performed using a heater that is controlled by a control element of another type provided in close contact with the heat sink 70 .
- the present invention can be applied to air conditioners each including a heater and a control element that controls the heater.
Abstract
An air conditioner includes: an air passage 23 that is formed in a cabinet 20 so as to connect a suction port 21 and a blowoff port 22 to each other, which are open on a surface of the cabinet 20; a blower fan 25 that is disposed inside the air passage 23 so as to extend in one direction; a heat exchanger 27 that is disposed so as to be opposed to the suction port 21 and cools air flowing in through the suction port 21; a heater 28 a that is disposed between the blower fan 25 and the heat exchanger 27 in order to heat air flowing in through the suction port 21 and is shorter in a longitudinal direction than the blower fan 25; a control element 52 that controls the heater 28 a and is disposed outside the air passage 23 adjacently to the air passage 23; and a heat sink 70 that is in close contact with the control element 52 and is disposed between the blower fan 25 and the heat exchanger 27, on an outside of the heater 28 a in the longitudinal direction.
Description
- This application is based on Japanese Patent Application No. 2010-046934 filed on Mar. 3, 2010, the contents of which are hereby incorporated by reference.
- 1. Field of the Invention
- The present invention relates to an air conditioner including a heater and a control element that controls the heater.
- 2. Description of Related Art
- A conventional air conditioner is disclosed in JP-A-H8-152179. This air conditioner is configured as an integrated type in which an indoor section that is disposed indoors is installed at its front portion, and an outdoor section that is disposed outdoors is installed at its back portion. In the outdoor section, a compressor that operates a refrigeration cycle is disposed. At the rear surface of the outdoor section, an outdoor heat exchanger that is connected to the compressor is disposed, and an outdoor fan that cools the outdoor heat exchanger is provided so as to face the outdoor heat exchanger.
- A suction port is open on the front surface of the indoor section, and a blowoff port is open at a position above the suction port. In the indoor section, an air passage is formed that is constituted by a blower duct connecting the suction port and the blowoff port to each other, and a blower fan is provided inside the air passage. Between the blower fan and the suction port, an indoor heat exchanger is disposed that is connected to the compressor via a refrigerant pipe. Between the blower fan and the indoor heat exchanger, a PTC (positive temperature coefficient) heater is disposed.
- Upon the start of a cooling operation, the compressor is driven to operate the refrigeration cycle. In this operation, the indoor heat exchanger functions as an evaporator on a low temperature side of the refrigeration cycle, and the outdoor heat exchanger functions as a condenser on a high temperature side of the refrigeration cycle. The outdoor fan is driven to cause the outdoor heat exchanger to exchange heat with the outside air thereby to radiate heat. The blower fan is driven to cause air inside a room to flow into the air passage through the suction port and the air cooled by heat exchange with the indoor heat exchanger to be sent out into the room through the blowoff port. Thus, cooling of the room is performed.
- Upon the start of a heating operation, the compressor is driven to operate the refrigeration cycle. In this operation, the indoor heat exchanger functions as the condenser on the high temperature side of the refrigeration cycle, and the outdoor heat exchanger functions as the evaporator on the low temperature side of the refrigeration cycle. The outdoor fan is driven to cause the outdoor heat exchanger to exchange heat with the outside air thereby to absorb heat. The blower fan is driven to cause air inside a room to flow into the air passage through the suction port, which is then heated by heat exchange with the indoor heat exchanger. Furthermore, by the driving of the PTC heater, the air inside the air passage is further heated. The air thus heated is sent out into the room through the blowoff port, and thus heating of the room is performed.
- The PTC heater is made up of a heat generation element having PTC characteristics and electrodes sandwiching the heat generation element therebetween, and a voltage is applied between the electrodes to drive the PTC heater. When the heat generation element is heated to a temperature higher than its Curie point, the resistance value thereof increases rapidly, leading to a decrease in the current value and heat generation amount of the heat generation element. This stabilizes the heat generation amount of the PTC heater, so that hot air at a predetermined temperature can be easily generated, and the occurrence of overheating can be prevented.
- In this case, however, at start-up, the PTC heater is at a low temperature and the heat generation element therefore has a low resistance value, so that an overcurrent might flow to exceed a tolerable current level based on a power supply capacitance. As a solution to this, JP-A-2003-59623 discloses a method of controlling the driving of a PTC heater, in which an electric current flowing through the PTC heater at start-up is monitored in order to prevent the electric current from exceeding a tolerable current level based on a power supply capacitance. That is, by a control circuit employing a triac element, duty control of the PTC heater is performed so that, at start-up, the PTC heater is driven with the duty ratio thereof increased gradually. This can prevent an overcurrent from occurring at the start-up of the PTC heater.
- According to the above-described conventional air conditioner, however, due to a large heat generation amount of the triac element, electrical equipment provided in the air conditioner are heated. This impairs the safety of the air conditioner, which has been problematic. Furthermore, installing a fan for cooling the triac element increases the power consumption and cost of the air conditioner, which is also problematic.
- It is an object of the present invention to provide an air conditioner that achieves a reduction in power consumption and cost and can improve safety.
- In order to achieve the above-described object, the present invention includes: an air passage that is formed in a cabinet so as to connect a suction port and a blowoff port to each other, which are open on a surface of the cabinet; a blower fan that is disposed inside the air passage so as to extend in a longitudinal direction; a heat exchanger that is disposed so as to be opposed to the suction port and exchanges heat with air flowing in through the suction port; a heater that is disposed between the blower fan and the heat exchanger in order to heat air flowing in through the suction port and is shorter in a longitudinal direction than the blower fan; a control element that controls the heater and is disposed outside the air passage adjacently to the air passage; and a heat sink that is in close contact with the control element and is disposed between the blower fan and the heat exchanger, on an outside of the heater in the longitudinal direction.
- According to this configuration, when a cooling operation is performed, air taken from a room into the air passage through the suction port by the driving of the blower fan exchanges heat with the heat exchanger and thus is cooled, and the air is then sent out into the room through the blowoff port. When a heating operation is performed, air taken from the room into the air passage through the suction port by the driving of the blower fan is heated by the heater that is controlled by the control element. During the heating operation, the air flowing through the air passage may be further heated by the heat exchanger. The control element is disposed outside the air passage adjacently to the air passage, and in order to avoid heat radiation of the heater, the heat sink in close contact with the control element is disposed between the blower fan and the heat exchanger, on the outside of the heater in the longitudinal direction. The control element is cooled by an airflow flowing through the air passage via the heat sink.
- The control element that controls the heater is disposed adjacently to the air passage and the heat sink is disposed inside the air passage, and thus the control element can be cooled by an airflow flowing through the air passage via the heat sink. This eliminates the need to install a fan for cooling the control element, and thus power consumption and cost can be reduced and the safety of the air conditioner can be improved.
- Furthermore, in the longitudinal direction, the heat sink is disposed on the outside of the heater that is shorter than the blower fan, and thus the temperature rise of the control element due to heat radiation of the heater can be suppressed. Moreover, air heated by heat exchange with the heat sink is sent out from an end portion of the air passage, and thus the efficiency of a heating operation can be improved. In addition, the heat sink is disposed in a dead space between the blower fan and the heat exchanger, on the outside of the heater in the longitudinal direction, and thus the air conditioner can be prevented from increasing in size due to the installation of the heat sink.
- Furthermore, in the present invention, preferably, in the air conditioner configured as above, the heater is formed by a PTC heater, and the control element is formed by a triac element. According to this configuration, duty control of the PTC heater is performed by the triac element, and thus the occurrence of an overcurrent at the start-up of the PTC heater is prevented.
- Furthermore, in the present invention, more preferably, the air conditioner configured as above further includes: a circuit substrate on which the control element is mounted; a cup-shaped substrate holder that has a window portion for inserting the control element thereinto, open on an opposed surface of the substrate holder, which is opposed to the heat sink, and holds the circuit substrate; and a molding material that is filled in the substrate holder so as to mold the circuit substrate and the control element.
- According to this configuration, the circuit substrate is disposed in the cup-shaped substrate holder, and the control element mounted on the circuit substrate is brought into close contact with the heat sink via the window portion. The molding material is filled in the substrate holder, so that the circuit substrate is molded and the control element disposed at the window portion is also molded. In a case where, during a cooling operation, low temperature air comes in contact with the heat sink and thus dew condensation occurs in the substrate holder, since the molding material is filled, it is possible to prevent dew condensation water from being deposited on the circuit substrate and the control element.
- Furthermore, in the present invention, the air conditioner configured as above may have the following configuration. That is, the heat sink has a guide groove that is recessed therein so as to extend in one direction, and the substrate holder has a fitting portion to be fitted into the guide groove. Further, the width between both side walls of the guide groove is set to be greater at least part of a region between the side walls than at an open surface of the guide groove, and through fitting between the guide groove and the fitting portion, the substrate holder is guided to be slid in the one direction. According to this configuration, the fitting portion of the substrate holder is inserted in a sliding manner from one direction into the guide groove of the heat sink, after which the circuit substrate is disposed in the substrate holder, and the control element is mounted to the heat sink.
- Furthermore, in the present invention, the air conditioner configured as above may have the following configuration. That is, an engaging protrusion is provided on the opposed surface of the substrate holder, and an engaging hole is provided in the heat sink, which is engaged with the engaging protrusion so that positioning of the heat sink and the substrate holder relative to each other is performed. According to this configuration, the fitting portion of the substrate holder is slid from one direction into the guide groove of the heat sink, and the engaging protrusion is engaged with the engaging hole, by which positioning of the substrate holder is performed.
- Furthermore, in the present invention, more preferably, in the air conditioner configured as above, the control element is fastened to the heat sink with a screw, and a groove portion into which the control element is fitted is recessed in the heat sink. According to this configuration, the control element is installed by being fitted into the groove portion of the heat sink and then is fastened thereto with a screw. At this time, the groove portion prevents the control element from being rotated due to the screw being firmly screwed down.
- Furthermore, in the present invention, more preferably, in the air conditioner configured as above, an opening portion is formed on one of wall surfaces of the air passage in the longitudinal direction, and a heat sink holder is provided that has an arm portion made of an elastic body and used to sandwich two circumferential surfaces of the heat sink, which are opposed to each other, and is mounted to the one of wall surfaces of the air passage by being fitted into the opening portion. According to this configuration, while holding the two surfaces of the heat sink between the arm portions that are deformed elastically, the heat sink holder is fitted into the opening portion and mounted to the wall surface of the air passage by, for example, being fastened thereto with a screw.
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FIG. 1 is a perspective view showing an air conditioner according to an embodiment of the present invention. -
FIG. 2 is a cross-sectional side view showing the air conditioner according to the embodiment of the present invention. -
FIG. 3 is a front view showing the air conditioner according to the embodiment of the present invention. -
FIG. 4 is a perspective view showing an intermediate wall of the air conditioner according to the embodiment of the present invention. -
FIG. 5 is a perspective view showing a control circuit unit of the air conditioner according to the embodiment of the present invention. -
FIG. 6 is an exploded perspective view showing the control circuit unit of the air conditioner according to the embodiment of the present invention. -
FIG. 7 is a cross-sectional side view showing a heat sink and a substrate holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state where they are fitted to each other. -
FIG. 8 is a front view showing the heat sink and the substrate holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in the state where they are fitted to each other. -
FIG. 9 is a cross-sectional top view showing the heat sink and the substrate holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in the state where they are fitted to each other. -
FIG. 10 is a perspective view showing a wiring state of the control circuit unit of the air conditioner according to the embodiment of the present invention. -
FIG. 11 is a front view showing the heat sink and a heat sink holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state before they are fitted to each other. -
FIG. 12 is a front view showing the heat sink and the heat sink holder of the control circuit unit of the air conditioner according to the embodiment of the present invention, in a state where they are fitted to each other. - The following describes an embodiment of the present invention with reference to the appended drawings.
FIGS. 1 , 2, and 3 are a perspective view, a cross-sectional side view, and a front view showing an air conditioner according to one embodiment, respectively.FIGS. 1 and 3 show a state without an exterior cover 30 (seeFIG. 2 ). Anair conditioner 1 is configured as an integrated type including anindoor section 2 that is disposed indoors and anoutdoor section 4 that is disposed outdoors adjacently to theindoor section 2. - A
suction port 21 is provided in a front portion of theindoor section 2, and anoutdoor heat exchanger 42 is provided in a front portion of theoutdoor section 4. In the following description, a front side refers to asuction port 21 side, and a back side (rear side) refers to anoutdoor heat exchanger 42 side. Furthermore, a right side and a left side of theair conditioner 1 refer to the right side and the left side thereof in a view facing thesuction port 21 from the front, respectively. - The
indoor section 2 and theoutdoor section 4 are installed on abottom plate 3, and apartition wall 5 is provided so that theindoor section 2 on the front side and theoutdoor section 4 on the back side are separated from each other. Theindoor section 2 constitutes acabinet 20 surrounded on its outer side by thebottom plate 3, thepartition wall 5, and theexterior cover 30. At a right end portion in thecabinet 20, anelectrical equipment box 31 containing electrical equipment is provided. Similarly to theindoor section 2, theoutdoor section 4 constitutes acabinet 40 surrounded on its outer side by thebottom plate 3, thepartition wall 5, and an exterior cover (not shown). - In the
outdoor section 4, acompressor 41 that operates a refrigeration cycle is disposed at an end portion on the right side. At the rear surface of theoutdoor section 4, theoutdoor heat exchanger 42 that is connected to thecompressor 41 via arefrigerant pipe 47 is disposed. Anoutdoor fan 43 formed by a propeller fan is disposed at a center portion in the lateral direction in a view facing theoutdoor heat exchanger 42 and cools theoutdoor heat exchanger 42. Theoutdoor fan 43 and theoutdoor heat exchanger 42 are disposed in ahousing 44 that is supported by thepartition wall 5 via abracket 45. Thehousing 44 constitutes a duct that guides an airflow from theoutdoor fan 43 to theoutdoor heat exchanger 42. - The
suction port 21 is open on the front surface of theexterior cover 30 covering theindoor section 2, and ablowoff port 22 is open at a position above thesuction port 21. In theindoor section 2, anair passage 23 is provided that connects thesuction port 21 and theblowoff port 22 to each other. The rear surface and side surfaces of theair passage 23 are constituted by anintermediate wall 24 mounted on thebottom plate 3. A wall of theair passage 23 below and in the vicinity of theblowoff port 22 is constituted by aduct member 29 that can be mounted and demounted when theexterior cover 30 is removed. Alouver 26 that can change a direction in which air is blown out through theblowoff port 22 is mounted to theduct member 29. - Inside the
air passage 23, ablower fan 25 formed by a cross-flow fan is provided so as to extend in the lateral direction. Between theblower fan 25 and thesuction port 21, anindoor heat exchanger 27 that is connected to thecompressor 41 via therefrigerant pipe 47 is disposed so as to be opposed to thesuction port 21. Theindoor heat exchanger 27 is provided in the longitudinal direction of theblower fan 25 so as to have substantially the same width as that of theblower fan 25. Below theindoor heat exchanger 27, adrain pan 32 is disposed that collects dew condensation water from theindoor heat exchanger 27 and drains it to the outside. Thedrain pan 32 extends to below acontrol circuit unit 50, which is described later, and collects dew condensation water produced from thecontrol circuit unit 50. - A
heater unit 28 is disposed between theblower fan 25 and theindoor heat exchanger 27. As described later, theheater unit 28 is held by anangle 80 fastened with a screw to aside surface portion 24 a (seeFIG. 4 ) of theintermediate wall 24. Theindoor heat exchanger 27 and theheater unit 28 are covered above by theduct member 29. When the screw used for mounting theangle 80 is unscrewed and theduct member 29 is removed, theheater unit 28 can be mounted and demounted from above. - The
heater unit 28 is formed by lamination of aPTC heater 28 a made up of a semiconductor element and electrodes sandwiching the semiconductor element therebetween and afin 28 b of a honeycomb structure. ThePTC heater 28 a is shorter in the longitudinal direction than theblower fan 25, and inside theair passage 23, aspace portion 33 is formed on the right side of thePTC heater 28 a. In thespace portion 33, aterminal portion 28 c of theheater unit 28 is disposed. - The
control circuit unit 50 including atriac element 52 that controls thePTC heater 28 a is disposed behind theterminal portion 28 c. By thetriac element 52, duty control of thePTC heater 28 a is performed so that, at start-up, thePTC heater 28 a is driven with the duty ratio thereof increased gradually. This can prevent an overcurrent from occurring at the start-up of thePTC heater 28 a. -
FIG. 4 shows a perspective view of theintermediate wall 24. Theintermediate wall 24 has theside surface portion 24 a constituting each of side walls of theair passage 23, and anopening portion 24 b is provided on a right-side one of theside surface portions 24 a. Thecontrol circuit unit 50 is mounted to the openingportion 24 b astride the inside and outside of theair passage 23. At this time, a heat sink 70 (seeFIG. 5 ) is disposed inside theair passage 23, and a substrate holder 60 (seeFIG. 5 ) is disposed on the outside of theair passage 23. -
FIGS. 5 and 6 show a perspective view and an exploded perspective view of thecontrol circuit unit 50, respectively. Thecontrol circuit unit 50 includes acircuit substrate 51, asubstrate holder 60, alid portion 68, theheat sink 70, and aheat sink holder 78. Thetriac element 52 is mounted on thecircuit substrate 51 and disposed in the cup-shapedsubstrate holder 60 made of a resinous molded article. As described later in detail, thesubstrate holder 60 is fitted to theheat sink 70, and an opening surface of thesubstrate holder 60 is closed with thelid portion 68 made of a resinous molded article. -
FIGS. 7 , 8, and 9 are a cross-sectional side view, a front view, and a cross-sectional top view showing a state where thesubstrate holder 60 and theheat sink 70 are fitted to each other, respectively. Theheat sink 70 is formed by extrusion molding of aluminum, and a plurality of thefins 71 are provided in a protruding manner on one surface of theheat sink 70. - On a
reference surface 70 a of theheat sink 70 on the side opposite to the surface on which thefins 71 are formed, aguide groove 73 is provided so as to extend in the vertical direction. Theguide groove 73 is formed by a croze whose both side walls are inclined and that thus is trapezoidal in cross section, and the width between the side walls of theguide groove 73 is set to be greater at part of a region between the side walls than at an open surface of theguide groove 73. Part of the side walls of theguide groove 73 may be formed in a squared U-shape in cross section so that the width between the side walls is made greater at part of the region between the side walls than at the open surface. On the bottom surface of theguide groove 73, agroove portion 72 squared U-shaped in cross section is recessed so as to extend in the vertical direction. At an upper portion of the bottom surface of thegroove portion 72, ascrew hole 74 is provided, and at a lower portion thereof, an engaginghole 75 is recessed. - In the
substrate holder 60, awindow portion 64 is open at an upper portion of anopposed surface 60 a thereof, which is opposed to theheat sink 70. On both sides of thewindow portion 64 on theopposed surface 60 a, afitting portion 61 to be fitted into theguide groove 73 is provided in a protruding manner at a plurality of positions. At a lower portion of theopposed surface 60 a, an engagingprotrusion 63 is provided in a protruding manner. Furthermore, a plurality of L-shapedribs 62 are provided on the inner circumferential surface of thesubstrate holder 60. - In assembling the
control circuit unit 50, first, as shown by an arrow A1 (seeFIG. 6 ), thefitting portions 61 of thesubstrate holder 60 are inserted from below into theguide groove 73 of theheat sink 70. Thesubstrate holder 60 thus is guided by theguide groove 73 to be slid upward, and at a time when the engagingprotrusion 63 is engaged with the engaginghole 75, positioning of theheat sink 70 and thesubstrate holder 60 relative to each other is achieved. This eliminates the need to fasten thesubstrate holder 60 to theheat sink 70 with a screw, and thus thesubstrate holder 60 can be easily fixed. - Next, the
circuit substrate 51 is mounted on theribs 62 in thesubstrate holder 60. A terminal 52 b of thetriac element 52 is bent, and thetriac element 52 is disposed parallel to thecircuit substrate 51. Thetriac element 52 is fitted into thegroove portion 72 of theheat sink 70 via thewindow portion 64. Then, as shown by an arrow A2 (seeFIG. 6 ), a screw 57 (seeFIG. 6 ) is inserted into a throughhole 52 a provided at an upper portion of thetriac element 52 and screwed into thescrew hole 74. Thus, thetriac element 52 is fixed to theheat sink 70 so as to be in close contact therewith. - At this time, since the
triac element 52 is fitted into thegroove portion 72 of theheat sink 70, thetriac element 52 is prevented from being rotated due to thescrew 57 being firmly screwed down. This can prevent the terminal 52 b of thetriac element 52 from being warped to be broken. Furthermore, at the time of firmly screwing down thescrew 57, thecircuit substrate 51 is not fixed to thesubstrate holder 60, which can more reliably prevent the terminal 52 b of thetriac element 52 from being warped to be damaged. - Furthermore, at an upper end of the
circuit substrate 51, aconcave portion 51 a from which the throughhole 52 a is exposed is formed by cutting out a portion of thecircuit substrate 51, which is opposed to the throughhole 52 a. Thetriac element 52 is fixed with thescrew 57 via theconcave portion 51 a. This can reduce the amount of two-dimensional protrusion of thetriac element 52 from thecircuit substrate 51. Thus, thesubstrate holder 60 can be reduced in size and thereby allows thecontrol circuit unit 50 to be reduced in size, and the amount of amolding material 58 used, which is described later, can be reduced. - After the
triac element 52 is mounted to theheat sink 70, themolding material 58 made of a resin such as urethane is filled in thesubstrate holder 60. Through hardening of themolding material 58, thecircuit substrate 51 and thetriac element 52 are molded, and thus thecircuit substrate 51 is fixed. In this case, prior to the hardening, part of themolding material 58, which flows along a gap between the periphery of thewindow portion 64 and theheat sink 70, is prevented by surface tension from flowing out to the periphery of thesubstrate holder 60. A shielding material that prevents themolding material 58 from flowing out may be provided at the periphery of thesubstrate holder 60. - If, during a cooling operation, low temperature air flowing through the
air passage 23 comes in contact with theheat sink 70, dew condensation may occur in thesubstrate holder 60. In such a case, since themolding material 58 is filled, it is possible to prevent dew condensation water from being deposited on thecircuit substrate 51 and thetriac element 52. - Furthermore, the
triac element 52 is disposed at an upper portion in thesubstrate holder 60. If voids are formed in themolding material 58, dew condensation water on the surface of themolding material 58 may reach thetriac element 52. In such a case, since thetriac element 52 is disposed at the upper portion in thesubstrate holder 60, the possibility that dew condensation water reaches thetriac element 52 can be reduced to a greater degree than in the case where thetriac element 52 is disposed at a lower portion in thesubstrate holder 60. -
FIG. 10 is a perspective view showing a state where thecircuit substrate 51 is fixed by filling themolding material 58. A lead 59 extending from thecircuit substrate 51 is taken out through an openingportion 65 that is open on the lower surface of thesubstrate holder 60. Thelead 59 is bent into a U-shape below thesubstrate holder 60 and is guided upward by a holdingportion 66 that is provided on a side surface of thesubstrate holder 60. - The
lead 59 is connected to the inside of the electrical equipment box 31 (seeFIG. 3 ) via an opening portion (not shown) provided at an upper portion of theelectrical equipment box 31. Thus, dew condensation water produced in thesubstrate holder 60 and allowed to slip along thelead 59 drips from a lower end of thelead 59 onto the drain pan 32 (seeFIG. 3 ) and thus is collected. This can prevent the entry of dew condensation water into theelectrical equipment box 31. - Next, as shown by an arrow A3 (see
FIG. 6 ), the opening surface of thesubstrate holder 60 is closed with thelid portion 68. On the inner surface of thelid portion 68, ahousing portion 68 a is recessed so as to be opposed to the openingportion 65 of thesubstrate holder 60 and to extend in the vertical direction. Thelead 59 is disposed in thehousing portion 68 a, which allows thelead 59 to be bent at an increased radius of curvature. This can prevent breakage of thelead 59. Furthermore, this can also prevent the lead 59 from being displaced in the lateral direction. - Next, using the
heat sink holder 78, holding of theheat sink 70 is performed.FIGS. 11 and 12 are front views showing a state before theheat sink 70 and theheat sink holder 78 are fitted to each other and a state where they have been fitted to each other, respectively. Theheat sink holder 78 is made of a resinous molded article, and at each of two portions thereof, which are upper and lower portions of theheat sink holder 78, anarm portion 78 a that constitutes an elastic body is provided in a protruding manner so as to extend in one direction. Thearm portion 78 a is formed in an L-shape in cross section and has a standingportion 78 c that is to lie along thereference surface 70 a of theheat sink 70. At a tip end of thearm portion 78 a, anail portion 78 b is formed so as to be opposed to the standingportion 78 c. - As shown by an arrow A4, the
heat sink 70 is inserted between both thearm portions 78 a while causing thearm portions 78 a to be bent elastically during the insertion. At this time, the standingportion 78 c comes to lie along thereference surface 70 a of theheat sink 70, and thenail portion 78 b provided at the tip end of thearm portion 78 a is engaged with thefins 71. Thearm portions 78 a thus sandwich therebetween two surfaces of theheat sink 70, which are opposed to each other in the vertical direction, and thereby holds theheat sink 70. - The
heat sink holder 78 is fitted into the openingportion 24 b (seeFIG. 4 ) of theintermediate wall 24. Then, a screw is inserted into a throughhole 78 d provided at each of upper and lower ends of theheat sink holder 78 and into a through hole (not shown) provided on the periphery of the openingportion 24 b and screwed to be secured to ascrew portion 80 a (seeFIG. 3 ) of theangle 80. Thus, thecontrol circuit unit 50 is mounted to theintermediate wall 24. - At this time, the
substrate holder 60 containing thetriac element 52 is disposed outside theair passage 23 adjacently to theair passage 23. Theheat sink 70 in close contact with thetriac element 52 protrudes into theair passage 23 and is disposed between theblower fan 25 and theindoor heat exchanger 27, on the outside of thePTC heater 28 a in the longitudinal direction. - A common screw is used for mounting the
angle 80 and thecontrol circuit unit 50 to theintermediate wall 24, and thus the number of components used can be reduced. Furthermore, the use of thearm portions 78 a allows theheat sink 70 to be easily held and thus eliminates the need for a screw for fitting theheat sink 70 and theheat sink holder 78 to each other, so that the number of components used can be reduced. In addition, thearm portions 78 a are fitted onto the inner circumferential surface of the openingportion 24 b while covering the upper and lower surfaces of theguide groove 73, and thus it is possible to prevent air from leaking from theair passage 23 via theguide groove 73. - In the
air conditioner 1 configured as above, upon the start of a cooling operation, thecompressor 41 is driven to operate the refrigeration cycle. In this operation, theindoor heat exchanger 27 functions as an evaporator on a low temperature side of the refrigeration cycle, and theoutdoor heat exchanger 42 functions as a condenser on a high temperature side of the refrigeration cycle. Theoutdoor fan 43 is driven to cause theoutdoor heat exchanger 42 to exchange heat with the outside air thereby to radiate heat. Theblower fan 25 is driven to cause air inside a room to flow into theair passage 23 through thesuction port 21 and the air cooled by heat exchange with theindoor heat exchanger 27 to be sent out into the room through theblowoff port 22. Thus, cooling of the room is performed. - Upon the start of a heating operation, the
compressor 41 is driven to operate the refrigeration cycle. In this operation, theindoor heat exchanger 27 functions as the condenser on the high temperature side of the refrigeration cycle, and theoutdoor heat exchanger 42 functions as the evaporator on the low temperature side of the refrigeration cycle. Theoutdoor fan 43 is driven to cause theoutdoor heat exchanger 42 to exchange heat with the outside air thereby to absorb heat. Theblower fan 25 is driven to cause air inside a room to flow into theair passage 23 through thesuction port 21, which is then heated by heat exchange with theindoor heat exchanger 27. - Furthermore, by the driving of the
PTC heater 28 a, the air flowing through theair passage 23 is further heated. In this regard, theblower fan 25 and theindoor heat exchanger 27 are formed so as to extend further to the lateral sides than thePTC heater 28 a. This can increase a heat exchange area of theindoor heat exchanger 27. Furthermore, air flowing through thespace portion 33 on the lateral side of thePTC heater 28 a cools thetriac element 52 via theheat sink 70. At this time, the air flowing through thespace portion 33 exchanges heat with theheat sink 70 and thus is heated. - The air heated by the
indoor heat exchanger 27 and thePTC heater 28 a is sent out into the room through theblowoff port 22, and thus heating of the room is performed. - During a heating operation, the
compressor 41 may be deactivated so that air is heated by thePTC heater 28 a alone. Furthermore, an integrated air conditioner capable only of cooling based on the operation of a refrigeration cycle may be modified so that a heating operation by thePTC heater 28 a is enabled. - According to this embodiment, the
triac element 52 that controls thePTC heater 28 a is disposed adjacently to theair passage 23 and theheat sink 70 is disposed inside theair passage 23, and thus thetriac element 52 can be cooled by an airflow flowing through theair passage 23 via theheat sink 70. This eliminates the need to install a fan for cooling thetriac element 52, and thus power consumption and cost can be reduced and the safety of theair conditioner 1 can be improved. - Furthermore, in the longitudinal direction, the
heat sink 70 is disposed on the outside of thePTC heater 28 a that is shorter than theblower fan 25, and thus the temperature rise of thetriac element 52 due to heat radiation of thePTC heater 28 a can be suppressed. Moreover, air heated by heat exchange with theheat sink 70 is sent out from an end portion of theair passage 23, and thus the efficiency of a heating operation can be improved. In addition, theheat sink 70 is disposed in a dead space between theblower fan 25 and theindoor heat exchanger 27, on the outside of thePTC heater 28 a in the longitudinal direction, and thus theair conditioner 1 can be prevented from increasing in size due to the installation of theheat sink 70. - Furthermore, the
substrate holder 60 is formed in a cup shape and has thewindow portion 64 open therein for inserting thetriac element 52 thereinto, and by themolding material 58 filled in thesubstrate holder 60, thecircuit substrate 51 and thetriac element 52 are molded. Thus, in a case where, during a cooling operation, low temperature air comes in contact with theheat sink 70 and thus dew condensation occurs in thesubstrate holder 60, since themolding material 58 is filled, it is possible to prevent dew condensation water from being deposited on thecircuit substrate 51 and thetriac element 52. - Furthermore, in the
heat sink 70, theguide groove 73 is so formed that the width between both the side walls thereof is greater at least part of the region between the side walls than at the open surface of theguide groove 73, and thesubstrate holder 60 has thefitting portion 61 to be fitted into theguide groove 73, so that thesubstrate holder 60 can be easily fitted to theheat sink 70. Furthermore, since there is no need for a screw for fitting thesubstrate holder 60 to theheat sink 70, it is possible to reduce a phenomenon in which, during a cooling operation, dew condensation occurs in thesubstrate holder 60 due to heat conduction via the screw. - Furthermore, the engaging
protrusion 63 is provided in thesubstrate holder 60, and the engaginghole 75 is provided in theheat sink 70, so that through engagement between the engagingprotrusion 63 and the engaginghole 75, positioning of theheat sink 70 and thesubstrate holder 60 relative to each other can be easily performed, and thus assembling workability can be improved. - Furthermore, the
triac element 52 is fitted into thegroove portion 72 recessed in theheat sink 70 and is fastened in that state with thescrew 57, and thus thetriac element 52 is prevented from being rotated due to thescrew 57 being firmly screwed down. This can prevent the terminal 52 b of thetriac element 52 from being warped to be broken. - Furthermore, the
heat sink holder 78 has thearm portion 78 a that is made of an elastic body and used to sandwich the two circumferential surfaces of theheat sink 70, which are opposed to each other, and is mounted by being fitted into the openingportion 24 b on a wall surface of theair passage 23, so that theheat sink 70 can be easily held by theheat sink holder 78. - In this embodiment, air flowing through the
air passage 23 is heated by thePTC heater 28 a that is controlled by thetriac element 52 in close contact with theheat sink 70. There is, however, no limitation thereto. Heating may be performed using a heater that is controlled by a control element of another type provided in close contact with theheat sink 70. - The present invention can be applied to air conditioners each including a heater and a control element that controls the heater.
-
-
- 1 Air conditioner
- 2 Indoor section
- 3 Bottom plate
- 4 Outdoor section
- 5 Partition wall
- 20, 40 Cabinet
- 21 Suction port
- 22 Blowoff port
- 23 Air passage
- 24 Intermediate wall
- 24 b Opening portion
- 25 Blower fan
- 26 Louver
- 27 Indoor heat exchanger
- 28 Heater unit
- 28 a PTC heater
- 29 Duct member
- 30 Exterior cover
- 31 Electrical equipment box
- 41 Compressor
- 42 Outdoor heat exchanger
- 43 Outdoor fan
- 47 Refrigerant pipe
- 50 Control circuit unit
- 51 Circuit substrate
- 52 Triac element
- 58 Molding material
- 59 Lead
- 60 Substrate holder
- 61 Fitting portion
- 63 Engaging protrusion
- 64 Window portion
- 70 Heat sink
- 71 Fin
- 72 Groove portion
- 73 Guide groove
- 75 Engaging hole
- 78 Heat sink holder
- 78 a Arm portion
Claims (7)
1. An air conditioner, comprising:
an air passage that is formed in a cabinet so as to connect a suction port and a blowoff port to each other, which are open on a surface of the cabinet;
a blower fan that is disposed inside the air passage so as to extend in a longitudinal direction;
a heat exchanger that is disposed so as to be opposed to the suction port and exchanges heat with air flowing in through the suction port;
a heater that is disposed between the blower fan and the heat exchanger in order to heat air flowing in through the suction port and is shorter in a longitudinal direction than the blower fan;
a control element that controls the heater and is disposed outside the air passage adjacently to the air passage; and
a heat sink that is in close contact with the control element and is disposed between the blower fan and the heat exchanger, on an outside of the heater in the longitudinal direction.
2. The air conditioner according to claim 1 , wherein
the heater is formed by a PTC heater, and the control element is formed by a triac element.
3. The air conditioner according to claim 1 or 2 , further comprising:
a circuit substrate on which the control element is mounted;
a cup-shaped substrate holder that has a window portion for inserting the control element thereinto, open on an opposed surface of the substrate holder, which is opposed to the heat sink, and holds the circuit substrate; and
a molding material that is filled in the substrate holder so as to mold the circuit substrate and the control element.
4. The air conditioner according to claim 3 , wherein
the heat sink has a guide groove that is recessed therein so as to extend in one direction, and the substrate holder has a fitting portion to be fitted into the guide groove,
a width between both side walls of the guide groove is set to be greater at least part of a region between the side walls than at an open surface of the guide groove, and
through fitting between the guide groove and the fitting portion, the substrate holder is guided to be slid in the one direction.
5. The air conditioner according to claim 4 , wherein
an engaging protrusion is provided on the opposed surface of the substrate holder, and an engaging hole is provided in the heat sink, which is engaged with the engaging protrusion so that positioning of the heat sink and the substrate holder relative to each other is performed.
6. The air conditioner according to claim 3 , wherein
the control element is fastened to the heat sink with a screw, and a groove portion into which the control element is fitted is recessed in the heat sink.
7. The air conditioner according to claim 1 or 2 , wherein
an opening portion is formed on one of wall surfaces of the air passage in the longitudinal direction, and
a heat sink holder is provided that has an arm portion made of an elastic body and used to sandwich two circumferential surfaces of the heat sink, which are opposed to each other, and is mounted to the one of wall surfaces of the air passage by being fitted into the opening portion.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2010046934A JP5079831B2 (en) | 2010-03-03 | 2010-03-03 | Air conditioner |
JP2010-046934 | 2010-03-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20110214443A1 true US20110214443A1 (en) | 2011-09-08 |
Family
ID=44515283
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/039,058 Abandoned US20110214443A1 (en) | 2010-03-03 | 2011-03-02 | Air conditioner |
Country Status (4)
Country | Link |
---|---|
US (1) | US20110214443A1 (en) |
JP (1) | JP5079831B2 (en) |
CN (1) | CN102192558B (en) |
CA (1) | CA2732963C (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN109708210A (en) * | 2019-02-25 | 2019-05-03 | 广东美的制冷设备有限公司 | Heat exchanger components for air conditioner indoor unit and the air conditioner indoor unit with it |
US20190376699A1 (en) * | 2018-06-07 | 2019-12-12 | Tadiran Consumer And Technology Products Ltd. | Building structure for garage mounted apparatus |
EP3521712A4 (en) * | 2016-09-27 | 2020-01-01 | Mitsubishi Electric Corporation | Outdoor unit for air conditioner, and air conditioner |
WO2021103900A1 (en) * | 2019-11-29 | 2021-06-03 | 广东美的制冷设备有限公司 | Sealing assembly for window air conditioner, and window air conditioner having same |
CN113188234A (en) * | 2021-05-13 | 2021-07-30 | 珠海格力电器股份有限公司 | Power module condensation prevention control method and device, storage medium and air conditioning system |
Families Citing this family (5)
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KR100563288B1 (en) * | 2002-10-31 | 2006-03-27 | 마쓰시타 레키 가부시키가이샤 | Sealed type motorized compressor and reprigerating device |
CN104676871A (en) * | 2013-11-26 | 2015-06-03 | 珠海格力电器股份有限公司 | Cooling device, air conditioner and cooling device assembly method |
JP7151129B2 (en) * | 2018-03-30 | 2022-10-12 | 株式会社富士通ゼネラル | air conditioner |
KR102148994B1 (en) * | 2019-11-29 | 2020-08-27 | 전혜영 | Thermostat |
CN113970175B (en) * | 2020-07-24 | 2023-05-02 | 广东美的制冷设备有限公司 | Air conditioner, radiation control method and device thereof and computer readable storage medium |
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CN109708210A (en) * | 2019-02-25 | 2019-05-03 | 广东美的制冷设备有限公司 | Heat exchanger components for air conditioner indoor unit and the air conditioner indoor unit with it |
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Also Published As
Publication number | Publication date |
---|---|
JP5079831B2 (en) | 2012-11-21 |
CA2732963A1 (en) | 2011-09-03 |
CA2732963C (en) | 2013-11-05 |
CN102192558B (en) | 2013-12-18 |
CN102192558A (en) | 2011-09-21 |
JP2011179789A (en) | 2011-09-15 |
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