WO2019167118A1

WO2019167118A1 - Manufacturing method and manufacturing mold for air conditioner

Info

Publication number: WO2019167118A1
Application number: PCT/JP2018/007222
Authority: WO
Inventors: 大舘　一夫
Original assignee: 日立ジョンソンコントロールズ空調株式会社
Priority date: 2018-02-27
Filing date: 2018-02-27
Publication date: 2019-09-06
Also published as: TW201937119A; CN110418925A; JPWO2019167118A1; CN110418925B; TWI679380B; JP6441549B1

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

Air conditioner manufacturing method and mold

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

Conventionally, the condensed water produced | generated with an indoor unit at the time of the air_conditioning | cooling and dehumidification driving | operation of an air conditioner is drained so that patent document 1 may be described.
Specifically, the condensed water in the indoor unit is received by a drain pan and drained to the outside through a hose connected to the drain hole of the drain pan.

The drain pan is molded with resin using a resin mold.

JP 2017-227398 A (FIG. 3A, FIG. 3B, paragraph 0022, etc.)

By the way, when the above-described drain hole is molded with a resin mold, there is a case where the hole is blocked if there is a molding defect in the current mold configuration. In this case, water overflows from the drain pan of the indoor unit, and water leaks from the indoor unit.

Therefore, when there is a molding defect in the drain pan and the resin has entered the drain hole, the resin that has entered the human hand is removed.
Therefore, there is a molding defect in the drain pan, and if the removal process by hand is not performed properly, there is a possibility that water leaks from the indoor unit.

The present invention was devised in view of the above circumstances, and an object thereof is to provide an air conditioner manufacturing method and a manufacturing mold that can perform drain pan molding with high reliability.

In order to solve the above-described problem, a method for manufacturing an air conditioner according to a first aspect of the present invention is an air conditioner including an indoor unit including a drain pan having a drain hole for discharging condensed water generated by cooling or dehumidifying operation. A manufacturing method comprising a first mold and a second mold for forming the drain hole of the drain pan, and the first mold is moved when the first mold moves after the drain hole is formed. The first mold overlaps with a part of the mating portion between the first mold and the second mold.

A mold for manufacturing an air conditioner according to a second aspect of the present invention is a mold for manufacturing an air conditioner including an indoor unit including a drain pan having a drain hole for discharging condensed water generated by cooling or dehumidifying operation. A first mold and a second mold for forming the drain hole of the drain pan, and the first mold and the second mold when the first mold moves after the drain hole is formed. The first mold is configured to overlap with a part of the mating part of the mold.

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

The perspective view which shows the indoor unit and outdoor unit of the air conditioner of embodiment which concerns on this invention. The schematic cross-sectional view which shows an indoor unit. The perspective view which notched some indoor units. The cross-sectional view around the drain hole of the drain pan. Sectional drawing of the formation process of a drain pan. Sectional drawing of the formation process of a drain pan. Sectional drawing of the formation process of a drain pan. The expanded sectional view of the drain hole vicinity at the time of removing A metal mold | die, B metal mold | die, and C metal mold | die after injection molding at the time of the shaping | molding malfunction of a drain pan. Sectional drawing which shows the state which shape | molds the drain hole vicinity of the drain pan of a modification. The expanded sectional view of the drain hole vicinity at the time of removing A metal mold | die, B metal mold | die, and C metal mold | die after the injection molding at the time of the shaping | molding malfunction of the drain pan of a modification.

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

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

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

The indoor unit Ci is installed indoors and performs indoor air conditioning.
The outdoor unit Co is installed outdoors, and main mechanical elements of the refrigeration cycle are stored therein.

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

The outdoor heat exchanger 2 is installed in a shape bent in an L shape when viewed from above on the left side and the rear side toward the inner and outer peripheral portions of the blower chamber Co1. In front of the outdoor heat exchanger 2, an outdoor fan 3 for sending air to the outdoor heat exchanger 2 from behind the outdoor unit Co (arrow α10 in FIG. 1) is arranged.

Inside the machine room Co2, accumulators, compressors, expansion valves, four-way valves, etc. (not shown) constituting the refrigeration cycle are connected via a pipe 14. The outdoor fan 3 is driven at the upper right of the outdoor unit Co. An electrical component box 4 for controlling a fan motor, a compressor, and the like is provided.

FIG. 2 shows a schematic cross-sectional view of the indoor unit Ci. 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 installed on the outer periphery, and an indoor fan 6 is installed in the center. In addition to these, the indoor unit Ci includes a drain pan 7, a housing base 8,

filters

9 a and 9 b, a front panel 10, a left and right wind direction plate 11, and an up and down wind direction plate 12.

The indoor heat exchanger 5 has a plurality of fins f and a plurality of heat transfer tubes g penetrating 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 fed from the outside by the indoor fan 6 (arrow α11 in FIG. 2).

The indoor fan 6 is a fan that sends room air into the indoor heat exchanger 5 by driving 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 on which the fan blades 6a are installed, and an indoor fan motor (not shown) as a drive source.

The drain pan 7 receives condensed water from the indoor heat exchanger 5, the pipe 14, and the like, and is disposed below the front indoor heat exchanger 5a.
The housing base 8 is a strength member on which devices such as the indoor heat exchanger 5 and the indoor fan 6 are installed.

The filter 9a is installed on the front side of the indoor heat exchanger 5, and removes dust from the air toward the front air suction port h1. The filter 9b is installed on the upper side of the indoor heat exchanger 5, and removes dust from the air toward the upper air suction port h2.

The front panel 10 is a design panel that is installed so as to cover the filter 9a on the front side, and is turnable forward around a lower end axis (not shown).
The left and right wind direction plates 11 (see FIG. 2) are members that adjust the flow in the left and right direction of the air blown into the room as the indoor fan 3 rotates. The vertical wind direction plate 12 is a member that adjusts the vertical flow of air blown into the room as the indoor fan 3 rotates.

FIG. 4 shows a cross-sectional view around the drain hole 7 h of the drain pan 7.
The drain pan 7 is formed with a drain hole 7h which is a drain hole. A drain pipe 13 is connected to the drain hole 7 h of the drain pan 7. Although the drain piping 13 is comprised by the flexible hose and tube, for example, it is not limited to this.

The moisture received by the drain pan 7 is discharged to the outside through the drain pipe 13.
In addition to the drain water, the refrigerant leaked from the indoor heat exchanger 5 and the pipe 14 is also guided into the drain pan 7. The drain pan 7 is formed with, for example, four walls 7k so that the drain water received in the indoor heat exchanger 5 and the pipe 14 and the leaked refrigerant do not flow out of the indoor unit Ci. It has a bottomed dish shape with an opening above it.

The drain pan 7 is injection-molded using a resin.
The drain pan 7 is formed with a front support portion 7s1 and a side support portion 7s2 for supporting the drain pan 7 inside the indoor unit Ci so as to extend in the front lower side and the rear lower side, respectively.

FIG. 5A to FIG. 5C show cross-sectional views of the forming process of the drain pan 7.

As shown in FIG. 5A, the drain pan 7 is molded using a resin mold A mold 16, a B mold 17, and a C mold 18.
The A mold 16 forms the front lower part shape of the drain pan 7. The A mold 16 is formed in a shape for molding the front support portion 7 s 1 and the side support portion 7 s 2 of the drain pan 7.

B Mold 17 molds the internal shape of the drain pan 7 and a part of the drain hole 7h. Therefore, the B mold 17 is formed with a drain pan internal shape portion 17a and a drain hole part forming convex portion 17b protruding rearward and downward from the drain pan internal shape portion 17a. The drain hole part forming convex portion 17b moves through the abutting surface 7h1 of the B die 17 and the C die 18 when the B die 17 is removed after molding (arrow α29 in FIG. 6). The drain hole part forming convex part 17b may have a semi-cylindrical shape or any other shape as long as it partially protrudes into the drain hole 7h.

The C mold 18 molds the rear shape of the drain pan 7. The C mold 18 has a shape that forms the rear shape of the drain pan 7, and a core pin 18p for molding the drain hole 7h of the discharge hole is fixed. The core pin 18p is formed with a drain hole part forming concave part 18p1 that is in contact with the drain hole part forming convex part 17b of the B mold 17 and a B mold contact part 18p2 that is in contact with the B mold 17. ing. The core pin 18p will be described as a part of the C die 18.

A part of the drain hole part forming protrusion 17b of the B mold 17 is configured to bite into the C mold 18 (core pin 18p).
The drain pan 7 is formed as follows.

First, as shown in FIG. 5A, the A mold 16, the B mold 17, and the C mold 18 are combined (arrow α20 in FIG. 5A). Then, a cavity 7 </ b> C having the shape of the drain pan 7 is formed between the A mold 16, the B mold 17, and the C mold 18.
Subsequently, as shown in FIG. 5B, resin is filled into a cavity 7 </ b> C between the A mold 16, the B mold 17, and the C mold 18 from a resin filling port (not shown).

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

Here, at the time of molding failure, the resin may enter between the butted surfaces 7h1 of the B mold 17 and the C mold 18, and the drain hole 7h may be blocked.

FIG. 6 shows an enlarged cross-sectional view of the vicinity of the drain hole 7h when the A mold 16, the B mold 17, and the C mold 18 are removed after injection molding at the time of molding failure of the drain pan 7.
However, as shown in FIG. 6, the resin in which the drain hole part forming convex part 17b of the B mold 17 has entered the abutting surface 7h1 due to the movement of the B mold 17 after molding (arrow α22 in FIG. 6). Can be broken through a part j1 (arrow α29 in FIG. 6). Therefore, the drain hole 7h is fully closed and water leakage is suppressed.

According to the above configuration, there is a molding defect of the drain hole 7h, and the drain hole 7h is not completely closed even if the removal process by a human hand is not properly performed.
Therefore, an air conditioner having an indoor unit that can suppress the occurrence of water leakage due to clogging of the drain hole 7h can be provided.

<Modification>
FIG. 7A shows a state where the vicinity of the drain hole 7h of the drain pan 7 of the modified example is shown, and FIG. 7B shows an A mold 26, a B mold 27, and a C mold after injection molding at the time of molding failure of the drain pan 7 of the modified example. The expanded sectional view of the drain hole 7h vicinity at the time of removing 28 is shown.

As shown in FIG. 7A, in the modification, a butted portion 27h1 between the B mold 27 and the C mold 28 is formed outside the drain hole 7h. Other configurations are the same as those in the embodiment, and are denoted by reference numerals in the 20s.
In the modified example, a part of the drain hole part forming protrusion 27b of the B mold 27 is bitten into the C mold 28 (core pin 28p) outside the drain hole 7h of the drain pan 7.

At the time of molding failure, the resin may enter between the butted surfaces 27h1 of the B mold 27 and the C mold 28, and the drain hole 7h may be blocked.
However, as shown in FIG. 7B, when the A die 26, the B die 27, and the C die 28 are removed after the molding (arrows α31, α32, α33 in FIG. 7B), the movement of the B die 27 (see FIG. 7B). 7A and the arrow α32 in FIG. 7B, the drain hole partial formation convex portion 27b of the B mold 27 can break through the resin part j2 that has entered the abutting surface 27h1 (arrow α32 in FIG. 7B).

Therefore, even when the butted portion 27h1 between the B mold 27 and the C mold 28 is formed outside the drain hole 7h, the drain hole 7h is fully closed, and water leakage is suppressed.

<< Other Embodiments >>
1. Although the case where three molds for molding the vicinity of the drain hole 7 of the drain pan 7 are described has been described, the mold may be configured using four or more molds.

2. The configuration described in the above embodiment shows an example of the present invention, and various specific forms are possible within the scope of the claims.

7, 27 Drain pan 7h, 27h Drain hole 17, 27 B mold (first mold)
7h1, 27h1 mating surface (gating part)
18, 28 C mold (second mold)
18p, 28p core pin (second mold)
C Air conditioner Ci Indoor unit

Claims

A method of manufacturing an air conditioner including an indoor unit including a drain pan having a drain hole for discharging condensed water generated by cooling or dehumidifying operation,
A first mold and a second mold for forming the drain hole of the drain pan;
When the first mold moves after forming the drain hole, the first mold overlaps with a part of an abutting portion between the first mold and the second mold. A method of manufacturing a harmony machine.
In the manufacturing method of the air conditioner of Claim 1,
A part of the abutting part is disposed inside or outside the drain hole. A method of manufacturing an air conditioner, wherein:
A mold for manufacturing an air conditioner including an indoor unit including a drain pan having a drain hole for discharging condensed water generated by cooling or dehumidifying operation,
A first mold and a second mold for forming the drain hole of the drain pan;
When the first mold moves after forming the drain hole, the first mold is configured to overlap a part of the mating portion of the first mold and the second mold. An air conditioner manufacturing mold characterized by that.
In the air conditioner manufacturing mold according to claim 3,
A part of the abutting part is arranged inside or outside the drain hole. A manufacturing mold for an air conditioner.