JP3966258B2 - Manufacturing method of fan for air conditioning indoor unit - Google Patents

Description

The present invention relates to a method for manufacturing a fan of an air conditioning indoor unit that is formed integrally with a motor rotor by insert molding.

  2. Description of the Related Art Conventionally, an air conditioner that improves indoor comfort by blowing air conditioned in a building, a house, or the like indoors is known. For example, an air conditioner can keep a room at a comfortable temperature by blowing warm air or cold air indoors.

  Such an air conditioner is provided with a blower for blowing air conditioned indoors.

For example, the blower disclosed in Patent Document 1 is a blower built in a wall-hanging air-conditioning indoor unit, and is connected to a crossflow fan that blows air after air conditioning into the room, and the crossflow fan. A motor rotor and a motor stator for rotating the motor rotor. The motor rotor is disposed radially outward of the motor stator and is rotated about the rotation axis by the motor stator. Further, the cross flow fan and the motor rotor are connected by screws or the like. In such a blower, in order to blow air indoors, first, the motor stator rotates the motor rotor. And this rotational force is transmitted to the crossflow fan connected with a motor rotor, and a crossflow fan is rotated. As the cross flow fan rotates, the conditioned air is blown indoors.
Japanese Patent Laid-Open No. 01-290999

  However, the conventional cross flow fan has the following problems.

  That is, in the conventional crossflow fan, in order to achieve a highly accurate connection with the motor rotor, a connection method by insert molding may be employed instead of a connection method using screws or the like. When this connection method by insert molding is adopted, the motor rotor loaded in the molding die is thermally expanded by heat applied to the molding die during molding. Then, it becomes difficult for the thermally expanded motor rotor to come off from the molding die, and the releasability of the motor rotor with respect to the molding die is deteriorated. For this reason, it has the problem that productivity falls and product cost becomes high.

The subject of this invention is providing the manufacturing method of the fan of the air-conditioning indoor unit which can aim at the cost reduction by improving the production efficiency by insert molding.

The method of manufacturing a fan for an air conditioning indoor unit according to claim 1 includes: a side plate that holds one end of a plurality of blades arranged in an annular shape around a rotation shaft; and a motor rotor connected to the side plate by insert molding. A manufacturing method for manufacturing a fan of an air-conditioning indoor unit comprising a molding die including a movable die and a fixed die , wherein the first step, the second step, and the third step And steps. In the first step, a cylindrical portion including a flange portion that is in close contact with the side plate and connected to the side plate and a non-flange portion is formed on the motor rotor. The non-flange portion is a portion that is further away from the side plate than the flange portion, has an outer peripheral surface that is closer to the rotating shaft than the outer peripheral surface of the flange portion, and does not contact the side plate. In the second step, the flange portion is positioned in the space on the movable mold side, the non-flange portion is positioned in the space on the fixed mold side, and the surface opposite to the side plate side of the flange portion is the non-fixed mold surface. The motor rotor is loaded into the molding die so as to be in contact with a portion outside the space where the flange portion is located . In the third step, molten resin is injected into the space on the movable die side of the molding die, and the contact portion between the surface of the flange portion opposite to the side plate side and the fixed die is the die pressing and cutting portion. In such a state that the molten resin does not flow into the space on the fixed mold side, the side plate is insert-molded to connect the flange portion and the side plate.

  Here, the motor rotor formed in the first step has a flange portion. For this reason, a level | step difference is formed in the thickness direction of a motor rotor by the flange part which protruded in the outer diameter side of the motor rotor. In the second step of loading the motor rotor into the insert molding die for integrally molding the motor rotor and the fan, a part of the motor rotor and the molding die is provided on the third surface of the flange portion. To form a die pressing part. Then, insert molding is performed in a state where a gap is left between the fourth surface and the molding die. Thereby, even when the motor rotor is thermally expanded at the time of molding, it is possible to escape the thermal expansion due to the gap, so that it is possible to prevent the occurrence of a problem that it is difficult to remove the molded product from the molding die. Therefore, the releasability of the motor rotor from the mold can be improved to improve the production efficiency, and the cost of the product can be reduced.

The method for manufacturing a fan for an air conditioning indoor unit according to claim 2 is the method for manufacturing a fan for an air conditioning indoor unit according to claim 1 , wherein, in the second step, the cylindrical portion of the motor rotor is formed. A clearance is provided between the surface on the inner diameter side and the molding die and / or between the surface on the outer diameter side of the non-flange portion and the molding die.

  Here, between the inner diameter side surface (fifth surface) of the motor rotor and the molding die, between the outer diameter side surface (fourth surface) excluding the flange portion and the molding die. A gap is formed on one or both sides. For this reason, even if the motor rotor is thermally expanded at the time of molding, the dimension increased by the thermal expansion can be released at the gap portion. Therefore, since the mold release property between the molding die and the motor rotor can be further improved, the production efficiency can be improved and the cost of the product can be reduced.

The method for manufacturing a fan for an air conditioning indoor unit according to claim 3 is the method for manufacturing a fan for an air conditioning indoor unit according to claim 1 or 2 , wherein in the third step, the molten resin is a flange portion. Are injected into the space between the outer diameter side surface and the molding die and the space between the side plate side surface of the flange portion and the molding die.

  Here, in the third step, the molten resin is a space between the outer diameter side surface (second surface) of the flange portion of the motor rotor and the molding die and the connection side surface (first surface). ) And the molding die. For this reason, a highly accurate connection can be easily performed by solidifying molten resin and forming a side plate.

According to the method for manufacturing a fan of an air conditioning indoor unit according to claim 1 , even when the motor rotor is thermally expanded at the time of insert molding, the dimension increased by the thermal expansion is set to the fourth surface of the motor rotor and the molding die. Can be released in the gap formed between the two, so that the mold releasability from the molding die is improved, the production efficiency is improved, and the production cost can be reduced.

According to the method for manufacturing a fan of an air conditioning indoor unit according to a second aspect of the present invention, a dimensional increase due to thermal expansion of the motor rotor can be absorbed by a gap formed between the motor rotor and the molding die. For this reason, since the mold release property with respect to the molding die of the motor rotor can be improved, the production efficiency can be improved and the production cost can be reduced.

According to the method for manufacturing a fan of an air conditioning indoor unit according to claim 3 , it is possible to easily perform highly accurate connection by forming the side plate by solidifying the molten resin.

<Overall configuration of air conditioner>
FIG. 1 shows the appearance of an air conditioner 1 equipped with a cross flow fan (an air conditioning indoor unit fan) according to an embodiment of the present invention.

  This air conditioning apparatus 1 is an apparatus for supplying conditioned air into a room. The air conditioner 1 includes an indoor unit 2 attached to an indoor wall surface and the like, and an outdoor unit 3 installed outside the room.

  An indoor heat exchanger 50 is accommodated in the indoor unit 2, and an outdoor heat exchanger 30 is accommodated in the outdoor unit 3. The heat exchangers 30 and 50 are connected by the refrigerant pipe 4 to constitute a refrigerant circuit.

<Schematic configuration of refrigerant circuit of air conditioner>
The structure of the refrigerant circuit of the air conditioning apparatus 1 is shown in FIG. This refrigerant circuit mainly includes an indoor heat exchanger 50, an accumulator 31, a compressor 32, a four-way switching valve 33, an outdoor heat exchanger 30, and an electric expansion valve 34.

  The indoor heat exchanger 50 provided in the indoor unit 2 exchanges heat with the air that comes into contact therewith. Further, the indoor unit 2 is provided with a crossflow fan (fan for an air-conditioning indoor unit) 71 for sucking indoor air, passing the air through the indoor heat exchanger 50 and exhausting the air into the room. ing. The cross flow fan 71 is formed in a long and thin cylindrical shape, and is arranged so that the central axis is parallel to the horizontal direction. The cross flow fan 71 is rotationally driven around the central axis by an indoor fan motor 72 provided in the indoor unit 2. The detailed configuration of the indoor unit 2 will be described later.

  The outdoor unit 3 is connected to a compressor 32, a four-way switching valve 33 connected to the discharge side of the compressor 32, an accumulator 31 connected to the suction side of the compressor 32, and a four-way switching valve 33. An outdoor heat exchanger 30 and an electric expansion valve 34 connected to the outdoor heat exchanger 30 are provided. The electric expansion valve 34 is connected to the pipe 41 via the filter 35 and the liquid closing valve 36, and is connected to one end of the indoor heat exchanger 50 via the pipe 41. The four-way switching valve 33 is connected to the pipe 42 via the gas closing valve 37 and is connected to the other end of the indoor heat exchanger 50 via the pipe 42. The pipes 41 and 42 correspond to the refrigerant pipe 4 in FIG. Further, the outdoor unit 3 is provided with a propeller fan 38 for discharging the air after heat exchange in the outdoor heat exchanger 30 to the outside. The propeller fan 38 is rotated by an outdoor fan motor 39.

<Configuration of indoor unit>
The indoor unit 2 has a shape that is long in the lateral direction when viewed from the front (see FIG. 1). The indoor unit 2 is mainly configured by an upper casing 6, a blower mechanism 7, and an indoor heat exchanger unit 5 (see FIG. 3) housed inside the indoor unit 2. The upper casing 6 covers the upper part of the indoor unit 2. The air blowing mechanism 7 constitutes the lower part of the indoor unit 2.

  Hereinafter, each configuration of the indoor unit 2 will be described with reference to FIG. 3.

  The indoor heat exchanger unit 5 includes an indoor heat exchanger 50, an auxiliary pipe (not shown), and the like.

  The indoor heat exchanger 50 is disposed to face the circumferential surface of the cross flow fan 71 and is attached so as to surround the front, upper, and rear of the cross flow fan 71. The indoor heat exchanger 50 allows the air sucked from the suction ports 60 and 61 to pass through the cross flow fan 71 as the cross flow fan 71 rotates, and exchanges heat with the refrigerant passing through the heat transfer tubes. To do.

  The auxiliary pipe connects the indoor heat exchanger 50 and the refrigerant pipe 4 outside the indoor unit 2. In this auxiliary pipe, refrigerant flows between the indoor heat exchanger 50 and the outdoor heat exchanger 30.

<Configuration of blower mechanism>
The blower mechanism 7 is a device for blowing the air heat-exchanged in the indoor heat exchanger 50 into the room. The blower mechanism 7 constitutes the lower part of the indoor unit 2, and as shown in FIGS. 3 and 4, the lower casing 70, the blower unit 8 and the like are modularized.

(Lower casing)
The lower casing 70 includes an outer surface portion 74, a support portion 78, and the like.

  The outer surface portion 74 is a portion that appears in the field of view as the outer surface of the indoor unit 2 in a front view, and is arranged such that the upper end is inclined toward the front side of the indoor unit 2. In addition, the outer surface portion 74 is provided with a blowout port 741 having an opening along the longitudinal direction of the indoor unit 2. As shown in FIG. 3, the air outlet 741 communicates with the space inside the support portion 78 in which the cross flow fan 71 is accommodated, and the air flow generated by the cross flow fan 71 passes through the air outlet 741. It blows out into the room through. In addition, the air outlet 741 is provided with a horizontal flap 742 for guiding the air blown into the room. The horizontal flap 742 is provided so as to be rotatable about an axis parallel to the longitudinal direction of the indoor unit 2. The horizontal flap 742 can be opened and closed by being rotated by a flap motor (not shown).

  The support portion 78 is surrounded by the outer surface portion 74. The blower unit 8, the electrical component box 73, the indoor heat exchanger unit 5, and the like are attached to the support portion 78 from above. And the support part 78 supports the ventilation unit 8, the electrical component box 73, the indoor heat exchanger unit 5, etc. from the downward direction.

<Blower unit>
The blower unit 8 includes a cross flow fan 71, an indoor fan motor 72 for rotating the cross flow fan 71, and an electrical component box 73 for storing electrical components for controlling the drive of the indoor fan motor 72. ing.

(Cross flow fan)
The cross flow fan 71 is made of resin such as AS resin, and has a long and thin cylindrical shape. The cross flow fan 71 is formed by insert molding using a rotor (motor rotor) 713 described later as an insert product. This insert molding will be described in detail later. The cross flow fan 71 is arranged so that the central axis, that is, the rotation axis A1 is horizontal.

  The cross flow fan 71 rotates around the rotation axis to generate an air flow. This air flow is a flow of air that is taken in from the suction ports 60 and 61, passes through the indoor heat exchanger 50, and blows out from the air outlet 741 into the room. The cross flow fan 71 is located approximately at the center of the indoor unit 2 in a side view.

  Further, as shown in FIG. 5, the cross flow fan 71 includes an end plate (side plate) 710, a blade 711, and a shaft 712. The end plates 710 are provided at both ends of the cross flow fan 71 and hold the end portions of the wing portions 711. A plurality of wing portions 711 are arranged in a ring shape between end plates 710 provided at both ends of the cross flow fan 71. The shaft 712 is disposed at the center of the end plate 710 and on the rotation axis A1, and serves as a rotation axis when the cross flow fan 71 rotates. The rotor 713 has a substantially cylindrical shape, and rotates about the rotation axis A <b> 1 by a magnetic field generated by the stator 720. The rotor 713 is made of a resin having a melting point equal to or higher than the melting point of the resin forming the cross flow fan 71 and containing fine magnet particles. Moreover, the rotor 713 is arrange | positioned in the radial direction outer side of the stator 720 of the indoor fan motor 72 mentioned later.

  In the present embodiment, in particular, the rotor 713 has a flange portion 714 protruding in the outer diameter direction on the connection side with the end plate 710. Here, the surface of the protruding flange portion 714 on the end plate 710 side is the first surface 714a, the radially outer surface is the second surface 714b, and the surface opposite to the first surface is the third surface 714c. When the outer surface of the rotor 713 excluding the flange portion 714 is the fourth surface 714d and the inner surface of the rotor 713 is the fifth surface 714e, the end plate 710 has the first surface 714a and the second surface 714e. It is formed as a resin that covers the surface 714b. The rotor 713 and the end plate 710 are integrally formed.

(Indoor fan motor)
The indoor fan motor 72 rotates the cross flow fan 71 around the rotation axis. The indoor fan motor 72 is a thin outer rotor type motor as shown in FIG. As shown in FIG. 5, the indoor fan motor 72 has a stator 720, a bearing 722, and a bearing holding portion 723.

  The stator 720 is for rotating a rotor 713 integrally formed with the end plate 710 of the cross flow fan 71, and includes an iron core, a coil, and the like (not shown) for generating a magnetic field. The stator 720 further has a fixing portion 725. The stator 720 is supported by the support portion 78 via a rubber holding member 726 that wraps the fixing portion 725 (see FIG. 4).

  The bearing 722 is a resin member and supports the shaft 712 of the cross flow fan 71. The bearing holding part 723 is a rubber part and supports the bearing 722.

<Cross flow fan molding method>
FIG. 6 shows a flow of a molding operation when the rotor 713 is integrally formed with the end plate 710 as an insert.

  First, the rotor 713 and the shaft 721 shown in FIG. 7 are loaded into predetermined positions of a molding die 800 for insert molding (step S101). Next, the molding die 800 is closed by combining the movable die 801 and the stationary die 802 (step S102). Then, the resin forming the end plate 710 heated and melted is injected under pressure from the gate G into the cavity of the molding die 800 (step S103). Thereafter, the injected molten resin is cooled and solidified in the molding die 800 to form the end plate 710 (step S104). After the resin is solidified, the molding die 800 is opened (step S105), and the connected body of the end plate 710, the shaft 721 and the rotor 713 is taken out (step S106).

  In this embodiment, when the rotor 713 is loaded at a predetermined position in the molding die 800 in the above-described step S102, the rotor 713 is fixed on the third surface of the flange portion 714 as shown in FIG. 802 contacts. For this reason, the contact portion between the fixing mold 802 and the third surface of the flange portion 714 becomes a die pressing portion, and the molten resin 803 flows into the fixing mold 802 side from the flange portion 714. It wo n’t come. That is, molten resin is injected into the space between the first surface and the second surface of the flange portion 714 and the molding die 800. Further, a gap S is left between the fixing mold 802 at the time of molding and the inner diameter side surface (fifth surface 714e) of the flange portion 714. Further, between the outer diameter side surface of the rotor 713 excluding the flange portion 714 and the fixing mold 802, that is, the outer diameter side surface of the rotor 713 excluding the second surface of the flange portion 714 (fourth surface 714d). ) And the fixing mold 802 are also in a state of having a gap S therebetween. Thus, insert molding is performed by injecting the molten resin into the molding die 800 with the gap S provided.

<Characteristics of the cross flow fan of this embodiment>
(1)
In the cross flow fan 71 of the present embodiment, the rotor 713 connected to the end plate 710 by insert molding includes a flange portion 714.

  In general, when insert molding for connecting a fan (end plate) and a rotor is performed, as shown in FIG. 9, molten resin 1803 is injected while molding dies 1801 and 1802 are heated, and molding is performed. The rotor 1713 loaded in the molds 1801 and 1802 is also heated. For this reason, in a conventional crossflow fan having no flange portion, the rotor 1713 is thermally expanded in the fixing mold 1802 during insert molding, and the rotor 1713 is difficult to be removed from the fixing mold 1802. As described above, in the conventional cross flow fan, when the product after molding is taken out, the mold release property between the molding die 1802 and the rotor of the cross flow fan is deteriorated, and the productivity is lowered.

  Therefore, in the cross flow fan 71 of the present embodiment, as shown in FIG. 8, since the rotor 713 has a flange portion 714, the molding die 800 and the third surface 713c of the flange portion 714 are formed during molding. Can be used as a die pressing part. For this reason, a gap S can be formed between the fourth surface 714d and the fixing mold 2 of the molding mold 800, with the mold pressing part as a boundary. Therefore, even if the rotor 713 is thermally expanded at the time of molding, it is possible to release the thermally expanded portion in the gap S. Therefore, the releasability of the rotor 713 from the molding die 800 is improved, and the productivity is improved. Product cost can be reduced.

(2)
Furthermore, in the cross flow fan 71 of the present embodiment, at the time of molding, as shown in FIG. 7, the inner diameter side surface (fifth surface 714e) of the rotor 713 closer to the fixing mold 802 than the flange portion 714, the flange The molding die 800 is designed such that a gap S is provided between the outer diameter side surface (the fourth surface 714d) excluding the portion 714 and the fixing die 802. For this reason, even when the rotor 713 is thermally expanded, the dimension increased by the thermal expansion due to the gap S can be released, so that the rotor 713 can be easily taken out from the fixing mold 802 after molding. Therefore, by further improving the releasability of the rotor 713 from the molding die 800, the productivity can be improved and the cost of the product can be reduced.

<Other embodiments>
As mentioned above, although one Embodiment of this invention was described, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of invention.

(A)
In the above embodiment, when the rotor 713 is loaded in the molding die 800, the inner diameter side surface (fifth surface 714e) of the rotor 713 of the cross flow fan 71 and the outer diameter side surface excluding the flange portion 714. The molding die 800 is designed so that a gap is left between the (fourth surface 714d) and the fixing die 802. However, the present invention is not limited to this. For example, the clearance S between either the inner diameter side surface (fifth surface 714e) of the rotor 713 or the outer diameter side surface (fourth surface 714d) excluding the flange portion 714 and the fixing mold 802. The molding die 800 may be designed so as to be free.

(B)
In the said embodiment, the example which applied this invention to the crossflow fan was given and demonstrated. However, the present invention is not limited to this. For example, a fan in which a rotor (motor rotor) and an end plate (side plate) 710 are integrally formed can be applied to a sirocco fan that is also used in an air conditioning indoor unit.

(C)
In the said embodiment, although the crossflow fan was demonstrated using AS resin, this invention is not limited to this. For example, in addition to the AS resin, any resin having a melting point lower than that of the molding resin of the rotor 713 can be similarly applied.

  It can be applied to a cross flow fan or the like that is mounted on an air conditioner or the like and is integrally molded with a motor rotor as an insert.

1 is an external view of an air conditioner in which a crossflow fan according to an embodiment of the present invention is employed. The block diagram of a refrigerant circuit. The right side sectional view of an indoor unit. The top view of the right side part of a ventilation unit. XX sectional drawing of a crossflow fan and an indoor fan motor. The flowchart which shows the connection process of a cross flow fan, a rotor, and a shaft. Sectional drawing which shows the structure inside the metal mold | die at the time of insert molding of the crossflow fan of this embodiment. FIG. 8 is an enlarged view showing the configuration inside the mold of FIG. 7 in more detail. Sectional drawing which shows the structure inside a metal mold | die at the time of insert molding of the conventional crossflow fan.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Air conditioning apparatus 2 Indoor unit 3 Outdoor unit 7 Blower mechanism 8 Blower unit (blower unit)
50 Indoor heat exchanger (air conditioning unit)
71 Crossflow fan (air conditioner indoor unit fan)
710 End plate (side plate)
711 Wings (wing pieces)
712 Shaft 713 Rotor (Motor rotor)
714 Flange portion 714a First surface 714b Second surface 714c Third surface 714d Fourth surface 714e Fifth surface 72 Indoor fan motor 720 Stator (motor stator)
800 Molding die 801 Movable die 802 Fixing die 803 Molten resin (side plate)
A1 Rotating shaft G Gate S Clearance

Claims (3)

A side plate (710) holding one end of a plurality of blades (711) arranged in an annular shape around the rotation axis (A1), a motor rotor (713) connected to the side plate (710) by insert molding A manufacturing method for manufacturing a fan (71) of an air conditioning indoor unit provided with a molding die (800) composed of a movable die (801) and a fixed die (802) ,
A flange portion (714) that is in close contact with the side plate (710) and connected to the side plate (710), and is farther from the side plate (710) than the flange portion (714), and an outer peripheral surface (714d) Is a cylindrical portion composed of a non-flange portion that is closer to the rotating shaft (A1) than the outer peripheral surface (714b) of the flange portion (714) and does not contact the side plate (710). 713) a first step;
The flange part (714) is located in the space on the movable mold (801) side, the non-flange part is located in the space on the fixed mold (802) side, and the side plate ( The motor rotor (713) is molded so that the surface (714c) opposite to the 710) side is in contact with a portion outside the space where the non-flange portion of the fixed mold (802) is located. A second step of loading into the mold (800);
A molten resin (803) is injected into a space on the movable mold (801) side of the molding mold (800) , and a surface of the flange portion (714) opposite to the side plate (710) side ( 714 c) and the fixed mold (802) are in contact with each other, and the side plate (710 ) is in a state where the molten resin (803) does not flow into the space on the fixed mold (802) side. ) Insert molding and connecting the flange part (714) and the side plate (710),
A method for manufacturing a fan (71) of an air conditioning indoor unit. In the second step, between the inner surface (714e) of the cylindrical portion of the motor rotor (713) and the molding die (800) and / or outside of the non-flange portion A gap (S) is provided between the radial surface (714d) and the molding die (800).
The manufacturing method of the fan (71) of the air-conditioning indoor unit of Claim 1 . In the third step, the molten resin (803) includes a space between an outer diameter side surface (714b) of the flange portion (714) and the molding die (800), and the flange portion. (714) is injected into a space between the side plate (710) side surface (714a) of (714) and the molding die (800).
The manufacturing method of the fan (71) of the air-conditioning indoor unit of Claim 1 or 2 .

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