U.S. patent application number 12/682217 was filed with the patent office on 2010-08-19 for air conditioner indoor unit.
Invention is credited to Jihong Liu, Isao Ohgami, Mariko Takakura.
Application Number | 20100206514 12/682217 |
Document ID | / |
Family ID | 40824177 |
Filed Date | 2010-08-19 |
United States Patent
Application |
20100206514 |
Kind Code |
A1 |
Liu; Jihong ; et
al. |
August 19, 2010 |
AIR CONDITIONER INDOOR UNIT
Abstract
An air conditioner indoor unit A includes a body casing 1, which
accommodates a fan 2 and a heat exchanger 3. A top plate 13 is
arranged in an upper portion of the body casing 1. A longitudinal
reinforcement rib 14, which divides the top plate 13 into a first
region 13a and a second region 13b, is formed in the top plate 13.
A first lateral reinforcement rib 15, which extends between the
longitudinal reinforcement rib 14 and a corresponding one of side
edges 13c of the top plate 13, is formed in the first region 13a. A
second lateral reinforcement rib 16, which extends between the
longitudinal reinforcement rib 14 and the other side edge 13c of
the top plate 13, is formed in the second region 13b. The
reinforcement ribs 14, 15, 16 thus significantly increase the
rigidity of the top plate 13 as a whole. Further, if the first and
second lateral reinforcement ribs 15, 16 are formed by
stretch-forming, torsion and flexure of the top plate 13 caused by
spring back after the ribs 15, 16 are formed are decreased. As a
result, the top plate 13 is mounted with increased work
efficiency.
Inventors: |
Liu; Jihong; (Sakai-shi,
JP) ; Takakura; Mariko; (Sakai-shi, JP) ;
Ohgami; Isao; (Sakai-shi, JP) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
40824177 |
Appl. No.: |
12/682217 |
Filed: |
December 18, 2008 |
PCT Filed: |
December 18, 2008 |
PCT NO: |
PCT/JP2008/073106 |
371 Date: |
April 8, 2010 |
Current U.S.
Class: |
165/67 |
Current CPC
Class: |
F24F 1/0007 20130101;
F24F 13/20 20130101 |
Class at
Publication: |
165/67 |
International
Class: |
F28F 9/00 20060101
F28F009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 27, 2007 |
JP |
2007-336953 |
Claims
1. An air conditioner indoor unit having a body casing
accommodating a fan and a heat exchanger, the body casing having a
top plate arranged in an upper portion thereof, the top plate
having a longitudinal reinforcement rib dividing the top plate into
first and second regions, one or more first lateral reinforcement
ribs and one or more second lateral reinforcement ribs, the first
lateral reinforcement ribs are arranged in the first region and
between the longitudinal reinforcement rib and one of two side
edges of the top plate that face the longitudinal reinforcement
rib, and wherein the second lateral reinforcement ribs are arranged
in the second region and between the longitudinal reinforcement rib
and the other side edge.
2. The air conditioner indoor unit according to claim 1, wherein
the top plate has a rectangular shape, the longitudinal
reinforcement rib extending parallel to the side edges of the top
plate.
3. The air conditioner indoor unit according to claim 1 or 2,
wherein said one or more first lateral reinforcement ribs and said
one or more second lateral reinforcement ribs extend in a direction
perpendicular to the longitudinal reinforcement rib and the side
edges of the top plate.
4. The air conditioner indoor unit according to claim 3, wherein
said one or more first lateral reinforcement ribs include a pair of
first lateral reinforcement ribs, and said one or more second
lateral reinforcement ribs include a pair of second lateral
reinforcement ribs, and wherein one of the first lateral
reinforcement ribs and a corresponding one of the second lateral
reinforcement ribs are aligned along a common straight line, and
the other first lateral reinforcement rib and the corresponding
second lateral reinforcement rib are arranged along mutually offset
straight lines.
5. The air conditioner indoor unit according to claim 3, wherein
said one or more first lateral reinforcement ribs include three or
more first lateral reinforcement ribs, said one or more second
lateral reinforcement ribs include three or more second lateral
reinforcement ribs, and wherein some of the first lateral
reinforcement ribs and corresponding ones of the second lateral
reinforcement ribs are aligned along common straight lines, and the
other first lateral reinforcement ribs and the corresponding second
lateral reinforcement ribs are arranged along mutually offset
straight lines.
6. The air conditioner indoor unit according to claim 1, wherein
the top plate has the side edges and a pair of end edges extending
perpendicular to the side edges, an edge bending rib extending
downward being formed in each side edge and each end edge.
7. The air conditioner indoor unit according to claim 1, wherein
the longitudinal reinforcement rib is formed through bending.
8. The air conditioner indoor unit according to claim 1, wherein
said one or more first lateral reinforcement ribs and said one or
more second lateral reinforcement ribs are formed by
stretch-forming.
Description
TECHNICAL FIELD
[0001] The present invention relates to an indoor unit for an air
conditioner, and, more particularly, to a configuration of a top
plate of an indoor unit for an air conditioner.
BACKGROUND ART
[0002] This type of indoor unit for an air conditioner (which is,
for example, an indoor unit for a built-in type air conditioner)
includes a top plate having increased rigidity. Methods for
increasing the rigidity of the top plate include spot welding of an
L-shaped angle bar to the top plate and formation of a
reinforcement rib on the top plate to which the L-shaped angle bar
has been spot-welded. However, such methods for increasing the
rigidity of the top plate necessitate an additional component,
which is the L-shaped angle bar attached to the top plate. This not
only raises the cost for manufacturing the indoor unit but also
increases the weight of the indoor unit and the thickness of the
top plate.
[0003] The technique for increasing the rigidity of the top plate
by forming parallel reinforcement ribs on this type of top plate
has been conventionally known as disclosed in Patent Document
1.
[0004] The technique disclosed in Patent Document 1 relates to a
configuration of a top plate for supporting a fan and fan motor to
the top plate each in a suspended state. A plurality of
reinforcement ribs are formed on the top plate. However, in the
technique described in Patent Document 1, deflection of the top
plate caused by static pressure and torsion and flexure of the top
plate caused by spring back after the top plate is formed are not
considered.
[0005] Patent Document 1: Japanese Laid-Open Patent Publication No.
2006-105573
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an objective of the present invention to
decrease deflection of a top plate caused by static pressure and
torsion and flexure of the top plate caused by spring back after
the top plate is formed, without increasing the manufacturing cost
and the weight.
[0007] To achieve the foregoing objective and in accordance with
one aspect of the present invention, an air conditioner indoor unit
having a body casing 1 accommodating a fan 2 and a heat exchanger 3
is provided. The body casing 1 has a top plate 13 arranged in an
upper portion thereof. The top plate 13 has a longitudinal
reinforcement rib 14 dividing the top plate 13 into first and
second regions 13a, 13b, one or more first lateral reinforcement
ribs 15, and one or more second lateral reinforcement ribs 16. The
first lateral reinforcement ribs 15 are arranged in the first
region 13a and between the longitudinal reinforcement rib 14 and
one of two side edges 13c of the top plate 13 that face the
longitudinal reinforcement rib 14. The second lateral reinforcement
ribs 16 are arranged in the second region 13b and between the
longitudinal reinforcement rib 14 and the other side edge 13c.
[0008] In the above-described configuration, the longitudinal
reinforcement rib 14 and the lateral reinforcement ribs 15, 16 are
formed on the top plate 13. This significantly increases the
rigidity of the top plate 13 as a whole. If the lateral
reinforcement ribs 15, 16 are formed by stretch-forming, one or
more first lateral reinforcement ribs 15 and one or more second
lateral reinforcement ribs 16, which are formed in the first region
13a and the second region 13b, respectively, decrease torsion and
flexure of the top plate 13 caused by spring back after the first
and second lateral reinforcement ribs 15, 16 are formed. This
increases work efficiency when the top plate 13 is mounted.
[0009] The top plate 13 preferably has a rectangular shape, and the
longitudinal reinforcement rib 14 preferably extends parallel to
the side edges 13c of the top plate (13). In this configuration,
the top plate 13, which is shaped rectangular, is divided into the
first region 13a and the second region 13b. The longitudinal
reinforcement rib 14 is usable as a member for supporting an upper
end of a component arranged in the body casing, which is, for
example, a partition plate 9.
[0010] The one or more first lateral reinforcement ribs 15 and the
one or more second lateral reinforcement ribs 16 preferably extend
in a direction perpendicular to the longitudinal reinforcement rib
14 and the side edges 13c of the top plate 13. In this
configuration, the lengths of the first and second lateral
reinforcement ribs 15, 16 are minimized. This simplifies formation
of the first and second lateral reinforcement ribs 15, 16. If the
first and second lateral reinforcement ribs 15, 16 are formed by
stretch-forming, torsion and flexure of the top plate 13 caused by
spring back after the lateral reinforcement ribs 15, 16 are formed,
are decreased further effectively. As a result, the top plate 13 is
mounted with further improved work efficiency.
[0011] The one or more first lateral reinforcement ribs 15
preferably include a pair of first lateral reinforcement ribs 15,
and the one or more second lateral reinforcement ribs 16 include a
pair of second lateral reinforcement ribs 16. One of the first
lateral reinforcement ribs 15 and a corresponding one of the second
lateral reinforcement ribs 16 are preferably aligned along a common
straight line, and the other first lateral reinforcement rib 15 and
the corresponding second lateral reinforcement rib 16 are
preferably arranged along mutually offset straight lines. In this
configuration, the first and second lateral reinforcement ribs 15,
16 are located in accordance with the positions and the shape of
the components arranged in the body casing 1.
[0012] The one or more first lateral reinforcement ribs 15
preferably include three or more first lateral reinforcement ribs
15, and the one or more second lateral reinforcement ribs 16
preferably include three or more second lateral reinforcement ribs
16. Some of the first lateral reinforcement ribs 15 and
corresponding ones of the second lateral reinforcement ribs 16 are
preferably aligned along common straight lines, and the other first
lateral reinforcement ribs 15 and the corresponding second lateral
reinforcement ribs 16 are preferably arranged along mutually offset
straight lines. In this configuration, the first and second lateral
reinforcement ribs 15, 16 are located further effectively in
accordance with the positions and the shapes of the components
arranged in the body casing 1.
[0013] The top plate 13 preferably has the side edges 13c and a
pair of end edges 13d, 13e extending perpendicular to the side
edges 13c. An edge bending rib 17 extending downward is preferably
formed in each side edge 13c and each end edge 13d, 13e. In this
configuration, the edge bending rib 17 increases the rigidity of
the side edges 13c and the end edges 13d, 13e of the first and
second regions 13a, 13b, which are divided by the longitudinal
reinforcement rib 14 on the top plate 13. This increases the
rigidity of the top plate 13 as a whole further effectively. If the
first and second lateral reinforcement ribs 15, 16 are formed by
stretch-forming, torsion and flexure of the top plate 13 caused by
spring back after the lateral reinforcement ribs 15, 16 are formed
are decreased further effectively. As a result, the top plate 13 is
mounted with improved work efficiency.
[0014] The longitudinal reinforcement rib 14 is preferably formed
through bending. In this configuration, spring back does not occur
after the longitudinal reinforcement rib 14 is formed. Also, the
top plate 13 is formed by the first and second regions 13a, 13b,
which are fully separated areas, thus preventing the first and
second lateral reinforcement ribs 15, 16 from being twisted or
flexed after the lateral reinforcement ribs 15, 16 are formed. This
improves work efficiency when the top plate 13 is mounted.
[0015] The one or more first lateral reinforcement ribs 15 and the
one or more second lateral reinforcement ribs 16 are formed by
stretch-forming. This configuration simplifies the steps for
molding the first and second lateral reinforcement ribs 15, 16.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view showing a top plate of an air
conditioner indoor unit according to a first embodiment of the
present invention;
[0017] FIG. 2 is a longitudinal cross-sectional view showing the
air conditioner indoor unit of the first embodiment of the
invention;
[0018] FIG. 3(a) is a diagram showing a die, or, specifically, an
edge bending punch and a rib forming punch, which are used to mold
a top plate of the air conditioner indoor unit of the first
embodiment of the invention;
[0019] FIG. 3(b) is a diagram showing a holder for the die;
[0020] FIG. 3(c) is a diagram showing a die block of the die;
[0021] FIG. 3(d) is a diagram showing a blank; and
[0022] FIG. 4 is a perspective view showing a top plate of an air
conditioner indoor unit according to a second embodiment of the
present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
First Embodiment
[0023] An indoor unit for an air conditioner according to a first
embodiment of the present invention will now be described with
reference to FIGS. 1 to 3(d).
[0024] A top plate 13, which is illustrated in FIG. 1, is optimal
for use in a body casing 1 of an air conditioner indoor unit A (for
2 HP(1.5 kW)) shown in FIG. 2.
[0025] With reference to FIG. 2, the air conditioner indoor unit A
is a built-in type arranged in the path of a duct and includes the
rectangular parallelepiped body casing 1. The body casing 1
accommodates a fan 2 and a heat exchanger 3.
[0026] A sirocco fan having a scroll type fan casing 5 and a
multi-blade impeller 6, which is arranged in the fan casing 5, is
employed as the fan 2. The fan 2 draws air from an air inlet port 7
of the fan casing 5 and blasts the air through an outlet port 8,
which is arranged in the distal end of the fan casing 5.
[0027] The space in the body casing 1 is divided into a fan chamber
10 and a heat exchange chamber 11 by a partition plate 9. The fan 2
is arranged in the fan chamber 10 with a distal portion of the fan
casing 5 supported by the partition plate 9.
[0028] The heat exchanger 3 is arranged in the heat exchange
chamber 11 in an inclined state. Indoor air Wr is drawn through an
inlet duct 4a, which communicates with the fan chamber 10, and sent
into the heat exchange chamber 11 through the fan 2. The heat
exchanger 3 selectively cools and heats the indoor air Wr that has
been blasted out from the fan 2. After having been cooled or
heated, the air is blasted out into the room from an outlet duct 4b
as conditioned air W. A drain pan 12 is arranged in the heat
exchange chamber 11.
[0029] As illustrated in FIG. 1, a longitudinal reinforcement rib
14, which divides a top plate 13 of the body casing 1 into first
and second regions 13a, 13b, is formed in the top plate 13. The
first region 13a has two first lateral reinforcement ribs 15, which
are formed between the longitudinal reinforcement rib 14 and the
corresponding one of two side edges 13c of the top plate 13. The
second region 13b has two lateral reinforcement ribs 16, which are
formed between the longitudinal reinforcement rib 14 and the
corresponding one of the two side edges 13c of the top plate 13.
Edge bending ribs 17 extending downward are formed along the side
edges 13c and end edges 13d, 13e, which extend perpendicular to the
side edges 13c, of the top plate 13. The edge bending ribs 17 thus
increase the rigidity of the top plate 13 at the side edges 13c and
the end edges 13d, 13e of the first and second regions 13a,
13b.
[0030] The longitudinal reinforcement rib 14 is a recessed groove
that extends parallel to the side edges 13c of the top plate 13 and
divides the top plate 13 into the first and second regions 13a,
13b. In the present embodiment, the longitudinal reinforcement rib
14 is formed through bending. The top plate 13 is divided into the
first and second regions 13a, 13b, each of which has a rectangular
shape, by the longitudinal reinforcement rib 14. After the
longitudinal reinforcement rib 14 is formed, the first and second
regions 13a, 13b are prevented from being distorted through
machining. The longitudinal reinforcement rib 14 functions as a
member for supporting an upper end of the partition plate 9 (see
FIG. 2).
[0031] To minimize the length of each of the first and second
lateral reinforcement ribs 15, 16, it is preferable that the first
and second lateral reinforcement ribs 15, 16 both extend
perpendicular to the side edges 13c of the top plate 13. However,
the first and second lateral reinforcement ribs 15, 16 may be
inclined with respect to a direction perpendicular to the
longitudinal reinforcement rib 14 (up to approximately 45.degree.).
The numbers of the first and second lateral reinforcement ribs 15,
16 may be selected in accordance with the size of the corresponding
one of the first and second regions 13a, 13b, respectively. The
first lateral reinforcement ribs 15 may be shaped differently in
the first region 13a, and the second lateral reinforcement ribs 16
may be shaped differently in the second region 13b. The positions
of the first and second lateral reinforcement ribs 15, 16 may be
determined in accordance with the shapes and the positions of the
devices arranged in the body casing 1. For example, with reference
to FIG. 1, one of the first lateral reinforcement ribs 15 in the
first region 13a and the corresponding one of the second lateral
reinforcement ribs 16 in the second region 13b are aligned along a
straight line in a direction perpendicular to the longitudinal
reinforcement rib 14 and the side edges 13c of the top plate 13.
The other one of the first lateral reinforcement ribs 15 and the
corresponding one of the second lateral reinforcement ribs 16 are
arranged along offset straight lines in directions perpendicular to
the longitudinal reinforcement rib 14 and the side edges 13c of the
top plate 13, without being aligned along a line.
[0032] The first and second lateral reinforcement ribs 15, 16 of
the top plate 13 are formed by stretch-forming.
[0033] Stretch forming of the top plate 13 will hereafter be
described.
[0034] The stretch forming is performed using a die illustrated in
FIGS. 3(a) to 3(c). The top plate 13 is formed using a blank 13'
shown in FIG. 3(d).
[0035] First, the blank 13' shown in FIG. 3(d) is mounted on a die
block X, which is illustrated in FIG. 3(c). The blank 13' is
maintained by a holder Y, which is shown in FIG. 3(b) and arranged
on the blank 13'. In this state, by pressing an edge bending punch
Za and a rib forming punch Zb, which are illustrated in FIG. 3(a),
against the blank 13', the top plate 13 is shaped. Before the
stretch forming, the longitudinal reinforcement rib 14 is formed in
the blank 13' in advance through bending. Generally, the stretch
forming simplifies the molding steps but causes torsion and flexure
of a formed product caused by spring back after the product is
formed.
[0036] However, in the present embodiment, as has been described,
the longitudinal reinforcement rib 14 and the first and second
lateral reinforcement ribs 15, 16 are formed on the formed top
plate 13, thus significantly increasing the rigidity of the top
plate 13 as a whole. Further, since the first and second lateral
reinforcement ribs 15, 16 are formed in the corresponding first and
second regions 13a, 13b, which are separated from each other by the
longitudinal reinforcement rib 14, torsion and flexure of the top
plate 13 caused by spring back after the first and second lateral
reinforcement ribs 15, 16 are formed are decreased. This improves
work efficiency when the top plate 13 is mounted.
Second Embodiment
[0037] As illustrated in FIG. 4, a configuration of a top plate for
an air conditioner indoor unit according to a second embodiment of
the present invention will hereafter be described mainly about the
differences from the first embodiment.
[0038] In a top plate 13 of an air conditioner indoor unit (for 5
HP (3.75 kW)) of the second embodiment, four first lateral
reinforcement ribs 15 are formed in a first region 13a, and four
second lateral reinforcement ribs 16 are arranged in a second
region 13b. In the second embodiment, like the first embodiment,
some of the first lateral reinforcement ribs 15 and the
corresponding ones of the second lateral reinforcement ribs 16 are
aligned along common straight lines, and the other ones of the
first lateral reinforcement ribs 15 and the corresponding other
ones of the second lateral reinforcement ribs 16 are arranged along
offset straight lines without being aligned along common straight
lines. Specifically, two of the first lateral reinforcement ribs 15
in the first region 13a and the corresponding two of the second
lateral reinforcement ribs 16 in the second region 13b are aligned
along common straight lines in directions perpendicular to the
longitudinal reinforcement rib 14 and the side edges 13c of the top
plate 13. The other two of the first lateral reinforcement ribs 15
and the corresponding other two of the second lateral reinforcement
ribs 16 are arranged along offset straight lines in directions
perpendicular to the longitudinal reinforcement rib 14 and the side
edges 13c of the top plate 13, without being aligned along common
straight lines.
[0039] The configuration of the other components of the second
embodiment is the same as the configuration of the corresponding
components of the first embodiment, and the advantages of the
second embodiment are equivalent to those of the first embodiment.
Accordingly, explanation of the configuration of these components
and the advantages of the second embodiment are omitted herein.
[0040] In the first and second embodiments, the air conditioner
indoor unit is embodied as a built-in type indoor unit, but the
present invention may be used in other types of air conditioner
indoor units.
* * * * *