Net resin molded body and operation method of air conditioner using the same

Abstract

Provided is a reticular resin molded body that controls the electrification of air introduced into a heat exchanger and improves the heat exchange efficiency of the heat exchanger, and an operation method of an air conditioner using the same. A reticular resin molded body composed of a thermoplastic resin, in a plate shape and having a plurality of air passage holes that pass through in the thickness direction, introduces air that has been subjected to electrification control therethrough into a heat exchanger, thereby improving the heat exchange efficiency of the heat exchanger. It is composed of a thermoplastic resin of polyethylene or polypropylene in which uncalcined powder of a smectite clay mineral is dissolved. In addition, the operation method of the air conditioner arranges the reticular resin molded body in a manner that it crosses an air flow path leading to the heat exchanger, and introduces air through the air passage holes into the heat exchanger.

Description

[0001] This application is a divisional application of the application filed on November 22, 2018, with application number 201880100642.5, entitled "Network Resin Molded Article and Method of Operating an Air Conditioner Using the Same". Technical Field

[0002] This invention relates to a mesh resin molded body capable of improving the heat exchange efficiency of a heat exchanger and an operating method of an air conditioner using the same, and more particularly to a mesh resin molded body capable of improving the heat exchange efficiency of a heat exchanger by electrically controlling the air introduced into the heat exchanger and an operating method of an air conditioner using the same. Background Technology

[0003] There have been attempts to improve the operating efficiency of air conditioners by increasing the heat exchange efficiency of the heat exchanger. In these attempts, most proposed methods are as follows: water is sprayed onto the heat exchanger (condenser) of the outdoor unit of the air conditioner, which is used to cool the heated circulating refrigerant, and the water evaporates (vaporizes), using the heat of vaporization to assist in heat dissipation at the surface of the heat exchanger.

[0004] On the other hand, Patent Document 1 discloses a method for reducing the temperature of air supplied to the heat exchanger (condenser) of an outdoor unit of an air conditioner by utilizing the heat of vaporization of water. This method provides a honeycomb porous body composed of a ceramic plate containing micropores, with multiple large vent holes formed on the upstream side of the condenser fan, extending in the direction of airflow along the fan. By vaporizing the water retained within the vent holes, the temperature of the air flowing towards the condenser fan is reduced with a small amount of water. Furthermore, by configuring the large vent holes, the pressure loss of the air is minimized, resulting in improved heat exchange efficiency of the heat exchanger.

[0005] Furthermore, Patent Document 2 discloses a plate-shaped mesh resin molded body, which, in the heat exchanger of an air conditioner with an air circulation system, is composed of a composite material of calcined ceramic powder and resin arranged in the air circulation path to change the temperature of the airflow passing through it. This mesh resin molded body is similar to Patent Document 1, being a plate-shaped resin molded body with a thickness of approximately 2-3 mm and large vent holes for minimizing air pressure loss. However, by including approximately 20% of powder obtained by low-temperature calcination of calcined ceramic (obtained by calcining together with glaze) in the base resin such as polyethylene, the heat exchange efficiency of the heat exchanger can be improved.

[0006] However, in recent years, the charged state of the pipes and other components that form the air flow path to the heat exchanger has affected the flow state of the air passing through them, and as a result, it has affected the heat exchange efficiency of the heat exchanger.

[0007] For example, Patent Document 3 discloses a method for improving cooling efficiency in an automotive cooling system by installing a self-discharge eliminator on a fan shroud made of a non-conductive synthetic resin material to suppress positive charge accumulation. When the voltage value on the surface of the non-conductive thin wall increases, the airflow along that surface changes, and the airflow easily leaves the surface of the thin wall, reducing the cooling efficiency of the cooling system. Therefore, a self-discharge eliminator is installed to suppress this situation and control the airflow.

[0008] Existing technical documents

[0009] Patent documents

[0010] Patent Document 1: Japanese Patent Application Publication No. 2012-72951

[0011] Patent Document 2: Japanese Patent Application Publication No. 2014-224621

[0012] Patent Document 3: Japanese Patent Application Publication No. 2016-117388 Summary of the Invention

[0013] The problem the invention aims to solve

[0014] In the indoor unit of an air conditioner, even when indoor air is drawn in, heat-exchanged by a heat exchanger, and then returned to the room, the interior decorative (front) panel is usually made of resin, thus generating an electrical charge, similar to the problem in Patent Document 3. While the resin molded body in Patent Document 2 is not explicitly described in this regard, if it has a function to eliminate the electrical charge, the turbulent airflow is controlled to a more ideal flow state, which can be understood as improving the operating efficiency of the air conditioner.

[0015] The present invention was made in view of the above circumstances, and its object is to provide a mesh resin molded body and an operating method of an air conditioner using the same, wherein the mesh resin molded body electrically controls the air introduced into a heat exchanger, thereby improving the heat exchange efficiency of the heat exchanger.

[0016] Solution for solving the problem

[0017] In the resin molded body described in Patent Document 2, the inventors focused not only on the physical properties of the calcined ceramic powder disposed therein affecting the airflow, but also on the resin itself. That is, it is difficult to conclude that a resin molded body with a thickness of at most 2-3 mm, through which airflow passes in the thickness direction, would be significantly affected by such a short airflow path, and even more so by the physical properties of the calcined ceramic powder exposed on the surface of the airflow path by the resin containing at least several tens of percent of the calcined ceramic powder. On the other hand, to improve the influence of the physical properties of the calcined ceramic powder, it is impractical to impart more calcined ceramic powder to the resin molded body, which would prevent resin molding. Through repeated experiments under these circumstances, the present invention was completed.

[0018] Furthermore, the mesh resin molded body according to the present invention is characterized in that it is a mesh resin molded body that electrically controls the air introduced into the heat exchanger and introduces the air into the heat exchanger, the mesh resin molded body being made of thermoplastic resin, plate-shaped and having vent holes extending through the thickness direction, the mesh resin molded body being made of thermoplastic resin of polyethylene or polypropylene colored by dissolving uncalcined powder of montmorillonite clay minerals.

[0019] According to the aforementioned mesh resin molded body, the heat exchange efficiency of the heat exchanger can be improved by using it to electrically control the air introduced into the heat exchanger.

[0020] In the above invention, a further feature is that the clay mineral is contained in the range of 2-5% by mass relative to the thermoplastic resin. Additionally, a further feature is that the uncalcined powder is formed by crushing mudstone. Furthermore, a further feature is that the mudstone contains at least 60-70 wt% SiO2 and 10-15 wt% Al2O3 by mass. According to the reticulated resin molded body, the heat exchange efficiency of the heat exchanger can be improved by reliably controlling the electrical charge of the air introduced into the heat exchanger using it.

[0021] In the above invention, the vent hole may also be hexagonal prism-shaped. Additionally, the planar opening ratio of the vent hole may be set to 70% or more. According to the mesh resin molded body, by using it, the flow of air introduced into the heat exchanger is not obstructed; on the other hand, even with a reduced contact area with the air passing through it, electrically controlled operation is possible, and the heat exchange efficiency of the heat exchanger can be improved.

[0022] In the above invention, a further feature is that when one main surface is set to a ground potential, the other main surface becomes a negative potential. According to the described mesh resin molded body, by reliably controlling the electrical charge of the air introduced into the heat exchanger, the heat exchange efficiency of the heat exchanger can be improved.

[0023] Furthermore, the air conditioner operation method according to the present invention is characterized in that: it is an air conditioner operation method that improves the heat exchange efficiency of the heat exchanger by electrically controlling the air introduced into the heat exchanger, wherein the method is configured with a mesh resin molded body having a plurality of vent holes penetrating in the thickness direction in a manner that crosses the air flow path leading to the heat exchanger, so that the air is introduced into the heat exchanger through the vent holes, wherein the mesh resin molded body is composed of a thermoplastic resin of polyethylene or polypropylene colored by dissolving uncalcined powder of montmorillonite clay minerals, and is in the form of a plate.

[0024] According to the method described, electrically controlling the air introduced into the heat exchanger can improve the heat exchange efficiency of the heat exchanger.

[0025] In the above invention, a further feature is that the mesh resin molded body is disposed between the electrostatic dust collector and the heat exchanger. According to the method, by removing the influence of dust through the electrostatic dust collector and reliably controlling the electrical charge of the air introduced into the heat exchanger, the heat exchange efficiency of the heat exchanger can be improved.

[0026] In the above invention, a further feature is that the planar opening ratio of the vent is set to 70% or more. According to this method, the flow of air introduced into the heat exchanger is not obstructed; on the other hand, even with a reduced contact area with the air passing through it, electrically controlled operation is possible, and the heat exchange efficiency of the heat exchanger can be improved.

[0027] In the above invention, a further feature is that when one main surface of the mesh resin molded body is set to a ground potential, the other main surface becomes a negative potential. According to the method, the air introduced into the heat exchanger can be reliably energized, thereby improving the heat exchanger's heat exchange efficiency. Attached Figure Description

[0028] Figure 1 This is a cross-sectional view of an air conditioner used in one embodiment of the present invention.

[0029] Figure 2 (a) Front view and (b) side view of the mesh resin molded body.

[0030] Figure 3 A flowchart illustrating a method for manufacturing a mesh resin molded body.

[0031] Figure 4 This is a table showing the results of potential measurements for the reticulated resin molded body.

[0032] Figure 5 A cross-sectional view showing an example configuration of a mesh resin molded body.

[0033] Explanation of reference numerals in the attached figures

[0034] 3. Reticulated Resin Molded Body

[0035] 4. Heat exchanger

[0036] 5. Airflow path

[0037] 10, 20 air conditioners Detailed Implementation

[0038] Regarding the operation method of an air conditioner according to an embodiment of the present invention, using Figure 1 and Figure 2 Please provide an explanation.

[0039] like Figure 1 As shown, the air conditioner 10 includes a grille 1, a filter 2, a mesh resin molded body 3, and a heat exchanger 4, which are sequentially arranged on the air flow path 5 and mounted on an air intake. In particular, the mesh resin molded body 3 is arranged to traverse the air flow path 5 leading to the heat exchanger 4. Except for the mesh resin molded body 3, it is similar to known air conditioners, and therefore descriptions are omitted.

[0040] Refer to together Figure 2 The mesh resin molded body 3 is made of thermoplastic resin of polyethylene (hereinafter referred to as PE) or polypropylene (hereinafter referred to as PP) containing uncalcined powder of montmorillonite-based clay minerals dissolved in it, and is a plate-shaped body having a plurality of circular vent holes 31 extending through in the thickness direction. Alternatively, the mesh resin molded body 3 may appropriately include blind portions 32 and frame portions 33 without vent holes 31. In this embodiment, blind portions 32 are provided at the four corners, and frame portions 33 are provided at the center in both the horizontal and vertical directions. Furthermore, through holes (not shown) may appropriately be provided in the frame portions 33 without compromising their strength.

[0041] Here, when the air conditioner 10 is running, air is drawn into the airflow path 5 through the intake port by a fan (not shown), passes through the grille 1 and the filter 2 respectively, and then passes through the mesh resin molded body 3 before being introduced into the heat exchanger 4, where heat exchange is performed on the surface of the heat exchanger 4 such as fins and the medium inside it.

[0042] In the air conditioner 10, it is known that by arranging the mesh resin molding body 3 in a manner that traverses the airflow path 5 leading to the heat exchanger 4, heat exchange efficiency can be improved. Although the details of the mechanism are not yet clear, it is believed that the mesh resin molding body 3 can be used to electrically control the air introduced into the heat exchanger 4 as follows.

[0043] For example, typical grilles and filters are made of non-conductive materials, which easily become positively charged as the air conditioner operates. If air passes through a positively charged grille or filter, as described in Patent Document 3, the air becomes positively charged, resulting in a flow that is different from the intended flow, which in turn reduces the heat exchanger's efficiency.

[0044] In contrast, the reticulated resin molded body 3 is a resin containing dissolved clay minerals, which can be confirmed to easily and stably obtain a negative potential. It can be considered that the charging state of the positively charged air is controlled in a way that mitigates the charging state. Therefore, it can be considered that the air flow can be made closer to the original desired flow, improving the heat exchange efficiency that is reduced due to the positive charge of the air and bringing it close to the original heat exchange efficiency.

[0045] Here, it is preferable that the vent 31 of the mesh resin molded body 3 has a planar opening ratio of 70% or more, so as not to obstruct the flow of air introduced into the heat exchanger 4. It should be noted that the vent 31 may also be hexagonal instead of circular when viewed from above.

[0046] The manufacturing method of this mesh resin molded body 3 uses Figure 3 Please provide an explanation.

[0047] like Figure 3 As shown, a mesh resin molded body 3, composed of thermoplastic resin containing dissolved clay minerals, can be obtained, for example, by injection molding, and has a color derived from the dissolved material. Typically, it is light brown, but the concentration increases due to the amount dissolved. Specifically, firstly, mudstone containing uncalcined montmorillonite-based clay minerals is crushed to an average particle size of, for example, 5–10 μm using a crushing device to obtain powder. This powder is then mixed with PE or PP at a predetermined ratio to produce mudstone granules containing clay minerals (S1). Next, resin granules composed of either PE or PP used in the production of the mudstone granules are mixed with the mudstone granules at a predetermined ratio to obtain mixed granules (S2). This mixed granules are fed into an injection molding machine, where the resin is melted inside the machine while the clay mineral powder is mixed with the resin. The mixture is then injected into a mold for molding the mesh resin molded body 3 (S3). By obtaining the mesh resin molded body 3 in this manner, the thermoplastic resin forming the mesh resin molded body 3 can dissolve clay minerals. By dissolving clay minerals in this way, it is possible to control the charge of air across the entire surface of the reticulated resin molded body 3. That is, the clay mineral particles are not simply dispersed in the resin, but rather the resin's properties are altered by dissolving the clay minerals in the resin.

[0048] The thermoplastic resin forming the network resin molded body 3 is in a colored state. That is, if the amount of dissolved clay minerals is small, the effect of air charging control is small; if the amount of clay minerals is large, the effect of charging control is saturated, and the molding of the network resin molded body 3 becomes more difficult. It is preferable to contain 2 to 10% clay minerals relative to the total amount of thermoplastic resin by mass ratio, and more preferably 2 to 5%.

[0049] In addition, montmorillonite contains (Na,Ca) 0.33 (Al,Mg)2Si4O 10 The chemical composition is (OH)₂·nH₂O, but mudstone containing montmorillonite-based clay minerals contains a large amount of SiO₂ and Al₂O₃ as the main oxides, as well as other oxides such as Na₂O, MgO, SO₃, K₂O, CaO, TiO₂, and FeO. Here, the mudstone used to obtain the montmorillonite-based clay minerals described above preferably contains at least 60–70 wt% SiO₂ and 10–15 wt% Al₂O₃ by mass ratio. With this composition, a large amount of montmorillonite is present, enabling reliable control of air charge.

[0050] Potential measurements were performed on this mesh resin molded body 3, and the results were used... Figure 4 Please provide an explanation.

[0051] First, using PE as the resin, a portion surrounding a vent 31 of a mesh resin molded body 3, containing 10% montmorillonite-based clay minerals by mass, is cut into a roughly ring shape, and this ring shape is used as a test piece. The test piece is placed on a grounding electrode made of a copper plate, with the lower main surface as the ground potential. The potential of the opposite main surface, i.e., the upper surface, is measured at two points (i.e., two opposite points in the horizontal direction on the upper surface) from a top-down view. This process is repeated by flipping the piece over and measuring the potential at the same two points. The measurement results are shown below. Figure 4 "Example". A surface potentiometer (Isoprobe-model 244) and its probe (model 1017) manufactured by MONROE ELECTRONICS were used in the measurements. Additionally, as a "comparative example", a ring-shaped body was similarly cut from a molded body of the same shape as the mesh resin molded body 3, made solely of PE, and the potential was similarly measured, as shown below. Figure 4 .

[0052] like Figure 4As shown, in the "Example," a negative potential is stably displayed on the opposite main surface relative to the ground potential of one main surface. In contrast, the "Comparative Example" exhibits unstable potentials, including some positive potentials. Furthermore, the average value of the potentials at all four locations is larger than the absolute value of the negative potential in the "Example." That is, according to the "Example" containing dissolved clay minerals, when one main surface is set to ground potential, the other main surface stably becomes negative potential. In other words, the mesh resin mold 3 obtained according to the "Example" can achieve charge control in a manner that mitigates the charged state of positively charged air.

[0053] Generally, clay minerals carry a negative charge and possess cation exchange capacity. However, it is believed that montmorillonite-based clay minerals have a larger cation exchange capacity, which allows the reticulated resin molded body 3 to stably achieve a negative potential. Furthermore, it is believed that because it is an uncalcined body, it can be finely dispersed and dissolved within the thermoplastic resin. This is because if the ceramic powder, as a calcined body, is dispersed, both PE and PP will lose their light transmittance, but the reticulated resin molded body 3, containing dissolved clay mineral powder, will not lose its light transmittance.

[0054] For specific configurations in air conditioners using the aforementioned mesh resin molded body 3. Figure 5 Please provide an explanation.

[0055] like Figure 5 As shown, the air conditioner 20 is a ceiling-mounted indoor unit. The main body 21 is embedded in the ceiling 11, and it contains a motor 22 and a fan 23 that rotates using the motor 22. Using the rotation of the fan 23, air is drawn into the room below through the intake 12 at the lower center of the main body 21, guided to the heat exchanger 4 on the outer periphery for heat exchange, and returned to the room through the outlet 13 on the outer periphery. Here, a grille 1 and a filter 2 are sequentially embedded in the intake 12 from bottom to top, and a mesh resin molded body 3 is further arranged on it in a manner that crosses the airflow path towards the heat exchanger 4.

[0056] With this configuration, even if the intake air is positively charged due to the grille 1 and filter 2, it can be controlled to moderate the charged state of the positively charged air by passing through the mesh resin molding 3 disposed between the grille 1, filter 2 and heat exchanger 4.

[0057] Furthermore, even if the filter 2 is an electrostatic dust collector that causes the passing air to be positively charged, the presence of a mesh resin molding body 3 between the filter 2 and the heat exchanger 4 allows for charge control in a way that mitigates the charge state of the positively charged air.

[0058] Furthermore, by arranging the mesh resin molding body 3 in a manner that crosses the airflow path leading to the heat exchanger of the air conditioner, it can be used in the same way for other types of air conditioners, as well as for both indoor and outdoor units, thereby improving heat exchange efficiency.

[0059] The embodiments of the present invention and variations based on these embodiments have been described above, but the present invention is not necessarily limited to these examples. Furthermore, those skilled in the art will discover various alternative embodiments and modifications without departing from the spirit of the present invention or the scope of the appended claims.

Claims

1. A mesh-like resin molded body, characterized in that, It is made of thermoplastic resin, is plate-shaped, and has multiple vent holes running through its thickness. Electrically controlled air is introduced through it into the heat exchanger, thereby improving the heat exchanger's heat exchange efficiency. The reticulated resin molded body is composed of thermoplastic resin containing uncalcined powder of montmorillonite clay minerals dissolved in it, and contains the clay minerals in a mass ratio of 2 to 10% relative to the thermoplastic resin, such that when one main surface is set to ground potential, the other main surface becomes negative potential.

2. The mesh resin molded article according to claim 1, characterized in that, The clay minerals are made by crushing mudstone.

3. The mesh resin molded article according to claim 2, characterized in that, It contains the clay mineral in a mass ratio of 2 to 5% relative to the thermoplastic resin.

4. The mesh resin molded article according to claim 3, characterized in that, The mudstone contains at least 60-70 wt% SiO2 and 10-15 wt% Al2O3 by mass ratio.

5. The mesh resin molded article according to claim 1, characterized in that, The planar opening ratio of the vent is set to 70% or more.

6. The mesh resin molded article according to claim 5, characterized in that, The vent is hexagonal prism-shaped.

7. A method for operating an air conditioner, characterized in that, It is an air conditioning operation method that uses electrical control to power the air introduced into the heat exchanger, thereby improving the heat exchange efficiency of the heat exchanger. The method involves arranging a mesh resin molded body with multiple vent holes extending in the thickness direction across the airflow path leading to the heat exchanger, so that air is introduced into the heat exchanger through the vent holes. The mesh resin molded body is composed of a thermoplastic resin containing uncalcined powder of montmorillonite clay minerals dissolved in it, and is plate-shaped. It contains the clay minerals in a mass ratio of 2% to 10% relative to the thermoplastic resin, such that when one main surface is set to ground potential, the other main surface becomes negative potential.

8. The method for operating an air conditioner according to claim 7, characterized in that, The mesh resin molded body is disposed between the electrostatic dust filter and the heat exchanger.

9. The method for operating an air conditioner according to claim 7, characterized in that, The planar opening ratio of the vent is set to 70% or more.

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