Air cooler shell and air cooler

Abstract

The utility model discloses an air cooler shell and an air cooler to solve the technical problems that an upper shell and a lower shell are manufactured independently, so that plate waste is large, and the technology is complex. The air cooler shell comprises an upper shell body and a lower shell body which are communicated with each other, the upper shell body forms a flow guide cylinder and is used for installing a blade part of a fan, and the lower shell body forms a flow guide cover and is used for installing a heat exchanger. The upper shell and the lower shell form an integrated structure formed by respectively performing plastic deformation processing on the same plate blank; the upper shell is formed by processing the middle part of the plate blank through first plastic deformation, and the lower shell is formed by processing the peripheral part of the middle part on the plate blank through second plastic deformation. Materials can be saved, waste is reduced, the manufacturing process is simplified, and efficiency is improved.

Description

Technical Field

[0001] Embodiments of the present application relate to an air cooler housing, a method for manufacturing the air cooler housing, and an air cooler. Background Art

[0002] An air cooler is a heat exchange device that uses air to cool a hot fluid. Figure 8 An air cooler manufactured and sold by the applicant of this application is mainly used in the lubrication cooling system of wind turbine gearbox to cool the lubricating oil of wind turbine gearbox. Figure 8 As shown, the air cooler mainly includes a fan, a heat exchanger, an upper shell and a lower shell, wherein the fan includes a motor and a blade part connected to the motor output shaft; the heat exchanger cools the hot fluid running in the heat exchanger through the airflow generated by the fan; the upper shell forms a circular guide tube and is used to install the blade part; the lower shell forms a square-mouthed guide cover and is used to install the heat exchanger; the fan motor is located above the blade part and is supported by a support system supported on the lower shell and passing through the upper shell; the upper shell and the lower shell are connected to each other. The working principle of the air cooler is: the airflow generated by the fan passes through the upper shell and the lower shell that are connected to each other, and the airflow cools the hot fluid (such as lubricating oil) running in the heat exchanger when passing through the lower shell.

[0003] Generally speaking, the upper shell, the lower shell and the support system are all made of steel sheet metal. Since the upper shell, the lower shell and the support system are obviously different in shape, size and structure, the current conventional practice is to laser cut the steel plate into multiple parts, respectively produce the upper shell, the lower shell and the support system through sheet metal processing, and then assemble them together. This practice leads to serious waste of steel sheet materials; at the same time, there are a large number of welding points in the entire shell and support system, which leads to time-consuming, labor-intensive, high energy consumption and high defect rate risk. In addition, due to the insufficient strength of the upper shell, the support system has to be supported on the lower shell and pass through the upper shell to carry the motor, resulting in a complex and large structure of the support system, further increasing the amount of steel plate used and increasing the manufacturing cost of the air cooler. Utility Model Content

[0004] One of the purposes of the present application is to provide an improved air cooler housing and an air cooler to solve the technical problems of large sheet material waste and complicated process caused by the independent manufacturing of the upper housing and the lower housing.

[0005] The second purpose of the present application is to provide an improved method for manufacturing an air cooler shell and an air cooler, which also solves the technical problems of large sheet material waste and complex process caused by the independent manufacturing of the upper shell and the lower shell.

[0006] The third purpose of this application is to provide an improved air cooler to solve the technical problem of complex and bulky supporting system structure.

[0007] According to a first aspect, an air cooler shell is provided, comprising: an upper shell and a lower shell which are connected to each other, wherein the upper shell forms a guide tube and is used to install the blade part of a fan, and the lower shell forms a guide cover and is used to install a heat exchanger; the upper shell and the lower shell constitute an integral structure formed by plastic deformation processing on the same plate blank; the upper shell is formed by the middle part of the plate blank through a first plastic deformation processing, and the lower shell is formed by the peripheral part of the middle part of the plate blank through a second plastic deformation processing.

[0008] As an optimization and / or instantiation of the air cooler housing of the first aspect, the upper housing includes a flange portion, and the flange portion forms a cylindrical structure.

[0009] As an optimization and / or embodiment of the air cooler housing of the first aspect, a root of the flange portion forms a trumpet-shaped connecting neck.

[0010] As an optimization and / or instantiation of the air cooler housing of the first aspect mentioned above, the first longitudinal section of the root of the flange portion has a first outer arc constituting the outer contour of the trumpet-shaped connecting neck and a first inner arc constituting the inner contour of the trumpet-shaped connecting neck, the radius of the first outer arc is 50mm-75mm, and the center axis of the cylindrical structure is located on the first longitudinal section.

[0011] As an optimization and / or embodiment of the air cooler housing of the first aspect, the root of the flange portion and the straight section of the cylindrical structure are formed by spinning.

[0012] As an optimization and / or instantiation of the air cooler shell of the first aspect mentioned above, the head of the flange portion is provided with a local reinforcement structure of the flange portion shell material, and the local reinforcement structure of the flange portion shell material is provided with a first connecting structure and / or a second connecting structure, the first connecting structure is used to install a bracket for mounting the motor of the fan, and the second connecting structure is used to externally connect an air guide tube to the cylindrical structure, and the local reinforcement structure of the flange portion shell material enables the bracket and / or the air guide tube to be completely supported by the flange portion.

[0013] As an optimization and / or instantiation of the air cooler housing of the first aspect, the housing material local reinforcement structure comprises a plastic deformation local reinforcement area formed by plastic deformation of the material of the cylinder of the head of the cylinder-like structure.

[0014] As an optimization and / or embodiment of the air cooler housing of the first aspect, the plastic deformation local reinforcement area is formed by bending the cylinder of the head of the cylinder structure outward.

[0015] As an optimization and / or embodiment of the air cooler housing of the first aspect, the plastic deformation local reinforcement area includes a bell mouth formed by bending the cylinder of the head of the cylindrical structure outward by spinning.

[0016] As an optimization and / or instantiation of the air cooler housing of the first aspect, the lip of the bell mouth constitutes a flange, and the flange is provided with a first connecting hole as the first connecting structure and / or a second connecting hole as the second connecting structure.

[0017] As an optimization and / or instantiation of the air cooler shell of the first aspect mentioned above, the second longitudinal section of the bell mouth has a second outer arc constituting the outer contour of the bell mouth and a second inner arc constituting the inner contour of the bell mouth, the radius of the second outer arc is 25mm-35mm, and the center axis of the cylindrical structure is located on the second longitudinal section.

[0018] As an optimization and / or instantiation of the air cooler shell of the first aspect mentioned above, the lower shell includes a rectangular top plate and four side walls formed by bending downward the periphery of the rectangular top plate, the four side walls and the top plate constitute the inner cavity of the air duct, and the upper shell is arranged above the top plate.

[0019] As an optimization and / or embodiment of the air cooler housing of the first aspect, a pair of side edges between adjacent side walls are welded or bonded as a whole.

[0020] As an optimization and / or instantiation of the air cooler housing of the first aspect, at least part of the four side walls are arranged to be inclined outwardly in a direction perpendicular to the rectangular top plate toward the opening of the air guide cover.

[0021] As an optimization and / or embodiment of the air cooler housing of the first aspect, outer edges of at least some of the four side walls are bent to form flanges for assembling the heat exchanger.

[0022] As an optimization and / or instantiation of the air cooler housing of the first aspect, the plate blank is a steel plate.

[0023] As an optimization and / or instantiation of the air cooler housing of the first aspect, the plate blank is a plate blank with through holes prefabricated in the middle portion.

[0024] As an optimization and / or instantiation of the air cooler housing of the first aspect, the height of the upper housing is 100 mm-200 mm.

[0025] In a second aspect, an air cooler includes a housing, and a fan and a heat exchanger mounted on the housing. The housing is the air cooler housing of the first aspect.

[0026] As an optimization and / or instantiation of the air cooler in the second aspect, the bracket is mounted on the first connecting structure, and the motor of the fan is mounted on the bracket.

[0027] As an optimization and / or instantiation of the air cooler in the second aspect, the air guide tube is installed on the first connecting structure, and the air guide tube is connected to the cylindrical structure.

[0028] According to a third aspect, a method for manufacturing an air cooler shell is provided, wherein the shell comprises: an upper shell and a lower shell which are connected to each other, wherein the upper shell forms a guide tube and is used to install the blade part of the fan, and the lower shell forms a guide cover and is used to install the heat exchanger; the method comprises: preparing a slab, performing a first plastic deformation processing and forming on the middle part of the slab to obtain an upper shell; performing a second plastic deformation processing and forming on the peripheral part of the middle part of the slab to obtain a lower shell; the upper shell and the lower shell constitute an integrated structure formed by performing plastic deformation processing on the slab respectively.

[0029] As an optimization and / or instantiation of the manufacturing method of the air cooler housing of the third aspect, the first plastic deformation process uses flanging to form a flanging portion, and the flanging portion forms a cylindrical structure.

[0030] As an optimization and / or embodiment of the manufacturing method of the air cooler housing according to the third aspect, the root of the flange portion forms a trumpet-shaped connecting neck.

[0031] As an optimization and / or instantiation of the manufacturing method of the air cooler housing according to the third aspect above, the first longitudinal section of the root of the flange portion has a first outer arc constituting the outer contour of the trumpet-shaped connecting neck and a first inner arc constituting the inner contour of the trumpet-shaped connecting neck, the radius of the first outer arc is 50mm-75mm, and the center axis of the cylindrical structure is located on the first longitudinal section.

[0032] As an optimization and / or instantiation of the manufacturing method of the air cooler housing according to the third aspect, the root of the flange portion and the straight section of the cylindrical structure are formed by spinning.

[0033] As an optimization and / or instantiation of the manufacturing method of the air cooler shell of the third aspect mentioned above, it also includes arranging a local reinforcement structure of the shell material of the flange portion at the head of the flange portion, and a first connecting structure and / or a second connecting structure are provided on the local reinforcement structure of the shell material of the flange portion, the first connecting structure is used to install a bracket for mounting the motor of the fan, and the second connecting structure is used to externally connect an air guide tube to the cylindrical structure, and the local reinforcement structure of the shell material of the flange portion makes the bracket and / or the air guide tube completely supported by the flange portion.

[0034] As an optimization and / or instantiation of the manufacturing method of the air cooler shell of the third aspect mentioned above, a plastic deformation local reinforcement zone is formed by plastically deforming the material of the cylinder of the head of the cylindrical structure, and the shell material local reinforcement structure includes the plastic deformation local reinforcement zone.

[0035] As an optimization and / or instantiation of the manufacturing method of the air cooler housing according to the third aspect, the plastic deformation local reinforcement area is formed by bending the cylinder of the head of the cylindrical structure outward.

[0036] As an optimization and / or embodiment of the manufacturing method of the air cooler housing according to the third aspect, the plastic deformation local reinforcement area comprises a bell mouth formed by bending the cylinder of the head of the cylindrical structure outward by spinning.

[0037] As an optimization and / or instantiation of the manufacturing method of the air cooler housing of the third aspect mentioned above, the lip of the bell mouth constitutes a flange, and after the cylinder of the head of the cylindrical structure is spun and bent outward, a first connecting hole serving as the first connecting structure and / or a second connecting hole serving as the second connecting structure are opened on the flange.

[0038] As an optimization and / or instantiation of the manufacturing method of the air cooler housing of the third aspect mentioned above, the second longitudinal section of the bell mouth has a second outer arc constituting the outer contour of the bell mouth and a second inner arc constituting the inner contour of the bell mouth, the radius of the second outer arc is 25mm-35mm, and the center axis of the cylindrical structure is located on the second longitudinal section.

[0039] As an optimization and / or instantiation of the manufacturing method of the air cooler shell of the third aspect mentioned above, the plate blank is a rectangular plate, and the second plastic deformation processing includes bending the periphery of the rectangular plate downward to form four side walls, and the part of the rectangular plate located between the four side walls and the upper shell forms a rectangular top plate, and the four side walls and the top plate constitute the inner cavity of the air duct, and the upper shell is arranged above the top plate.

[0040] As an optimization and / or embodiment of the manufacturing method of the air cooler housing according to the third aspect, a pair of side edges between each adjacent side wall are welded or bonded as a whole.

[0041] As an optimization and / or instantiation of the manufacturing method of the air cooler housing of the third aspect, at least part of the four side walls are inclined outwardly in a direction perpendicular to the rectangular top plate toward the opening of the air duct.

[0042] As an optimization and / or embodiment of the manufacturing method of the air cooler housing according to the third aspect, outer edges of at least some of the four side walls are bent to form flanges for assembling the heat exchanger.

[0043] As an optimization and / or instantiation of the method for manufacturing the air cooler housing according to the third aspect, the plate blank is a steel plate.

[0044] As an optimization and / or instantiation of the method for manufacturing the air cooler housing according to the third aspect, the plate blank is a plate blank with through holes prefabricated in the middle portion.

[0045] As an optimization and / or instantiation of the air cooler housing of the third aspect, the height of the upper housing is 100 mm-200 mm.

[0046] In a fourth aspect, an air cooler is provided, comprising a shell and a fan and a heat exchanger mounted on the shell, wherein the shell is manufactured by the manufacturing method of the air cooler shell according to the third aspect; wherein a mesh cover is covered above the blade portion of the fan in the guide tube.

[0047] In a fifth aspect, an air cooler is provided, comprising: a fan, comprising a motor and a blade portion connected to an output shaft of the motor; a heat exchanger, wherein the airflow generated by the fan cools the hot fluid running in the heat exchanger; an upper shell, forming a guide tube and used to install the blade portion; a lower shell, forming a guide cover and used to install the heat exchanger; wherein the upper shell and the lower shell are connected to each other; a local reinforcement structure of an upper shell material is provided on the upper shell, a first connecting structure is provided on the local reinforcement structure of the upper shell material, a bracket for loading the motor is installed on the first connecting structure, and the local reinforcement structure of the upper shell material enables the bracket to be completely supported by the upper shell.

[0048] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the local reinforcement structure of the upper shell material includes a plastic deformation local reinforcement area formed by plastic deformation of the material of the cylinder body of the head of the guide cylinder.

[0049] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the plastic deformation local reinforcement zone is formed by bending the cylinder body of the head of the guide cylinder outward.

[0050] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the plastic deformation local reinforcement area includes a bell mouth formed by spinning and bending the cylinder body of the head of the guide cylinder outward.

[0051] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the lip of the bell mouth constitutes a flange, and a first connecting hole serving as the first connecting structure is provided on the flange.

[0052] As an optimization and / or instantiation of the air cooler of the fifth aspect, a second connecting hole is opened on the flange, and the second connecting hole is externally connected to an air guide tube on the flange through a connecting piece, and the air guide tube is connected to the guide tube by docking.

[0053] As an optimization and / or instantiation of the air cooler of the fifth aspect above, the second longitudinal section of the bell-mouth has a second outer arc constituting the outer contour of the bell-mouth and a second inner arc constituting the inner contour of the bell-mouth, the radius of the second outer arc is 25mm-35mm, and the central axis of the guide tube is located on the second longitudinal section.

[0054] As an optimization and / or instantiation of the air cooler of the fifth aspect, the upper shell includes a flange portion, which is formed by flanging on a plate blank; the remaining portion of the upper shell formed on the plate blank is used to form the lower shell.

[0055] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the root of the flange portion and the straight section of the guide tube are formed by spinning.

[0056] As an optimization and / or instantiation of the air cooler of the fifth aspect above, the root of the flange portion forms a trumpet-shaped connecting neck; the first longitudinal section of the root of the flange portion has a first outer arc constituting the outer contour of the trumpet-shaped connecting neck and a first inner arc constituting the inner contour of the trumpet-shaped connecting neck, the radius of the first outer arc is 50mm-75mm, and the central axis of the guide tube is located on the first longitudinal section.

[0057] As an optimization and / or instantiation of the air cooler of the fifth aspect above, the bracket includes a core and at least two connecting arms circumferentially spaced around the core, and the outer end of each connecting arm of the at least two connecting arms is respectively mounted on the corresponding first connecting structure; the motor is loaded on the core, and the output shaft of the motor passes downward through the core and is connected to the blade part.

[0058] As an optimization and / or instantiation of the air cooler according to the fifth aspect, a portion of the guide tube located above the bracket is covered with a mesh cover.

[0059] As an optimization and / or instantiation of the air cooler of the fifth aspect above, a curved connecting piece is provided at the outer end of each of the at least two connecting arms, and the curved connecting piece has an outer portion and an inner portion, the outer portion is connected to the corresponding first connecting structure, and the inner portion is connected to the outer end of the corresponding connecting arm, and the upper surface of the connecting arm is lower than the upper surface of the outer portion so that a mesh cover placement groove is formed on the upper surface of the connecting arm, and the mesh cover is placed in the mesh cover placement groove.

[0060] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the curved connecting member is an angled steel plate, and two intersecting walls on the angled steel plate serve as the outer portion and the inner portion respectively.

[0061] As an optimization and / or instantiation of the air cooler according to the fifth aspect, the bracket is a spoke-shaped bracket formed by a plurality of connecting arms distributed at intervals around the core.

[0062] As an optimization and / or instantiation of the air cooler of the fifth aspect above, a second connecting structure is provided on the local reinforcement structure of the upper shell material, and the second connecting structure is used to externally connect the air guide tube to the guide tube; the height of the upper shell is 100mm-200mm.

[0063] The upper shell and the lower shell are plastically deformed on the same slab to form an integrated structure, which has the following advantages: First, save materials and reduce waste: the existing practice is to cut the steel plate into different parts to make the upper shell and the lower shell separately, which will cause a lot of sheet waste. Processing the same slab to form an integrated structure can maximize the use of materials and reduce the cutting and waste of sheet materials. Second, simplify the manufacturing process and improve efficiency: the upper shell and the lower shell are manufactured in an integrated manner, eliminating the process of assembling the upper shell and the lower shell together, simplifying the production process. The manufacturing process of the entire shell is more continuous and efficient. Third, reduce welding points, reduce energy consumption and defective rate. Fourth, improve the integrity and strength of the entire shell: the upper shell and the lower shell are made of the same slab, which avoids the structural discontinuity at the connection of different parts, and has better integrity and strength. Fifth, the appearance is more beautiful: the integrated shell is more unified and smooth in appearance, and has a higher aesthetics. Sixth, reduce weight: Traditional assembled shells have overlaps and additional connectors at the joints. The one-piece structure can avoid unnecessary weight gain while ensuring strength, which is conducive to the lightweight of the entire machine.

[0064] By arranging a local reinforcement structure of the upper shell material on the upper shell, a first connecting structure is provided on the local reinforcement structure of the upper shell material, and a bracket for loading the motor is installed on the first connecting structure, the local reinforcement structure of the upper shell material makes the bracket completely supported by the upper shell. This design simplifies the structure of the existing support system, and there is no need to support the support system on the lower shell and pass through the upper shell.

[0065] The present application is further described below in conjunction with the accompanying drawings and specific embodiments. Additional aspects and advantages of the present application will be partially given in the following description, partially become apparent from the following description, or be understood through practice. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] The drawings constituting a part of this specification are used to assist in the understanding of the present application. The contents provided in the drawings and the related descriptions in this specification may be used to explain the present application, but shall not constitute an improper limitation on the present application.

[0067] Figure 1 This is a schematic diagram of the overall structure of an air cooler according to an embodiment of the present application.

[0068] Figure 2 for Figure 1 AA section view.

[0069] Figure 3 for Figure 1 Exploded view of the parts of the air cooler shown.

[0070] Figure 4for Figure 3 Schematic diagram of the structure of the middle shell.

[0071] Figure 5 for Figure 3 Orthographic projection of the middle shell.

[0072] Figure 6 for Figure 3 Lateral orthographic projection of the middle bracket.

[0073] Figure 7 for Figure 3 Orthographic projection of the center bracket from top view.

[0074] Figure 8 A photograph of an air cooler manufactured and sold by the applicant of this application. DETAILED DESCRIPTION

[0075] The present application is described clearly and completely below in conjunction with the accompanying drawings. A person of ordinary skill in the art will be able to implement the present application based on these descriptions. Before describing the present application in conjunction with the accompanying drawings, it should be noted that:

[0076] The technical solutions and technical features provided in each section, including the following description, can be combined with each other without conflict. In addition, where possible, these technical solutions, technical features and related combinations can be assigned specific technical themes and protected by relevant patents.

[0077] The embodiments of the present application involved in the following description are generally only a part of the embodiments rather than all the embodiments. Based on these embodiments, all other embodiments obtained by ordinary technicians in this field without making creative work should fall within the scope of patent protection.

[0078] Regarding the terms and units in this specification: The terms "include", "comprises", "have" and any variations thereof in this specification and the corresponding claims and related parts are intended to cover non-exclusive inclusions. In addition, other relevant terms and units can be reasonably interpreted based on the relevant content provided in this specification.

[0079] Figure 8 A photo of an air cooler manufactured and sold by the applicant of this application. Figure 8As shown, the air cooler mainly includes a fan 1, a heat exchanger, an upper shell 3 and a lower shell 4, wherein the fan 1 includes a motor and a blade part connected to the motor output shaft; the heat exchanger cools the hot fluid running in the heat exchanger through the airflow generated by the fan 1; the upper shell 3 forms a circular guide tube and is used to install the blade part; the lower shell 4 forms a square-mouthed guide cover and is used to install the heat exchanger; the motor of the fan 1 is located above the blade part and is supported by a support system 5 supported on the lower shell and passing through the upper shell; the upper shell 3 and the lower shell 4 are connected to each other. The working principle of the air cooler is: the airflow generated by the fan 1 passes through the upper shell 3 and the lower shell 4 that are connected to each other, and the airflow cools the hot fluid (such as lubricating oil) running in the heat exchanger when passing through the lower shell 4.

[0080] The upper shell 3, the lower shell 4 and the support system 5 are all made of steel sheet metal. Since the upper shell 3, the lower shell 4 and the support system 5 are obviously different in shape, size and structure, the current conventional practice is to laser cut the steel plate into multiple parts, respectively produce the upper shell 3, the lower shell 4 and the support system 5 through sheet metal processing, and then assemble them together. This practice leads to serious waste of steel sheet materials; at the same time, there are a large number of welding points in the entire shell and the support system 5, which leads to time-consuming, labor-intensive, high energy consumption and high defect rate risk. In addition, due to the insufficient strength of the upper shell 3, the support system 5 has to be supported on the lower shell 4 and pass through the upper shell 3 to carry the motor, resulting in the complex and bulky support system structure 5, which further increases the amount of steel plate and increases the manufacturing cost of the air cooler.

[0081] Figure 1 This is a schematic diagram of the overall structure of an air cooler according to an embodiment of the present application. Figure 2 for Figure 1 AA section view. Figure 3 for Figure 1 Exploded view of the parts of the air cooler shown. Figure 4 for Figure 3 Schematic diagram of the structural structure of the middle shell. Figure 5 for Figure 3 Orthographic projection of the middle shell. Figure 6 for Figure 3 Lateral orthographic projection of the middle bracket. Figure 7 for Figure 3 Orthographic projection of the center bracket. Figure 1-Figure 7As shown, the improved air cooler in the embodiment of the present application also includes a fan 1, a heat exchanger 2, an upper shell 3 and a lower shell 4, wherein the fan 1 includes a motor 11 and a blade part 12 connected to the output shaft of the motor 11; the heat exchanger 2 cools the hot fluid running in the heat exchanger 2 through the airflow generated by the fan 1; the upper shell 3 forms a circular guide tube and is used to install the blade part 12; the lower shell 4 forms a square-mouth guide cover and is used to install the heat exchanger 2; the motor 11 of the fan 1 is located above the blade part 12 and is supported by the bracket 51; the upper shell 3 and the lower shell 4 are connected to each other.

[0082] The upper shell 3 and the lower shell 4 constitute an integrated structure 6 formed by plastic deformation processing on the same plate (specifically, a steel plate). Specifically, the upper shell 3 is formed by the middle part of the plate through the first plastic deformation processing, and the lower shell 4 is formed by the peripheral part of the middle part of the plate through the second plastic deformation processing.

[0083] The upper shell 3 and the lower shell 4 are respectively plastically deformed on the same slab to form an integrated structure, which has the following advantages: First, save materials and reduce waste: the existing practice is to cut the steel plate into different parts to make the upper shell and the lower shell separately, which will cause more sheet waste. Processing on the same slab to form an integrated structure can maximize the use of materials and reduce the cutting and waste of sheet materials. Second, simplify the manufacturing process and improve efficiency: the upper shell and the lower shell are manufactured in an integrated manner, eliminating the process of assembling the upper shell and the lower shell together, simplifying the production process. The manufacturing process of the entire shell is more continuous and efficient. Third, reduce welding points, reduce energy consumption and defective rate. Fourth, improve the integrity and strength of the entire shell: the upper shell and the lower shell are made of the same slab, and the upper shell and the lower shell are integrated, avoiding the structural discontinuity at the connection of different components, and the integrity and strength are better. Fifth, the appearance is more beautiful: the integrated shell is more unified and smooth in appearance, and has a higher aesthetics. Sixth, reduce weight: Traditional assembled shells have overlaps and additional connectors at the joints. The one-piece structure can avoid unnecessary weight gain while ensuring strength, which is conducive to the lightweight of the entire machine.

[0084] Generally speaking, the upper shell 3 includes a flange portion, and the flange portion forms a cylindrical structure. Specifically, the first plastic deformation process can be formed by flanging the flange portion, and the flanging portion forms a cylindrical structure. Flanging is a general term for a type of sheet metal process, which can easily form the basic shape of the upper shell 3 in the middle part of the slab. The above-mentioned flanging preferably adopts an inner hole flanging, in which case the slab is a slab with a through hole prefabricated in the middle part.

[0085] The root of the flange portion can form a trumpet-shaped connection neck 31. In this way, a smooth transition connection between the upper shell 3 and the lower shell 4 can be achieved. The trumpet-shaped connection neck 31 forms a smooth transition area between the root of the flange portion and the upper shell 4, so that the upper shell 3 can be more smoothly connected to the lower shell 4. The trumpet-shaped connection neck 31 can guide the airflow to pass smoothly between the upper shell 3 and the lower shell 4, reduce the turbulence and turbulence of the airflow, reduce the airflow resistance at the connection, and help improve the cooling efficiency. The trumpet-shaped connection neck 31 can also increase the material thickness and cross-sectional area at the root of the flange portion, thereby enhancing the strength of the connection, improving the strength and rigidity of the connection, and making the connection between the upper and lower shells more firm and reliable. The trumpet-shaped connection neck 31 provides a more smooth and design-conscious shape for the entire shell, improving the aesthetics of the product.

[0086] In this embodiment, the first longitudinal section of the root of the flange portion has a first outer arc constituting the outer contour of the flared connecting neck 31 and a first inner arc constituting the inner contour of the flared connecting neck. The radius of the first outer arc (i.e. Figure 5 The R1 in the figure is 50mm-75mm, and the central axis of the cylindrical structure is located on the first longitudinal section. That is to say, the first longitudinal section of the trumpet-shaped connecting neck is composed of two inner and outer arcs, and the radius of the first outer arc is 50mm-75mm. For the air cooler shell itself, a good balance can be achieved in terms of airflow guidance, processing difficulty, strength, space utilization, etc.: if R1 is less than 50mm, the transition of the trumpet-shaped connecting neck 31 will be steeper, the airflow resistance will be large, and the processing difficulty will also increase; if R1 is greater than 75mm, it will occupy more radial space, resulting in a large amount of material consumption.

[0087] In this embodiment, the root of the flanging portion and the straight section of the cylindrical structure are specifically formed by spinning. During the spinning process, the slab and the spinning component (the component that contacts the slab to make it plastically deformed) rotate relative to each other. In this application, the advantages of using spinning are mainly: First, good strength and rigidity: During the spinning process, the material will produce plastic flow under the action of the spinning component, and the fiber structure will extend along the contour of the part to form a dense and continuous metal structure, which improves the strength and rigidity of the part, especially for curved structures such as trumpet-shaped connecting necks, spinning can achieve uniform and controllable work hardening. Secondly, high dimensional accuracy: Spinning can obtain highly consistent part dimensions, good dimensional accuracy and repeatability, and reduce the need for subsequent processing and finishing. Good surface quality. In addition, spinning can obtain a smooth and defect-free part surface, avoiding the common surface roughness, burrs and other problems in cutting, and also improves the aesthetics of the shell.

[0088] In addition, the following improvements can be made on the upper shell 3 to solve the technical problem that the supporting system 5 is complex and bulky.

[0089] like Figure 1-Figure 7 As shown, in the embodiment of the present application, the head of the flange portion is provided with a local reinforcement structure of the flange portion shell material, and a first connecting structure is provided on the local reinforcement structure of the flange portion shell material. The first connecting structure is used to install a bracket 51 for mounting the motor 11 of the fan 1, and the local reinforcement structure of the flange portion shell material enables the bracket 51 to be completely supported by the flange portion.

[0090] Specifically, the shell material local reinforcement structure includes a plastic deformation local reinforcement area formed by plastic deformation of the material of the cylinder of the head of the cylindrical structure.

[0091] More specifically, the plastic deformation local reinforcement zone is formed by bending the cylinder of the head of the cylindrical structure outward (usually by flanging the outer edge).

[0092] For example, an annular flange can be formed by flanging the outer edge of the cylindrical body of the head of the cylindrical structure. This annular flange and the straight portion of the upper shell 3 form a cross-sectional shape similar to an I-shaped cross section. Compared with a straight plate, the moment of inertia of the I-shaped cross section is significantly increased, thereby improving the shell's ability to resist bending deformation and enhancing the overall strength and rigidity of the upper shell 3.

[0093] The outer edge flanging may also be formed by a spinning process. In this case, the plastic deformation local reinforcement area includes a bell mouth 32 formed by spinning the cylinder body of the head of the cylindrical structure outwardly.

[0094] The formation of the bell mouth 32 is also a local plastic deformation of the material. The head material of the upper shell is bent outward by spinning, which increases the cross-sectional area and section modulus of this part, thereby significantly improving the strength and rigidity of the upper shell, enabling it to better withstand the vibration and load during fan operation.

[0095] When the fan 1 is running, the bell mouth 32 can guide the airflow to enter the upper housing 3 more smoothly and evenly, reducing the turbulence of the airflow and aerodynamic noise, which is beneficial to improving the cooling efficiency and reducing energy consumption.

[0096] In this embodiment, the lip of the bell mouth 32 constitutes a flange, and the flange is provided with a first connection hole (see Figure 4 ). By opening the first connection hole on the flange, the motor bracket can be conveniently and reliably connected to the upper housing. The flange provides sufficient connection area and support strength, simplifying the installation process of the motor bracket.

[0097] It can be seen that the bell mouth 32 is formed by spinning and bending the barrel of the head of the cylindrical structure outward, and the lip of the bell mouth 32 constitutes a flange. This structure is also an innovation of the present application.

[0098] In this embodiment, the second longitudinal section of the bell mouth 32 has a second outer arc constituting the outer contour of the bell mouth 32 and a second inner arc constituting the inner contour of the bell mouth. The radius of the second outer arc (i.e. Figure 5 R2) is 25mm-35mm, and the central axis of the cylindrical structure is located on the second longitudinal section.

[0099] The radius of the second outer arc is selected to be 25-35mm, which is an optimized range based on comprehensive consideration of factors such as the strength of the air cooler shell, airflow performance, and processing difficulty. A radius that is too small will cause the bell mouth 32 to be too steep, resulting in large airflow resistance and easy cracking of the material; a radius that is too large will occupy too much axial space, and the material will deform greatly and be difficult to process. The radius range of 25-35mm can achieve a good balance between various indicators.

[0100] By arranging a local reinforcement structure of the upper shell material on the upper shell 3, a first connecting structure is provided on the local reinforcement structure of the upper shell material, and a bracket 51 for loading the motor is installed on the first connecting structure. The local reinforcement structure of the upper shell material makes the bracket 51 completely supported by the upper shell 3. This design simplifies the structure of the existing support system, which is different from supporting the support system on the lower shell and passing through the upper shell.

[0101] In addition, a second connecting hole may be provided on the flange, and the second connecting hole is externally connected to an air guide tube 7 on the flange through a connecting piece (such as a threaded connecting piece), and the air guide tube 7 is connected to the guide tube by docking.

[0102] The fundamental significance of providing the air guide tube 7 is that, by providing the air guide tube 7, the height of the air guide tube formed by the upper shell 3 can be reduced, thereby ensuring the strength and rigidity of the upper shell 3. Reducing the height of the upper shell 3 by providing the air guide tube 7, thereby improving the strength and rigidity of the upper shell 3, is also an innovation of the present application.

[0103] The height of the upper shell 3 may preferably be 100 mm-200 mm, more preferably 120 mm-165 mm. This can ensure the strength and rigidity of the upper shell 3, while the height of the upper shell 3 is suitable for accommodating the blade part 12, ensuring that the gap between the inner wall of the upper shell 3 and the blade part 12 is within a reasonable range.

[0104] like Figure 1-Figure 7As shown, in the embodiment of the present application, the lower shell 4 includes a rectangular top plate 41 and four side walls 42 formed by bending downward the periphery of the rectangular top plate 41, the four side walls 42 and the top plate 41 constitute the inner cavity of the air duct, and the upper shell 3 is arranged above the top plate 41.

[0105] The lower shell 4 can usually be manufactured by using a rectangular plate blank, bending the periphery of the rectangular plate downward to form four side walls 42, and the portion of the rectangular plate between the four side walls 42 and the upper shell 3 forms a rectangular top plate 41.

[0106] In order to facilitate the folding of the periphery of the rectangular plate downward to form four side walls 42, a gap may be firstly provided between the portions of the rectangular plate where adjacent side walls are formed, so that after the periphery of the rectangular plate is folded downward to form four side walls 42, a pair of side edges will be formed between the adjacent side walls. At this time, the pair of side edges between the adjacent side walls may be welded or bonded together to ensure the airtightness of the air deflector.

[0107] In addition, at least part of the four side walls 42 may be arranged to be inclined outwardly in a direction perpendicular to the rectangular top plate 41 toward the opening of the air guide cover (the opening here particularly refers to the lower opening of the air guide cover) (see Figure 5 shown).

[0108] In this way, the opening area of ​​the air deflector can be guaranteed, air resistance can be reduced, and the air volume and cooling efficiency can be improved. In addition, the air flow distribution can be optimized and the air flow dead zone can be reduced. Compared with the vertical side wall, the inclined side wall forms an expansion structure similar to a bell mouth at the opening end of the air deflector. This structure can increase the cross-sectional area and section modulus of the opening end of the air deflector, and improve the air deflector's ability to resist bending deformation.

[0109] Optionally, at least some of the four side walls 42 are bent to form a flange for assembling the heat exchanger. The structure and function of the flange for assembling the heat exchanger are similar to those of a flange, which facilitates the installation of the heat exchanger 2.

[0110] like Figure 6 and Figure 7 As shown, the bracket 51 specifically comprises a core 511 and at least two connecting arms 512 circumferentially spaced around the core 511, and the outer ends of each connecting arm 512 of the at least two connecting arms 512 are respectively mounted on the corresponding first connecting structure; the motor 11 is mounted on the core 511, and the output shaft of the motor 11 passes downward through the core 511 and connects to the blade part 12. More specifically, the bracket 51 is a spoke-shaped bracket formed by a plurality of connecting arms 512 spaced around the core 511.

[0111] The core 511 may be an annular mounting seat with distributed through holes, and the base of the motor 11 may be fixed on the mounting seat by bolts.

[0112] The spoke-shaped bracket can provide stable and reliable support, reduce the obstruction of the support system to the airflow, reduce aerodynamic loss, and reduce material consumption and weight. The spoke-shaped bracket has a simple structure, and the connecting arms 512 are mostly made of profiles or pipes with regular cross-sections, which can be processed by conventional processes such as cutting and welding. The number and length of the connecting arms 512 can be flexibly adjusted according to actual needs.

[0113] In addition, a curved connecting piece is provided at the outer end of each connecting arm 512 of the at least two connecting arms 512, and the curved connecting piece has an outer portion and an inner portion, the outer portion is connected to the corresponding first connecting structure, and the inner portion is connected to the outer end of the corresponding connecting arm, and the upper surface of the connecting arm is lower than the upper surface of the outer portion, thereby forming a mesh cover placement groove on the upper surface of the connecting arm 512, and the mesh cover placement groove is used to place the mesh cover 8.

[0114] Specifically, the curved connecting member adopts an angled steel plate 513, and two intersecting walls on the angled steel plate 513 serve as the outer portion (on which a hole may be opened for connection with the first connecting hole by bolts) and the inner portion respectively.

[0115] Thus, the bracket 51 can be covered by the mesh cover 8, making the appearance of the entire air cooler more concise and beautiful, and greatly improving the design aesthetics of the air cooler.

[0116] The above is a description of the relevant contents of the present application. A person skilled in the art will be able to implement the present application based on these descriptions. Based on the above contents of this specification, all other embodiments obtained by a person skilled in the art without making any creative work shall fall within the scope of patent protection.

Claims

1. Air cooler housing, including: An upper shell and a lower shell connected to each other, wherein the upper shell forms a guide tube and is used to install the blade part of the fan, and the lower shell forms a guide cover and is used to install the heat exchanger; Features: The upper shell and the lower shell are formed into an integrated structure by plastic deformation processing on the same plate blank; The upper shell is formed by a middle portion of the plate blank through a first plastic deformation process, and the lower shell is formed by a peripheral portion of the middle portion of the plate blank through a second plastic deformation process.

2. The air cooler housing according to claim 1, characterized in that: The upper shell includes a flange portion, and the flange portion forms a cylindrical structure.

3. The air cooler housing according to claim 2, characterized in that: The root of the flange portion forms a trumpet-shaped connecting neck.

4. The air cooler housing according to claim 3, characterized in that: The first longitudinal section of the root of the flanging portion has a first outer arc constituting the outer contour of the trumpet-shaped connecting neck and a first inner arc constituting the inner contour of the trumpet-shaped connecting neck, the radius of the first outer arc is 50mm-75mm, and the central axis of the cylindrical structure is located on the first longitudinal section.

5. The air cooler housing according to claim 2, characterized in that: The root of the flange portion and the straight section of the cylindrical structure are formed by spinning.

6. The air cooler housing according to claim 2, characterized in that: The head of the flange portion is provided with a local reinforcement structure of the flange portion shell material, and the local reinforcement structure of the flange portion shell material is provided with a first connecting structure and / or a second connecting structure. The first connecting structure is used to install a bracket for mounting the motor of the fan, and the second connecting structure is used to externally connect an air guide tube to the cylindrical structure. The local reinforcement structure of the flange portion shell material enables the bracket and / or the air guide tube to be completely supported by the flange portion.

7. The air cooler housing according to claim 6, characterized in that: The shell material local reinforcement structure includes a plastic deformation local reinforcement area formed by plastic deformation of the material of the cylinder of the head of the cylindrical structure.

8. The air cooler housing according to claim 7, characterized in that: The plastic deformation local reinforcement area is formed by bending the cylinder of the head of the cylindrical structure outward.

9. The air cooler housing according to claim 8, characterized in that: The plastic deformation local reinforced area includes a bell mouth formed by spinning the cylinder of the head of the cylindrical structure and bending it outward.

10. The air cooler housing according to claim 9, characterized in that: The lip of the bell mouth forms a flange, and the flange is provided with a first connection hole as the first connection structure and / or a second connection hole as the second connection structure.

11. The air cooler housing according to claim 9, wherein: The second longitudinal section of the bell mouth has a second outer arc constituting the outer contour of the bell mouth and a second inner arc constituting the inner contour of the bell mouth, the radius of the second outer arc is 25mm-35mm, and the central axis of the cylindrical structure is located on the second longitudinal section.

12. The air cooler housing according to claim 1, wherein: The lower shell comprises a rectangular top plate and four side walls formed by bending the periphery of the rectangular top plate downwards, the four side walls and the top plate constitute the inner cavity of the air guide cover, and the upper shell is arranged above the top plate.

13. The air cooler housing according to claim 12, wherein: A pair of side edges between each adjacent side wall is welded or bonded into one piece; And / or, at least part of the four side walls are arranged to be inclined outwardly in a direction perpendicular to the rectangular top plate toward the opening of the air guide cover; And / or, outer edges of at least some of the four side walls are bent to form a flange for assembling the heat exchanger.

14. The air cooler housing according to claim 1, wherein: The slab is a steel plate; and / or, the slab is a slab with a through hole prefabricated in the middle part; and / or, the height of the upper shell is 100mm-200mm.

15. An air cooler comprising a housing and a fan and a heat exchanger mounted on the housing, characterized in that: The housing is an air cooler housing as claimed in any one of claims 1 to 14.

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