Vehicular air conditioner

Abstract

To sufficiently suppress deviation of a wind-velocity distribution on a whole surface of a filter.SOLUTION: A vehicular air conditioner (10) comprises: a duct (20) in which an air-blowing passage (21) is formed; an air-blowing unit (30) provided on the air-blowing passage (21); and a filter (50) arranged at a downstream side of the air-blowing unit (30) in the air-blowing passage (21). The air-blowing unit (30) is an axial-flow fan (31) in which a shaft line (CL) of a rotary shaft (33) extends along the air-blowing passage (21). The filter (50) has a filtering medium (60) having a pleat (61) in a mountain / valley shape formed thereon. In the filtering medium (60), the pleat (61) extends radially from an aggregation part (62) where the pleat (61) aggregates. When the filtering medium (60) is viewed in a direction of the shaft line (CL), a pleat depth (De) of the pleat (61) gradually becomes larger as approaching the aggregation part (62) in a radial direction of the shaft line (CL).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an improved technology for a vehicle air conditioner. [Background technology]

[0002] The vehicle air conditioning system includes a blower unit and a cooling heat exchanger disposed within a casing. The blower unit uses, for example, a centrifugal fan. The centrifugal fan draws in air (airflow) from one axial side and blows it outward in the radial direction. The cooling heat exchanger is disposed on the other axial side of the centrifugal fan and cools the air blown out from the centrifugal fan using a refrigerant. The wind speed distribution of the air blown out from the centrifugal fan varies depending on the radial position. More specifically, almost no wind flows along the axis, while much air flows at positions radially away from the axis. Patent Document 1, for example, is known as a technology for suppressing this bias in the wind speed distribution of the air.

[0003] The vehicle air conditioning system known from Patent Document 1 has a filter interposed between a centrifugal fan disposed within a casing and a cooling heat exchanger. The filter includes a filter material for filtering air blown from a centrifugal blower toward the cooling heat exchanger. The filter material is formed into a wave shape (corresponding to pleats) by folding along a plurality of folds extending radially from the axis of the centrifugal fan. The folds extend in a vertical direction. Therefore, the filter material can suppress bias in the pressure loss in the vertical direction on a surface perpendicular to the axial direction, thereby suppressing bias in the air velocity distribution. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2021-187286 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the filter of Patent Document 1, the folds only extend in the vertical direction, and it is not possible to eliminate the bias of the airflow in the horizontal direction perpendicular to the vertical direction. In other words, there is room for further improvement in order to sufficiently suppress the bias of the airflow velocity distribution over the entire surface perpendicular to the axial direction.

[0006] Therefore, an object of the present invention is to provide a technology that can more sufficiently suppress the bias in the air velocity distribution over the entire surface of the filter in a vehicle air conditioner. [Means for solving the problem]

[0007] In the following description, reference numerals in the accompanying drawings are placed in parentheses to facilitate understanding of the present invention, but the present invention is not limited to the illustrated forms.

[0008] According to the present disclosure, there is provided a vehicle air conditioner (10; 100) including a duct (20) having an air flow path (21) formed therein, an air blowing unit (30) provided in the air flow path (21), and a filter (50) arranged in the air flow path (21) downstream of the air blowing unit (30), The air blowing unit (30) is configured by an axial flow fan (31) having an axis (CL) of a rotation shaft (33) extending along the air blowing path (21), The filter (50) has a filter medium (60; 160) on which peak-valley pleats (61) are formed, The filter medium (60; 160) has pleats (61) extending radially from a gathering portion (62; 162) where the pleats (61) are gathered, When the filter material (60; 160) is viewed along the axis (CL) of the rotating shaft (33), the pleat depth (De) of the pleats (61) formed by the mountain folds (61a) and the valley folds (61b) becomes deeper in the radial direction of the axis (CL) as it approaches the collection portion (62; 162). [Effects of the Invention]

[0009] In the present invention, it is possible to more sufficiently suppress the bias in the air velocity distribution over the entire surface of the filter. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a cross-sectional view illustrating a vehicle air conditioner according to a first embodiment. [Figure 2] 2A is a view of the filter shown in FIG. 1 taken along the axis of the rotation shaft, FIG. 2B is a cross-sectional view taken along line 2B-2B in FIG. 2A, FIG. 2C is a cross-sectional view taken along line 2C-2C in FIG. 2A, FIG. 2D is a cross-sectional view taken along line 2D-2D in FIG. 2A, and FIG. 2E is a cross-sectional view taken along line 2E-2E in FIG. 2A. [Figure 3] Figure 3A is a process diagram for forming a pleated substrate in the filter manufacturing method of Example 1, Figure 3B is a process diagram for forming a pleated body from the pleated substrate, Figure 3C is a process diagram for joining one end of the pleated body, Figure 3D is a process diagram for unfolding the pleated body, Figure 3E is a process diagram for joining the unfolded pleated body, and Figure 3F is a process diagram for fitting a filter material made of a pleated body into a frame. [Figure 4] FIG. 4A is a diagram showing a first modified example of the filter, and FIG. 4B is a diagram showing a second modified example of the filter. [Figure 5] FIG. 6 is a cross-sectional view illustrating a vehicle air conditioner according to a second embodiment. [Figure 6] 6A is a view of the filter shown in FIG. 5 as viewed along the axis of the rotation shaft, FIG. 6B is a cross-sectional view taken along line 6B-6B in FIG. 6A, and FIG. 6C is a perspective view of the filter shown in FIG. 6B as viewed from the direction of arrow 6C. [Figure 7] Figure 7A is a process diagram for forming a pleated base in the filter manufacturing method of Example 2, Figure 7B is a process diagram for forming a pleated body from the pleated base, Figure 7C is a process diagram for joining one end of the pleated body, Figure 7D is a process diagram for diagonally cutting off a portion of the joined end, Figure 7E is a process diagram for unfolding the pleated body, Figure 7F is a process diagram for joining the unfolded pleated body, and Figure 7G is a process diagram for fitting a filter material made of a pleated body into a frame. DETAILED DESCRIPTION OF THE INVENTION

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the accompanying drawings. Note that the embodiments shown in the accompanying drawings are merely examples of the present invention, and the present invention is not limited to these embodiments.

[0012] Example 1 1 to 4, a vehicle air conditioner 10 according to a first embodiment will be described. As shown in FIG. 1, the vehicle air conditioner 10 includes a duct 20, a blower unit 30, a cooling heat exchanger 40, and a filter 50.

[0013] The duct 20 (housing 20) is formed, for example, with a rectangular cross section. An air flow path 21 is formed inside the duct 20, through which air Fa (air flow Fa) taken in from inside or outside the vehicle compartment can circulate. A blower unit 30, a cooling heat exchanger 40, and a filter 50 are provided in the air flow path 21.

[0014] The blower unit 30 blows air Fa (air flow Fa) taken in from inside or outside the vehicle cabin into the vehicle cabin. The blower unit 30 is configured with an axial fan 31 having an axis CL of a rotary shaft 33 extending along an air flow path 21. Here, within the air flow path 21, a passage 22 on the suction side of the axial fan 31 is sometimes referred to as the "suction-side passage 22," and a passage 23 on the discharge side of the axial fan 31 is sometimes referred to as the "discharge-side passage 23."

[0015] The axial fan 31 draws in an airflow Fa from one side in the axial direction Rs (the suction-side passage 22) and blows it to the other side in the axial direction Rs (the discharge-side passage 23). More specifically, the axial fan 31 includes a fan housing 32, a rotating shaft 33 rotatably housed within the fan housing 32, rotor blades 34 (rotor blades 34) housed within the fan housing 32 and mounted on the rotating shaft 33, stator blades 35 housed within the fan housing 32 and positioned behind the rotor blades 34, and an electric motor 36 that drives the rotor shaft 33. The stator blades 35 regulate the swirling flow generated behind the rotor blades 34 and redirect it into an axial flow.

[0016] The fan housing 32 includes a cylindrical housing body 32a and a cover portion 32b provided on the suction side (upstream side) of the housing body 32a. The housing body 32a is fitted, for example, onto the inner circumferential surface 20a of the duct 20. The cover portion 32b is formed, for example, in a conical shape that protrudes from the housing body 32a toward the upstream side, and has a suction port 32c at its tip. The suction port 32c is a circular hole located on the axis CL of the rotation shaft 33. The discharge port 32d of the housing body 32a is a hole that opens the entire housing body 32a.

[0017] The electric motor 36 is fixed to the fan housing 32. The motor shaft of the electric motor 36 may also serve as the rotary shaft 33.

[0018] The cooling heat exchanger 40 (evaporator 40) is disposed downstream (discharge side passage 23) of the axial fan 31 in the air flow path 21. The cooling heat exchanger 40 cools the air blown from the axial fan 31 by exchanging heat between the air and a refrigerant in a refrigeration cycle (not shown).

[0019] The filter 50 can promote uniformity of the wind speed distribution of the airflow Fa flowing through the airflow path 21. Furthermore, the filter 50 can remove foreign matter such as dust and mist mixed in the airflow Fa. The filter 50 is disposed between the axial flow fan 31 and the cooling heat exchanger 40 in the airflow path 21. In other words, the filter 50 is disposed downstream of the blower unit 30 in the airflow path 21 (discharge-side passage 23).

[0020] The axial flow fan 31, the cooling heat exchanger 40, and the filter 50 are arranged on the axis CL of the rotary shaft 33, for example.

[0021] The filter 50 includes a sheet-like (including film-like) filter medium 60 that allows airflow Fa to pass through, and a frame 70 that surrounds the outer periphery of the filter medium 60. The filter medium 60 is made of, for example, a woven fabric made of various fibers, or a nonwoven fabric such as filter paper or felt. Referring also to FIG. 2A, the filter medium 60 is formed in a rectangular shape (including a square shape) when viewed along the axis CL of the rotation shaft 33, and is surrounded by and fixed to the rectangular frame 70.

[0022] As shown in FIGS. 2A to 2E, the filter medium 60 has mountain-valley-shaped pleats 61 formed therein. The pleats 61 are "pleats" or "creases" with clearly defined ridges. More specifically, the filter medium 60 has the pleats 61 extending radially from a collection portion 62 where the pleats 61 are gathered. The collection portion 62 is located on the axis CL of the rotating shaft 33 (see FIG. 1). In other words, when the filter medium 60 is viewed along the axis CL of the rotating shaft 33, the pleats 61 have a configuration in which mountain folds 61a and valley folds 61b are alternately arranged in the circumferential direction. Here, the mountain folds 61a are apexes that protrude toward the axial fan 31 (see FIG. 1), and the valley folds 61b are bottoms that are recessed away from the axial fan 31. For example, when the filter medium 60 is viewed along the axis CL of the rotation shaft 33, 24 mountain folds 61a are provided at equal angles around the collection portion 62. Four of the 24 mountain folds 61a extend from the collection portion 62 toward the four corners of the rectangular filter medium 60.

[0023] 2A, 2D, and 2E, when this filter medium 60 is viewed along the axis CL of the rotation shaft 33, the pleat depth De formed by the mountain folds 61a and the valley folds 61b of the pleats 61 becomes deeper as it approaches the collection portion 62 in the radial direction of the axis CL. That is, as shown in FIGS. 2A and 2B, the pleat depth (outer pleat depth) of the outermost pleats 61 in the radial direction of the filter medium 60 is D1. The pleat depth (center pleat depth) of the pleats 61 at the collection portion 62 of the filter medium 60 is D2. The center pleat depth D2 is greater than the outer pleat depth D1.

[0024] Therefore, as shown in Figures 1 and 2A, the air Fa blown out by the axial fan 31 to an area radially away from the axis CL (radially outward) can also flow into the vicinity of the collection section 62, which has a large pleat depth De and low air resistance.

[0025] Next, an example of a method for manufacturing the filter 50 of the first embodiment will be described with reference to FIGS. 3A to 3F. First, as shown in Figure 3A, a sheet-like filter medium 60 is prepared, and unnecessary portions 82 are cut away, leaving portions 81 (pleated substrate 81) that will be used for pleating. One side 81a (first edge 81a) of this pleated substrate 81 becomes the base end that forms the collecting portion 62 (see Figure 2A), and an edge 81b (second edge 81b) opposite this first edge 81a becomes the tip of the pleats 61 (see Figure 2A) that extend radially from the collecting portion 62.

[0026] Next, as shown in FIG. 3B, pleating is performed on the pleated substrate 81 to obtain a pleated body 83. Next, as shown in FIG. 3C, one end 83a of the pleated body 83, which corresponds to the collection portion 62 (see FIG. 2A), is joined. Next, as shown in FIG. 3D, the pleated body 83 is unfolded around the one end 83a. Next, as shown in FIG. 3E, the unfolded pleated body 83 is joined so as not to close. This allows the filter medium 60 with pleats 61 formed thereon to be obtained. Finally, as shown in FIG. 3F, the filter medium 60 with pleats 61 formed thereon is fitted and fixed into the frame 70. This completes the production of the filter 50.

[0027] Fig. 4A shows a first modified example of filter 50. Filter 50 of the first modified example is formed in a circular shape in contrast to the rectangular filter 50 shown in Fig. 2A above, and is surrounded by and fixed to a circular frame body 70.

[0028] 4B shows a second modified example of the filter 50. The assembly parts 62 of the filter 50 of the second modified example are positioned apart in a direction intersecting the axis CL of the rotary shaft 33 (radial direction), that is, offset.

[0029] <Example 2> Second Embodiment A vehicle air conditioner 100 according to a second embodiment will be described with reference to Figures 5 to 7. Figure 5 corresponds to Figure 1, Figure 6 corresponds to Figure 2, and Figure 7 corresponds to Figure 3.

[0030] The vehicle air conditioner 100 of the second embodiment is characterized in that the filter material 60 of the filter 50 of the first embodiment shown in Figures 1 to 4 is replaced with the filter material 160 of the filter 150 shown in Figures 5 to 7. The other configuration of the vehicle air conditioner 100 is common to the vehicle air conditioner 10 of the first embodiment. The same reference numerals are used for the parts common to the vehicle air conditioner 10 of the first embodiment, and detailed description thereof will be omitted.

[0031] The filter 150 of Example 2 includes a filter medium 160 and a frame 70 that surrounds the outer periphery of the filter medium 160. The filter medium 160 has the same basic configuration as the filter medium 60 shown in FIG. 2. The filter medium 160 has peak-valley-shaped pleats 61 formed therein. More specifically, the filter medium 160 has pleats 61 that extend radially from a collection portion 162 where the pleats 61 are collected. The collection portion 162 has the same basic configuration as the collection portion 62 shown in FIG. 2.

[0032] The filter medium 160 of Example 2 has a pyramidal or conical configuration. When this pyramidal or conical filter medium 160 is viewed along the axis CL of the rotation shaft 33, the collection portion 162 is located on the most downstream side of the filter medium 160. In other words, the collection portion 162 is located the farthest from the discharge port 32d of the axial flow fan 31 of the filter medium 160. Therefore, the airflow Fa sent from the axial flow fan 31 can be smoothly collected at the collection portion 162, as shown in FIG. 6C .

[0033] Next, an example of a manufacturing method for the filter 150 of Example 2 will be described with reference to FIGS. 7A to 7G. The steps in FIGS. 7A to 7C are the same as those in FIGS. 3A to 3C. Next, as shown in FIG. 7D, a portion 83b of the joined end portion 83a is cut obliquely. By cutting obliquely, the filter medium 160 can be formed into a pyramidal or conical shape. Next, as shown in FIG. 7E, the pleated body 83 is unfolded around the end portion 83a. Next, as shown in FIG. 7F, the unfolded pleated body 83 is unfolded and joined together so as not to close. This allows the filter medium 160 with the pleats 61 formed thereon to be obtained. Finally, as shown in FIG. 7G, the filter medium 160 with the pleats 61 formed thereon is fitted and fixed into the frame 70. This completes the manufacture of the filter 50.

[0034] The collection portion 162 of the filter 150 of Example 2 may be configured to be positioned apart in a direction (radial direction) intersecting the axis CL of the rotating shaft 33, i.e., offset, like the collection portion 62 of the filter 50 of the second modified example shown in Figure 4B above.

[0035] The vehicle air conditioners 10, 100 described above can be summarized as follows.

[0036] 1 and 5. According to this embodiment, firstly, a vehicle air conditioner 10; 100 includes a duct 20 having an air passage 21 formed therein, a blower unit 30 provided in the air passage 21, and a filter 50; 150 arranged in the air passage 21 downstream of the blower unit 30 (discharge-side passage 23). The blower unit 30 is configured by an axial fan 31 having an axis CL of a rotary shaft 33 extending along the air passage 21.

[0037] See Figures 2, 4, and 6. The filter 50; 150 has a filter medium 60; 160 on which mountain- and valley-shaped pleats 61 are formed. The filter medium 60; 160 has a collection portion 62; 162 where the pleats 61 are collected, and the pleats 61 extend radially from the collection portion 62; 162. When the filter medium 60; 160 is viewed along the axis CL of the rotating shaft 33 (see Figures 1 and 5), the pleat depth De of the mountain folds 61a and valley folds 61b of the pleats 61 becomes deeper as it approaches the collection portion 62; 162 in the radial direction of the axis CL.

[0038] The axial flow fan 31 employed in the blower unit 30 draws air Fa (air flow Fa) from one side in the axial direction Rs (suction-side passage 22) and blows it to the other side in the axial direction Rs (discharge-side passage 23). The filter 50; 150, located downstream of the axial flow fan 31 (discharge-side passage 23), has pleats 61 extending radially from a collection portion 62, with the pleat depth De increasing toward the collection portion 62; 162. Therefore, the air Fa blown by the axial flow fan 31 to a region located radially (radially outward) of the axis CL (a region closer to the frame 70 from the axis CL) also flows into the vicinity of the collection portion 62, where the pleat depth De is deep and ventilation resistance is low. The air Fa reaching the filter 50; 150 does not need to flow over the peaks 61a (mountain folds 61a) of adjacent pleats 61. Furthermore, because the pleats 61 extend radially from the collection portion 62; 162, it is possible to suppress deviations in the airflow Fa in the horizontal direction R2 as well as in the vertical direction R1. As a result, it is possible to more sufficiently suppress deviations in the air velocity distribution over the entire surface of the filter 50; 150.

[0039] See Figures 1, 2A, 4A, and 6A. Secondly, preferably, in the vehicle air conditioner 10; 100 described above, the collecting portion 62; 162 is located on the axis CL of the rotary shaft 33. Since the collecting portion 62; 162 is located on the axis CL of the rotary shaft 33 in this manner, the air Fa sent from the axial flow fan 31 can flow relatively evenly over the entire surface of the filter 50; 150.

[0040] 1 and 4B. Third, preferably, in the vehicle air conditioner 10; 100 described above, the collecting portion 62; 162 is located away from the air conditioner 10; 100 in a direction intersecting the axis CL of the rotary shaft 33. For example, if the axis CL of the rotary shaft 33 of the axial fan 31 is tilted with respect to the air flow path 21, the filter 50; 150 can be located with the collecting portion 62; 162 aligned with the axis CL, and the axial fan 31 and the filter 50; 150 can be located substantially on the same axis CL. Alternatively, by locating the collecting portion 62; 162 offset from the axis CL, the desired air flow distribution in the air flow path 21 can be achieved and provided downstream of the filter 50; 150 (on the side opposite the axial fan 31, the cooling heat exchanger 40 side).

[0041] See Figures 5 and 6A to 6C. Fourth, preferably, in the vehicle air conditioner 100 described above, the filter material 160 is pyramidal or conical. When the filter material 160 is viewed along the axis CL of the rotary shaft 33, the collection portion 162 is located at the most downstream side of the filter material 160. In this way, since the collection portion 162 of the pyramidal or conical filter material 160 is located at the most downstream side, the air Fa sent from the axial fan 31 can be smoothly collected at the collection portion 162. As a result, the bias in the wind speed distribution across the entire surface of the filter 150 can be more sufficiently suppressed.

[0042] See Figures 2 and 6. Fifth, preferably, in the vehicle air conditioner 10; 100 described in any one of the first to fourth aspects, the filter material 60; 160 is surrounded by a rectangular or circular frame 70 when viewed along the axis CL of the rotary shaft 33. By surrounding the filter material 60; 160 with the rectangular or circular frame 70 in this way, the pleats 61 can be firmly held without being biased, and the filter material 60; 160 can be configured to fit the shape of the air flow path 21 and stably attached.

[0043] As long as the functions and effects of the present invention are achieved, the present invention is not limited to the embodiments. For example, the vehicle air conditioners 10, 100 of the embodiments can be combined with each other. [Industrial Applicability]

[0044] The vehicle air conditioners 10, 100 of the present invention are suitable for installation in vehicles such as passenger cars. [Explanation of symbols]

[0045] 10,100 Vehicle air conditioning equipment 20 Duct 21 Air flow path 30 Blower unit 31 Axial flow fan 33 Rotation axis 36 Electric motor 50,150 filters 60,160 Filter media 61 pleats 61a Mountain fold 61b Valley fold 62,162 Assembly area 70 Frame CL Axis of the rotating shaft De pleat depth

Claims

1. A vehicle air conditioner (10; 100) comprising: a duct (20) having an air flow path (21) formed therein; an air blowing unit (30) provided in the air flow path (21); and a filter (50) arranged in the air flow path (21) downstream of the air blowing unit (30), The air blowing unit (30) is configured by an axial flow fan (31) having an axis (CL) of a rotation shaft (33) extending along the air blowing path (21), The filter (50) has a filter material (60; 160) on which mountain-valley pleats (61) are formed, The filter medium (60; 160) has pleats (61) extending radially from a gathering portion (62; 162) where the pleats (61) are gathered, When the filter material (60; 160) is viewed along the axis (CL) of the rotation shaft (33), a pleat depth (De) formed by mountain folds (61 a) and valley folds (61 b) of the pleats (61) becomes deeper in the radial direction of the axis (CL) as it approaches the collection portion (62; 162).

2. 2. The vehicle air conditioning system according to claim 1, wherein the collection portion (62; 162) is located on the axis (CL) of the rotary shaft (33).

3. 2. The vehicle air conditioning system according to claim 1, wherein the collection portions (62; 162) are positioned apart from each other in a direction intersecting the axis (CL) of the rotation shaft (33).

4. The filter medium (60; 160) is pyramidal or conical, 2. The vehicle air conditioning system according to claim 1, wherein when the filter material (60; 160) is viewed along the axis (CL) of the rotation shaft (33), the collection portion (62; 162) is located at the most downstream side of the filter material (60; 160).

5. The vehicle air conditioning device according to any one of claims 1 to 4, wherein the filter material (60; 160) is surrounded by and fixed to a rectangular or circular frame body (70) when viewed along the axis (CL) of the rotating shaft (33).

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