Fan component, fan, fan unit, air conditioner, heat pump device, and method for manufacturing fan component

Abstract

To provide a fan member capable of suitably integral-molding a porous member and a resin member while maintaining a noise reduction effect of the porous member, a fan, a fan unit, an air conditioner, a heat pump device and a method for manufacturing the fan member.SOLUTION: A fan member 40 comprises a porous member 41 having a plurality of pores, and a resin member 42 molded integrally with the porous member 41. A melt flow rate (MFR) of resin constituting the resin member 42 is equal to or larger than 2 g / 10 min and is equal to or less than 45 g / 10 min. Some of the plurality of pores are filled with the resin.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a fan component, a fan, a fan unit, an air conditioner, a heat pump device, and a method for manufacturing a fan component. [Background technology]

[0002] It is known to use a porous member for the fan components in order to reduce the noise of the fan unit during rotation. Patent Document 1 discloses a fan having a porous member. When the fan rotates, the pores of the porous member allow airflow to pass from the top surface to the bottom surface of the fan. Therefore, the fan having a porous member reduces the noise of the fan unit during rotation.

[0003] Furthermore, as a method for manufacturing a fan component having a porous member, a method of integrally molding a porous member and a resin member is known. Patent Documents 2 and 3 disclose, as an example, a method using insert molding in which a porous member is fixed in a mold and resin is injected into the mold. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2021-134751 [Patent Document 2] Japanese Patent Application Publication No. 4-012199 [Patent Document 3] Japanese Utility Model Application Publication No. 6-025597 Summary of the Invention [Problem to be solved by the invention]

[0005] When insert molding a porous member as in Patent Document 2 and Patent Document 3, there is a problem that the resin flows into the pores of the porous member, filling the pores of the porous member with the resin. If the pores of the porous member are lost, there is a risk that the porous member will not be able to provide a sufficient noise reduction effect.

[0006] An object of the present disclosure is to provide a fan component, a fan, a fan unit, an air conditioner, a heat pump device, and a method for manufacturing a fan component that can suitably integrally mold a porous component and a resin component while maintaining the noise reduction effect of the porous component. [Means for solving the problem]

[0007] A fan component according to a first aspect of the present invention solves this problem. The fan component comprises a porous member having a plurality of pores, and a resin member molded integrally with the porous member, wherein the melt flow rate (MFR) of the resin constituting the resin member is not less than 2 g / 10 min and not more than 45 g / 10 min, and some of the plurality of pores are filled with the resin.

[0008] According to this configuration, since the melt flow rate (MFR) of the resin is 45 g / 10 min or less, the number of pores in the porous member filled with the resin can be reduced, and therefore the porous member and the resin member can be suitably molded integrally while maintaining the noise reduction effect of the porous member.

[0009] A fan member according to a second aspect is the fan member according to the first aspect, wherein the resin has a melt flow rate (MFR) of not less than 5 g / 10 min and not more than 40 g / 10 min. With this configuration, since the resin has a melt flow rate (MFR) of not more than 40 g / 10 min, the number of pores in the porous member filled with the resin can be reduced.

[0010] A fan member according to a third aspect is the fan member according to the second aspect, wherein the fan member is formed from a resin having a melt flow rate (MFR) of 5 g / 10 min or more and 35 g / 10 min or less. With this configuration, since the melt flow rate (MFR) of the resin is 35 g / 10 min or less, the number of pores in the porous member filled with the resin can be reduced.

[0011] A fan member according to a fourth aspect is the fan member according to any one of the first to third aspects, wherein the flow resistance of the porous member is not less than 0.5 kPa and not more than 1.1 kPa. With this configuration, since the flow resistance of the porous member is not less than 0.5 kPa and not more than 1.1 kPa, it is possible to maintain the noise reduction effect due to the porous structure while integrally molding the porous member with the resin member.

[0012] A fan member according to a fifth aspect is the fan member according to any one of the first aspect to the fourth aspect, wherein the porosity of the porous member is 20% or more and 90% or less, and the pore diameter of the porous member is 50 μm or more and 500 μm or less. With this configuration, since the porosity of the porous member is 20% or more and 90% or less, and the pore diameter of the porous member is 50 μm or more and 500 μm or less, it is possible to further reduce the pores of the porous member that are filled with resin.

[0013] A fan member according to a sixth aspect is the fan member according to the fifth aspect, wherein the porosity of the porous member is 30% or more and 90% or less, and the pore diameter of the porous member is 90 μm or more and 300 μm or less. With this configuration, since the porosity of the porous member is 30% or more and 90% or less, and the pore diameter of the porous member is 90 μm or more and 300 μm or less, it is possible to further reduce the pores of the porous member that are filled with resin.

[0014] A fan member according to a seventh aspect is the fan member according to any one of the first aspect to the sixth aspect, wherein the porous member has a hole filling portion, and the plurality of pores of the porous member are filled with the resin in the hole filling portion. According to this configuration, the pores of the porous member are filled with resin in the filling portion, so that the porous member can be suitably joined to the resin member.

[0015] A fan member according to an eighth aspect is the fan member according to any one of the first to seventh aspects, wherein the porous member has a central portion and a peripheral portion located around the central portion, the peripheral portion having a flow resistance different from the flow resistance of the central portion. According to this configuration, by making the flow resistance of the central portion and the flow resistance of the peripheral portion different in the porous member, it is possible to suitably control the bonding condition between the porous member and the resin member.

[0016] A fan member according to a ninth aspect is a fan member comprising a porous member and a resin member integrally molded with the porous member, the porous member having a porosity of 20% or more and 90% or less and a pore diameter of 50 μm or more and 500 μm or less. With this configuration, the porous member has a porosity of 20% or more and 90% or less and a pore diameter of 50 μm or more and 500 μm or less, so that the number of pores in the porous member filled with resin can be reduced. Therefore, the porous member and the resin member can be suitably molded integrally while maintaining the noise reduction effect of the porous member.

[0017] A fan according to a tenth aspect is configured using the fan component according to any one of the first aspect to the ninth aspect. According to this configuration, it is possible to provide a fan configured using the fan component.

[0018] A fan unit according to an eleventh aspect includes the fan according to the tenth aspect and a bellmouth. According to this configuration, a fan unit including a fan and a bellmouth can be provided.

[0019] An air conditioner according to a twelfth aspect includes the fan unit according to the eleventh aspect. According to this configuration, it is possible to provide an air conditioner including a fan unit.

[0020] A heat pump device according to a thirteenth aspect includes the fan unit according to the eleventh aspect. According to this configuration, it is possible to provide a heat pump device including a fan unit.

[0021] A manufacturing method according to a fourteenth aspect is a manufacturing method of a fan member including a porous member having a plurality of pores and a resin member molded integrally with the porous member, and includes a step of insert molding the porous member with a resin having a melt flow rate (MFR) of 2 g / 10 min or more and 45 g / 10 min or less. According to this configuration, since the melt flow rate (MFR) of the resin is 2 g / 10 min or more and 45 g / 10 min or less, when the porous member is insert molded, the resin is unlikely to flow into the pores of the porous member. Since the resin is unlikely to flow into the pores of the porous member, the pores of the porous member are likely to be maintained. By using a resin with such a melt flow rate (MFR), the porous member can be suitably insert molded while maintaining the noise reduction effect of the porous member. [Brief description of the drawings]

[0022] [Figure 1] FIG. 2 is a schematic diagram of the outdoor unit. [Diagram 2] FIG. [Diagram 3] FIG. 2 is a close-up view of a fan blade. [Figure 4] FIG. 2 is a schematic diagram showing a flow resistance measuring device. [Diagram 5] 5A to 5C are schematic diagrams illustrating steps in a method for manufacturing a fan component. [Figure 6] 5A to 5C are schematic diagrams illustrating steps in a method for manufacturing a fan component. [Figure 7] FIG. 4 is a diagram showing the relationship between the porosity, pore diameter, and flow resistance of a porous member. [Figure 8] FIG. 4 is a diagram showing the relationship between the porosity, pore size, and noise reduction effect of a porous member. [Figure 9] FIG. 13 is a diagram showing the noise reduction effect of a fan member relative to the MFR of a resin constituting the resin member, for each flow resistance of a porous member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] <Embodiment> An air conditioner 10A, a fan unit 20, a fan 30, a fan component 40, and a method for manufacturing the fan component 40 according to the embodiment will be described with reference to Figs.

[0024] <Air conditioner> As shown in Fig. 1, the air conditioner 10A of this embodiment is a device that adjusts the temperature of indoor air using a vapor compression refrigeration cycle. The air conditioner 10A of this embodiment includes an outdoor unit 10 and an indoor unit (not shown). Note that the air conditioner is not necessarily limited to a device that adjusts the temperature of indoor air using a vapor compression refrigeration cycle, and is a concept that includes, for example, an air purifier, a ventilation device, etc.

[0025] <Outdoor unit> The outdoor unit 10 is an outdoor unit 10 of an air conditioner 10A. The air conditioner 10A cools or heats indoor spaces, such as a house, an office, etc. The air conditioner 10A may cool or heat indoor spaces, such as a space in a warehouse where goods are stored, or a work space where goods are handled.

[0026] Fig. 1 is a schematic diagram of an outdoor unit 10 as viewed from the front. In the example of Fig. 1, a vertically-installed outdoor unit 10 is illustrated, but the outdoor unit 10 may be a horizontally-installed type. The outdoor unit 10 is connected to an indoor unit of an air conditioner 10A, for example, by a communication pipe. The indoor unit is provided with devices such as an indoor expansion valve and an indoor heat exchanger.

[0027] The outdoor unit 10 includes, for example, a lower unit 11. The lower unit 11 has a lower casing 12. The lower casing 12 is provided with components of a refrigerant circuit, such as a compressor, an outdoor heat exchanger, an outdoor expansion valve, an accumulator, an oil separator, and a control device having electronic components for controlling the refrigerant circuit. The air conditioner 10A includes a fan unit 20. The outdoor unit 10 includes the fan unit 20. The fan unit 20 is connected to, for example, the lower unit 11. An indoor unit of the air conditioner 10A may include the fan unit 20.

[0028] <Fan unit> The fan unit 20 includes a fan 30 and a bellmouth 21. In this embodiment, the fan 30 is arranged so that the central axis of rotation extends in the vertical direction. The fan unit 20 is configured, for example, so that air sucked in from the lower unit 11 is blown upwards through the bellmouth 21 by the fan 30. The bellmouth 21 in this embodiment is arranged so that the air flow KR passes through it from bottom to top. The bellmouth 21 has a cylindrical portion 21A provided around the fan 30. The cylindrical portion 21A is made of, for example, resin.

[0029] The fan unit 20 includes, for example, a motor 22 and a fan casing 23. A rotating shaft of the motor 22 is connected to the fan 30 so as to rotate the fan 30. The motor 22 is housed in, for example, a motor case.

[0030] The fan casing 23 is disposed, for example, on the upper part of the lower casing 12. The fan casing 23 houses, for example, the fan 30, the bellmouth 21, and the motor 22. The fan casing 23 has, for example, an air outlet 23A through which air blown out from the bellmouth 21 passes, and a support part 23B that supports the air outlet 23A. The fan casing 23 is made of, for example, resin.

[0031] <Fan> As shown in Fig. 2, the fan 30 of this embodiment is an axial flow fan. The fan 30 may be a centrifugal fan. The fan 30 includes a hub 31 and blades 32 provided around the hub 31. The hub 31 is formed in a cylindrical shape. The hub 31 is formed integrally with the blades 32. The hub 31 is formed with a shaft hole 31A to which a rotating shaft of the motor 22 is attached.

[0032] A plurality of blades 32 are arranged on the hub 31 at a fixed angular interval from each other in the circumferential direction. In this embodiment, the number of the blades 32 is three, but the number of the blades 32 may be less than three or more than three. The blades 32 are arranged so as to spread radially outward from the hub 31 in the rotation radius direction of the fan 30. Adjacent blades 32 do not overlap with each other in a front or rear view of the fan 30. The blades 32 are formed in a plate shape that is smoothly curved along the rotation radius direction and the rotation direction. The blades 32 have the same shape.

[0033] <Fan components> 1 and 2, the fan unit 20 includes a fan member 40. The fan member 40 is disposed in the fan unit 20 so as to reduce noise generated in the fan unit 20 by contacting the airflow KR. The member of the fan unit 20 that comes into contact with the airflow KR is formed by, for example, the fan member 40. In this embodiment, the fan 30 is formed by the fan member 40.

[0034] The fan member 40 includes a porous member 41 and a resin member 42 molded integrally with the porous member 41. The fan member 40 is formed by the resin member 42. In this embodiment, the blade 32 is configured by the porous member 41 and the resin member 42. The porous member 41 is disposed, for example, on the blade surface 32A of each blade 32. The blade surface 32A is, for example, a surface disposed so as to face the airflow KR. The thickness of the porous member 41 is approximately the same as the thickness of the resin member 42. The location where the porous member 41 is disposed is not limited to the blade 32. The hub 31 may be configured to include the porous member 41.

[0035] The fan member 40 is formed by insert molding the porous member 41 into the resin 42A (see FIG. 6) that forms the resin member 42. The porous member 41 is formed, for example, from a porous body. Examples of materials for forming the porous member 41 include resin, ceramics, and metal. Examples of resin include foamed resin. Specific examples of the resin porous member 41 include a foamed polystyrene resin (PS), a foamed ABS resin, a foamed acrylic styrene (AS), and a foamed polypropylene (PP). The porous member 41 may be formed from a foamed glass fiber reinforced styrene-acetallonitrile resin (ASG). A ceramic or metal porous sintered body can also be used as the porous member 41. A metal mesh can also be used as the porous member 41.

[0036] The porous member 41 has a plurality of pores. Some of the plurality of pores are filled with resin 42A. The porous member 41 has a porous structure. The porous structure has through holes that penetrate the blade 32 in the thickness direction. The through holes of the porous structure penetrate the blade 32 in the thickness direction by connecting the plurality of pores contained in the porous member 41. The pores allow the air flow KR to pass through. When the air flow KR passes through the pores of the porous member 41, noise caused by the fan unit 20 is reduced.

[0037] The resin member 42 is configured, for example, so that the air flow KR cannot flow therethrough. The resin member 42 is configured, for example, of a resin 42A. The resin member 42 is configured, for example, of a thermoplastic resin. The resin member 42 is configured, for example, of a polystyrene resin, an ABS resin, a glass fiber reinforced styrene-acrylonitrile resin (ASG), or a glass fiber reinforced polypropylene resin (PPGF).

[0038] The porous member 41 is formed, for example, from the same type of resin as the resin member 42. When the porous member 41 is a foam made of polystyrene resin, the resin member 42 is made of polystyrene resin. When the porous member 41 is a foam made of ABS resin, the resin member 42 is made of ABS resin. When the porous member 41 is a foam made of acrylic styrene, the resin member 42 is made of glass fiber reinforced styrene-acetallonitrile resin. When the porous member 41 is a foam made of polypropylene, the resin member 42 is made of glass fiber reinforced polypropylene resin. The porous member 41 may be formed from a different type of resin from the resin member 42, or may be formed from a material different from the resin.

[0039] When the porous member 41 is made of the same material as the resin member 42, the porous member 41 and the resin member 42 are likely to adhere to each other when the resin member 42 flows into the pores of the porous member 41 during insert molding of the fan member 40. The adhesion between the porous member 41 and the resin member 42 can improve the bonding strength between the porous member 41 and the resin member 42 during insert molding.

[0040] 3 and 6, the parameter indicating the ease of flow of the resin 42A into the porous member 41 includes, for example, the melt flow rate (MFR) of the resin 42A under predetermined conditions. For example, the larger the MFR, the easier the resin 42A flows into the porous member 41 during insert molding. The MFR is, for example, the melt mass-flow rate. The predetermined conditions are, for example, test conditions in accordance with ISO 1133. As an example, when the resin member 42 is a polystyrene resin, the predetermined conditions for measuring the MFR of the resin 42A are a temperature of 200° C. and a load of 5 kg in accordance with ISO 1133.

[0041] Under the specified conditions, the MFR of the resin 42A constituting the resin member 42 is 2 g / 10 min or more and 45 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 2 g / 10 min or more and 40 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 2 g / 10 min or more and 35 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 2 g / 10 min or more and 30 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 5 g / 10 min or more and 45 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 5 g / 10 min or more and 40 g / 10 min or less. Under the specified conditions, the MFR of the resin 42A may be 5 g / 10 min or more and 35 g / 10 min or less. The MFR of the resin 42A under the predetermined conditions may be 5 g / 10 min or more and 25 g / 10 min or less. The MFR of the resin 42A under the predetermined conditions may be 7 g / 10 min or more and 16.5 g / 10 min or less. The MFR of the resin 42A under the predetermined conditions may be 7 g / 10 min, or the MFR of the resin 42A under the predetermined conditions may be 16.5 g / 10 min. As an example, when the resin 42A is a polystyrene resin, the predetermined conditions for measuring the MFR of the resin 42A are a temperature of 200° C. and a load of 5 kg in accordance with ISO 1133. When the MFR of the resin 42A is 2 g / 10 min or more and 45 g / 10 min or less, the resin 42A is less likely to flow through the porous member 41.

[0042] The parameter indicating the ease of flow of the resin 42A through the porous member 41 includes, for example, the flow resistance of the porous member 41. For example, the greater the flow resistance of the porous member 41, the more difficult it is for the resin 42A to flow through the porous member 41 during insert molding. The flow resistance of the porous member 41 is adjusted, for example, in the formation stage of the porous member 41. The flow resistance of the porous member 41 is adjusted, for example, by the pulverized particle size of the material constituting the porous member 41.

[0043] In the embodiment, the flow resistance of the porous member 41 indicates how difficult it is for air to flow in the porous structure of the porous member 41. For example, the greater the flow resistance of the porous member 41, the more difficult it is for the air flow KR to pass through the porous member 41. When the flow resistance of the porous member 41 is large, the pore diameter of the porous member 41 tends to be small or the porosity of the porous member 41 tends to be low, so that the resin 42A becomes difficult to flow through the porous member 41.

[0044] FIG. 4 shows an example of a measuring device 60 for measuring the flow resistance of the porous member 41. The measuring device 60 is a jig for measuring the flow resistance of a test piece 61. The measuring device 60 has a first case 62 and a second case 63. The first case 62 constitutes a first chamber 64. The second case 63 constitutes a second chamber 65. The first chamber 64 and the second chamber 65 communicate with each other through a communication hole 66. The communication hole 66 is provided so as to penetrate the first case 62 and the second case 63. The test piece 61 is placed in the communication hole 66. The test piece 61 has a porous structure having a through hole penetrating from the first chamber 64 to the second chamber 65. Air can move between the first chamber 64 and the second chamber 65 by passing through the porous structure of the test piece 61.

[0045] The measuring device 60 has a first flow path 67, a second flow path 68, and a blower 69. The first flow path 67 is connected to the first chamber 64 so as to communicate the first chamber 64 with the outside of the first case 62. The second flow path 68 is connected to the second chamber 65 so as to communicate the second chamber 65 with the outside of the second case 63. The first flow path 67, the first chamber 64, the second chamber 65, and the second flow path 68 form an air flow path 70 in the measuring device 60. The blower 69 sends air from the first flow path 67 to the measuring device 60. The air sent by the blower 69 flows through the air flow path 70. The air that has flowed through the air flow path 70 flows out of the measuring device 60 from the second flow path 68.

[0046] The measurement device 60 has a first flow meter 71 and a second flow meter 72. The first flow meter 71 and the second flow meter 72 are, for example, air flow meters. The first flow meter 71 is configured to measure the amount of air passing through the first flow path 67. The second flow meter 72 is configured to measure the amount of air passing through the second flow path 68.

[0047] The measuring device 60 has a first differential pressure gauge 73 and a second differential pressure gauge 74. The first differential pressure gauge 73 and the second differential pressure gauge 74 are, for example, pressure gauges. The first differential pressure gauge 73 is configured to measure the pressure in the first chamber 64. The second differential pressure gauge 74 is configured to measure the pressure in the second chamber 65. In a state in which air is blown into the measuring device 60 by the blower 69, the difference between the pressure in the first chamber 64 and the pressure in the second chamber 65 is the flow resistance of the test piece 61.

[0048] The measuring device 60 is configured so that when the airflow rate of the first flow path 67 is 100 L / min, the difference between the airflow rate of the first flow path 67 and the airflow rate of the second flow path 68 is less than 1% of the airflow rate of the first flow path 67. The first case 62 and the second case 63 are configured so that air cannot move between the first chamber 64 and the second chamber 65 from a portion other than the communication hole 66. The test piece 61 is arranged so as to be sandwiched between the first case 62 and the second case 63. At this time, the portion where the first case 62 and the test piece 61 contact each other and the portion where the second case 63 and the test piece 61 contact each other are sealed by packing so that air does not leak. The air passing area on the surface of the test piece 61 is set to be the same regardless of the type of the test piece 61. The area of ​​the test piece 61 exposed to the first chamber 64 is set to be the same regardless of the type of the test piece 61. The area of ​​the test piece 61 exposed to the second chamber 65 is set to be the same regardless of the type of the test piece 61. The blower 69 is configured to ensure a flow rate of 100 L / min regardless of pressure loss due to the measuring device 60 and the test piece 61 so that the flow rate measured by the first flow meter 71 and the second flow meter 72 is stable.

[0049] The flow resistance of the porous member 41 is, for example, 0.2 kPa or more and 1.2 kPa or less. The flow resistance of the porous member 41 may be, for example, 0.3 kPa or more and 1.1 kPa or less. The flow resistance of the porous member 41 may be, for example, 0.35 kPa or more and 1.0 kPa or less. By setting the flow resistance of the porous member 41 to 0.2 kPa or more, the resin 42A does not easily flow through the porous member 41. On the other hand, by setting the flow resistance of the porous member 41 to 1.2 kPa or less, the resin 42A is appropriately filled into the pores of the porous member 41, so that the resin member 42 can be bonded to the porous member 41.

[0050] The flow resistance of the porous member 41 may be, for example, 0.4 kPa or more and 1.1 kPa or less. The flow resistance of the porous member 41 may be, for example, 0.5 kPa or more and 1.1 kPa or less. By setting the flow resistance of the porous member 41 to 0.4 kPa or more, the porous structure of the porous member 41 is suitably maintained in the fan member 40. By setting the flow resistance of the porous member 41 to 1.1 kPa or less, the resin member 42 can be suitably joined to the porous member 41 while maintaining the porous structure of the porous member 41.

[0051] The flow resistance of the porous member 41 is greater than a value obtained by multiplying the MFR of the resin 42A by the gravitational acceleration and then dividing the multiplied value by the cross-sectional area of ​​the porous member 41. The cross-sectional area of ​​the porous member 41 is the cross-sectional area of ​​the porous member 41 when the blade 32 is viewed from the thickness direction.

[0052] The flow resistance of the porous member 41 is set by the pore diameter and porosity of the porous member 41. The smaller the pore diameter of the porous member 41, the greater the flow resistance of the porous member 41, and the larger the pore diameter of the porous member 41, the smaller the flow resistance of the porous member 41. The smaller the porosity of the porous member 41, the greater the flow resistance of the porous member 41, and the greater the porosity of the porous member 41, the smaller the flow resistance of the porous member 41.

[0053] The pore size of the porous member 41 is, for example, the average pore size of the pores in the porous member 41. The method for measuring the average pore size is not particularly limited, and for example, the average pore size can be measured by a gas adsorption method also known as the BET method. The conditions of the gas adsorption method are, for example, test conditions in accordance with JIS Z8831-2 2010 or ISO 15901-2 2006. The conditions of the gas adsorption method may be test conditions in accordance with JIS Z8830 2013 or ISO 9277 2010. The porosity of the porous member 41 is, for example, the total volume of the pores in the porous member 41 relative to the total volume of the porous member 41.

[0054] The porosity of the porous member 41 is 20% or more and 90% or less, and the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less. The porosity of the porous member 41 may be 30% or more and 90% or less, and the pore diameter of the porous member 41 may be 90 μm or more and 300 μm or less. The porosity of the porous member 41 may be 30% or more and 80% or less, and the pore diameter of the porous member 41 may be 100 μm or more and 200 μm or less.

[0055] As shown in Fig. 3, the porous member 41 has a central portion 43 and a peripheral portion 44. In Fig. 3, the boundary between the central portion 43 and the peripheral portion 44 is indicated by a dashed line. The central portion 43 is a portion of the porous member 41 where the resin 42A does not flow and the porous structure is exposed. In the central portion 43, the pores of the porous member 41 are maintained so that the pores of the porous member 41 form through holes in the porous member 41 after the fan member 40 is insert molded.

[0056] The area of ​​the central portion 43 is, for example, 2400 mm 2 Above 6200mm 2 The area of ​​the central portion 43 is, for example, 2800 mm 2 Above 5800mm 2 The area of ​​the central portion 43 may be, for example, 3200 mm 2 Above 5400mm 2The area of ​​the central portion 43 is, for example, the area of ​​the central portion 43 of the porous member 41 disposed on one blade 32.

[0057] The peripheral portion 44 is located around the central portion 43, for example. The peripheral portion 44 is a portion of the porous member 41 through which the resin 42A flows. After the fan member 40 is insert-molded, the peripheral portion 44 may or may not maintain the pores of the porous member 41. The width D1 of the peripheral portion 44 is, for example, 2 mm or more and 6 mm or less. The width D1 of the peripheral portion 44 is, for example, 2.5 mm or more and 5.5 mm or less. The width D1 of the peripheral portion 44 is, for example, 3 mm or more and 5 mm or less. The width D1 of the peripheral portion 44 is, for example, the length from the end of the central portion 43 to the end of the porous member 41. The width D1 of the peripheral portion 44 is, for example, the shortest length among the lengths from the end of the central portion 43 to the end of the porous member 41.

[0058] The pore diameter of the peripheral portion 44 may be the same as the pore diameter of the central portion 43, or may be smaller than the pore diameter of the central portion 43. The porosity of the peripheral portion 44 may be the same as the pore diameter of the central portion 43, or may be smaller than the porosity of the central portion 43. In this embodiment, when the pore diameter of the peripheral portion 44 is the same as the pore diameter of the central portion 43, the porosity of the peripheral portion 44 is smaller than the porosity of the central portion 43. In this embodiment, when the porosity of the peripheral portion 44 is the same as the porosity of the central portion 43, the pore diameter of the peripheral portion 44 is smaller than the pore diameter of the central portion 43.

[0059] The flow resistance of the peripheral portion 44 is different from the flow resistance of the central portion 43. In this embodiment, the flow resistance of the peripheral portion 44 is greater than the flow resistance of the central portion 43. The flow resistance of the peripheral portion 44 is set to be different from the flow resistance of the central portion 43 when the porous member 41 is formed. Since the flow resistance of the peripheral portion 44 is greater than the flow resistance of the central portion 43, the resin 42A is less likely to flow beyond the peripheral portion 44 into the central portion 43 when the fan member 40 is insert molded. The flow resistance of the peripheral portion 44 may be greater than the flow resistance of the central portion 43 because the pores are compressed and the porosity is reduced when the porous member 41 is compressed by the mold 50 during insert molding (see FIG. 6).

[0060] As shown in FIG. 3, the porous member 41 has a hole filling portion 45. In the hole filling portion 45, the multiple pores of the porous member 41 are filled with resin 42A. The hole filling portion 45 is a portion that is formed by the resin 42A permeating into the pores of the porous member 41 when the fan member 40 is insert molded. The porous member 41 is connected to the resin member 42 by the hole filling portion 45. The hole filling portion 45 is located around the central portion 43. The hole filling portion 45 may overlap with the peripheral portion 44.

[0061] <Method of manufacturing fan components> As shown in Fig. 3 to Fig. 6, the manufacturing method is a method for manufacturing a fan member 40 including a porous member 41 having a plurality of pores and a resin member 42 molded integrally with the porous member 41. The manufacturing method includes a step of insert molding the porous member 41 with a resin 42A having a melt flow rate (MFR) of 2 g / 10 min or more and 45 g / 10 min or less. The fan member 40 is molded by, for example, insert molding. In Figs. 5 and 6, the right side of the figures corresponds to the hub 31 side of the blade 32 in the direction of the rotation radius. The left side of the figures corresponds to the outer end side of the blade 32 in the direction of the rotation radius. The manufacturing method includes a first step, a second step, and a third step.

[0062] The first step is a step of placing the porous member 41 in the mold 50. Fig. 5 shows a state in which the porous member 41 is placed in the mold 50 in the first step. The mold 50 is provided with pins 52 to be inserted into holes 51. In the first step, the pins 52 are placed so as to protrude from the holes 51. The porous member 41 is placed in the mold 50 so as to contact the pins 52.

[0063] The second step is a step of pressing the porous member 41 with a mold 50. In the second step, the porous member 41 is compressed in the thickness direction by the mold 50 so that the thickness of the porous member 41 is reduced from the first dimension W1 to a second dimension W2. The compression amount of the porous member 41 is set based on, for example, the flow resistance of the porous member 41 after compression.

[0064] The third step is a step of insert molding the porous member 41 with the resin 42A. As shown by the arrow in FIG. 6, the resin 42A is injected into the mold 50 from the right side of FIG. 6. In the step of injecting the resin 42A, the movement of the porous member 41 is suppressed by the pins 52. When the resin 42A fills the mold 50, the pins 52 are pressed into the holes 51 by the pressure of the resin 42A. Traces 52A of the pins 52 may remain on the resin member 42 after the insert molding (see FIG. 3). If the porous member 41 can be arranged in the mold 50 so that the porous member 41 does not move relative to the mold 50 during the insert molding, the holes 51 and the pins 52 may be omitted from the mold 50.

[0065] <Noise reduction effect of porous materials> The noise reduction effect of the fan member 40 is obtained by arranging the porous member 41 so that the airflow KR passes through the pores of the porous member 41. If the pores of the porous member 41 are too small or the porosity of the porous member 41 is too low, the airflow KR cannot pass through the pores of the porous member 41, and therefore a sufficient noise reduction effect cannot be obtained. If the pores of the porous member 41 are large or the porosity of the porous member 41 is high, the amount of the airflow KR passing through the pores of the porous member 41 increases. If the amount of the airflow KR passing through the pores of the porous member 41 increases, there is a risk that the original boosting effect of the fan 30 cannot be obtained. In order to maintain a sufficient noise reduction effect as well as to obtain the original boosting effect of the fan 30, the flow resistance of the porous member 41 is set based on the pore diameter and porosity of the porous member 41.

[0066] 7, the flow resistance value of the porous member 41 is mapped against the pore size and porosity of the porous member 41. In FIG. 7, the line where the flow resistance is 0.2 kPa is displayed by a dashed line. In a region where the flow resistance of the porous member 41 is 0.2 kPa or more, the resin 42A does not easily flow into the porous member 41 during insert molding. In a region where the flow resistance of the porous member 41 is 0.2 kPa or more, not only does the resin 42A not easily flow into the porous member 41 during insert molding, but the fan 30 can obtain a suitable pressure increase effect.

[0067] 8, the value of the noise reduction effect of the porous member 41 is mapped against the pore size and porosity of the porous member 41. The value of the noise reduction effect is, for example, the sound pressure at which the porous member 41 can reduce noise. In a region where the pore size of the porous member 41 is 50 μm or more and 500 μm or less and the porosity of the porous member 41 is 20% or more and 90% or less, the porous member 41 can maintain the noise reduction effect. The noise reduction effect is quantified as the noise level of the fan 30 provided with the porous member 41 compared to the noise level of the fan 30 without the porous member 41 in a fan 30 of the same shape.

[0068] 8, the region where the flow resistance is 0.2 kPa or more, the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less, and the porosity of the porous member 41 is 20% or more and 90% or less is indicated by a two-dot chain line. In the region indicated by the two-dot chain line, not only can the noise reduction effect be maintained, but also the fan 30 can obtain a suitable pressure increase effect.

[0069] FIG. 9 shows the ratio of the noise reduction effect of the fan member 40 to the MFR of the resin 42A constituting the resin member 42 when the flow resistance of the porous member 41 is 0.4 kPa, 0.5 kPa, 0.8 kPa, or 1.1 kPa. In order to obtain the data of FIG. 9, a plurality of test fans 30 are created. Specifically, the plurality of test fans 30 are formed by fan members 40 in which the flow resistance of the porous member 41 and the MFR of the resin 42A constituting the resin member 42 are different. The plurality of test fans 30 have the same shape. The porous members 41 of the fan members 40 constituting each of the plurality of test fans 30 are made of the same material so as to have different flow resistances. The resin members 42 of the fan members 40 constituting each of the plurality of test fans 30 are made of the same type of resin 42A with different MFRs. The porous members 41 of the fan members 40 constituting the test fans 30 are made of a foam of glass fiber reinforced styrene-acetallonitrile resin (ASG). The resin member 42 of the fan component 40 constituting the test fan 30 is made of glass fiber reinforced styrene-acetallonitrile resin (ASG). The data in Fig. 9 was obtained by measuring the noise generated when each of the test fans 30 rotated.

[0070] The noise reduction effect ratio in Fig. 9 is the ratio of the value of the noise reduction effect of the test fan 30 at each value of the MFR of the resin 42A to the maximum value of the noise reduction effect of the test fan 30 when the flow resistance of the porous member 41 is a predetermined value. According to Fig. 9, when the flow resistance of the porous member 41 is 1.1 kPa, the noise reduction effect reaches its maximum value when the MFR of the resin 42A is 25 g / 10 min. When the flow resistance of the porous member 41 is 1.1 kPa, and the MFR of the resin 42A is 35 g / 10 min, the fan 30 achieves a noise reduction effect of about 80% or more of the maximum value of the noise reduction effect.

[0071] As the MFR of resin 42A increases, resin 42A tends to flow more easily into the through-holes of porous member 41 during insert molding, which tends to reduce the noise reduction effect of fan member 40. In areas where the flow resistance of porous member 41 is large and the MFR of resin 42A is small, it is difficult to form fan 30, which may result in variation in the noise reduction effect of fan member 40.

[0072] The fan member 40 can obtain a noise reduction effect when the flow resistance of the porous member 41 is in the range of 0.4 kPa to 0.8 kPa and the MFR of the resin 42A is in the range of 2 g / 10 min to 45 g / 10 min. The fan member 40 can obtain a noise reduction effect of 20% or more of the maximum noise reduction effect when the flow resistance of the porous member 41 is in the range of 0.4 kPa to 1.1 kPa and the MFR of the resin 42A is in the range of 5 g / 10 min to 40 g / 10 min. Preferably, the fan member 40 can obtain a noise reduction effect of 30% or more of the maximum noise reduction effect when the flow resistance of the porous member 41 is in the range of 0.5 kPa to 1.1 kPa and the MFR of the resin 42A is in the range of 5 g / 10 min to 40 g / 10 min.

[0073] <Operation of the embodiment> The operation of this embodiment will now be described. In this embodiment, fan member 40 includes resin member 42 formed of resin 42A having an MFR of 2 g / 10 min or more and 45 g / 10 min or less. Resin 42A with an MFR of 45 g / 10 min or less does not easily flow into pores of porous member 41 during insert molding using resin 42A.

[0074] In one example of the fan member 40 of this embodiment, the flow resistance of the porous member 41 is 0.5 kPa or more and 1.1 kPa or less. In FIG. 7, the case where the flow resistance is 0.5 kPa and the case where the flow resistance is 1.1 kPa are shown by dashed lines. In FIG. 7, the range of the flow resistance from 0.5 kPa or more to 1.1 kPa or less is shown by the area between the dashed lines. When the flow resistance is 1.1 kPa or less, the resin 42A can flow through the porous member 41 during insert molding with the resin 42A. Therefore, in the fan member 40, the porous member 41 and the resin member 42 can be suitably joined. On the other hand, when the flow resistance is 0.5 kPa or more, the porous structure of the porous member 41 is maintained to an extent that the fan member 40 can obtain the noise reduction effect due to the porous structure during insert molding with the resin 42A.

[0075] The porous member 41 of this embodiment has a flow resistance such that the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less, and the porosity of the porous member 41 is 20% or more and 90% or less. Since the flow resistance of the porous member 41 is sufficiently large, the resin 42A does not easily flow through the porous member 41. The fan member 40 can not only maintain a sufficient noise reduction effect, but also makes it difficult for the resin 42A to flow into the pores of the porous member 41 during insert molding.

[0076] The porous member 41 of this embodiment has a peripheral portion 44. During insert molding of the fan member 40, the resin 42A first flows into the peripheral portion 44 and then flows through the peripheral portion 44 toward the central portion 43. Since the peripheral portion 44 of this embodiment has a width D1, it is possible to prevent the resin 42A from flowing into the central portion 43. The resin 42A flows into the peripheral portion 44, thereby forming a hole filling portion 45 in the porous member 41. Since the resin 42A flows into the pores in the hole filling portion 45, the porous member 41 and the resin member 42 are suitably joined by the hole filling portion 45.

[0077] <Effects of the embodiment> The effects of this embodiment will be described. (1) The fan member 40 includes a porous member 41 and a resin member 42. The MFR of resin 42A constituting the resin member 42 is 2 g / 10 min or more and 45 g / 10 min or less. Some of the pores of the porous member 41 are filled with resin 42A.

[0078] According to this configuration, since the MFR of the resin 42A is 45 g / 10 min or less, the number of pores in the porous member 41 filled with the resin 42A can be reduced. Therefore, the porous member 41 and the resin member 42 can be suitably molded integrally while maintaining the noise reduction effect of the porous member 41.

[0079] When the resin member 42 has an MFR of 45 g / 10 min or less, the resin 42A does not easily flow into the pores of the porous member 41 when the resin member 42 is molded integrally with the porous member 41. Since the resin 42A does not easily flow into the pores of the porous member 41, the pores of the porous member 41 are easily maintained.

[0080] When the MFR of the resin 42A is greater than 45 g / 10 min, the resin 42A flows easily into the mold 50, and the injection time during insert molding can be shortened. However, when the MFR of the resin 42A is too large, the resin 42A flows not only into the peripheral portion 44 of the porous member 41 but also into the central portion 43 of the porous member 41 during insert molding. When the resin 42A flows into the central portion 43 of the porous member 41, the resin 42A fills the pores in the central portion 43, and the pores of the porous member 41 become smaller. The reduced pores in the porous member 41 may reduce the noise reduction effect of the porous member 41. When the MFR of the resin 42A is less than 45 g / 10 min, the resin 42A can be prevented from penetrating into the central portion 43 of the porous member 41 during insert molding.

[0081] The MFR of the resin 42A may be 2 g / 10 min or more and 40 g / 10 min or less. With this configuration, the resin 42A is less likely to flow into the pores of the porous member 41, so that the pores of the porous member 41 are more likely to be maintained.

[0082] The MFR of the resin 42A may be 2 g / 10 min or more and 35 g / 10 min or less. With this configuration, the resin 42A is less likely to flow into the pores of the porous member 41, so that the pores of the porous member 41 are more likely to be maintained.

[0083] If the MFR of resin 42A is less than 2 g / 10 min, resin 42A does not flow easily inside mold 50 during insert molding, making it difficult to form fan component 40. If the MFR of resin 42A is too small, it is even more difficult for resin 42A to form fan component 40 when fan component 40 is to be made thinner. If the MFR of resin 42A is 2 g / 10 min or more, resin 42A can flow easily inside mold 50 during insert molding, making it possible to easily form fan component 40.

[0084] Resin 42A may have an MFR of not less than 5 g / 10 min and not more than 45 g / 10 min. This configuration allows resin 42A to flow more efficiently inside mold 50 during insert molding, thereby making it possible to more efficiently form fan member 40.

[0085] Moreover, according to this configuration, the pores to be filled with the resin 42A are appropriately set among the multiple pores of the porous member 41. By setting the MFR in this manner, it is possible to improve the bonding strength between the porous member 41 and the resin member 42 while maintaining the noise reduction effect due to the porous structure of the porous member 41.

[0086] (2) The MFR of resin 42A is 5 g / 10 min or more and 40 g / 10 min or less. With this configuration, since resin 42A has an MFR of 40 g / 10 min or less, the number of pores in porous member 41 filled with resin 42A can be reduced. Furthermore, when resin 42A has an MFR of 5 g / 10 min or more, resin 42A can flow favorably inside mold 50 during insert molding, and fan member 40 can be formed more favorably.

[0087] (3) The MFR of resin 42A is 5 g / 10 min or more and 35 g / 10 min or less. With this configuration, since resin 42A has an MFR of 35 g / 10 min or less, the number of pores in porous member 41 filled with resin 42A can be reduced. Furthermore, when resin 42A has an MFR of 5 g / 10 min or more, resin 42A can flow favorably inside mold 50 during insert molding, and fan member 40 can be formed more favorably.

[0088] (4) The flow resistance of the porous member 41 is 0.5 kPa or more and 1.1 kPa or less. With this configuration, since the flow resistance of the porous member 41 is 0.5 kPa or more, the number of pores in the porous member 41 filled with the resin 42A can be reduced. Meanwhile, since the flow resistance of the porous member 41 is 1.1 kPa or less, the resin 42A can be filled into the pores of the porous member 41 to the extent that the porous member 41 and the resin member 42 are integrated together. In this way, since the flow resistance of the porous member 41 in the fan member 40 is 0.5 kPa or more and 1.1 kPa or less, the porous member 41 can be molded integrally with the resin member 42 while maintaining the noise reduction effect due to the porous structure.

[0089] (5) The porosity of the porous member 41 is 20% or more and 90% or less, and the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less. With this configuration, the porosity of the porous member 41 is 20% or more and 90% or less, and the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less, so that the number of pores in the porous member 41 filled with the resin 42A can be reduced.

[0090] By increasing the flow resistance of the porous member 41, the resin 42A can be made difficult to flow into the porous member 41. Since the resin 42A is difficult to flow into the porous member 41, the resin 42A is difficult to flow into the pores of the porous member 41. By reducing the porosity and pore diameter so as to increase the flow resistance of the porous member 41, the pores of the porous member 41 can be easily maintained when the porous member 41 is molded integrally with the resin member 42. The porous member 41 having a porosity of 20% or more and 90% or less and a pore diameter of 50 μm or more and 500 μm or less can maintain the noise reduction effect as well as the flow resistance that makes it difficult for the resin 42A to flow into the pores of the porous member 41.

[0091] When the pore diameter of the porous member 41 is less than 50 μm, the noise reduction effect of the porous member 41 decreases. When the pore diameter of the porous member 41 is greater than 500 μm, the flow resistance of the porous member 41 decreases, so that the resin 42A easily flows into the pores of the porous member 41 during insert molding. When the porosity of the porous member 41 is less than 20%, the noise reduction effect of the porous member 41 decreases. When the porosity of the porous member 41 is greater than 90%, the flow resistance of the porous member 41 decreases, so that the resin 42A easily flows into the pores of the porous member 41 during insert molding.

[0092] (6) The porosity of the porous member 41 is 30% or more and 90% or less, and the pore diameter of the porous member 41 is 90 μm or more and 300 μm or less. With this configuration, the porosity of the porous member 41 is 30% or more and 90% or less, and the pore diameter of the porous member 41 is 90 μm or more and 300 μm or less, so that the number of pores in the porous member 41 filled with the resin 42A can be reduced.

[0093] (7) The porous member 41 has a hole filling portion 45. In the hole filling portion 45, the pores of the porous member 41 are filled with the resin 42A. According to this configuration, in the hole filling portion 45, the multiple pores of the porous member 41 are filled with the resin 42A, so that the porous member 41 can be suitably joined to the resin member 42 in the hole filling portion 45.

[0094] (8) The porous member 41 has a central portion 43 and a peripheral portion 44. The flow resistance of the peripheral portion 44 is different from the flow resistance of the central portion 43. According to this configuration, by making the flow resistance of the central portion 43 and the flow resistance of the peripheral portion 44 different in the porous member 41, the bonding condition between the porous member 41 and the resin member 42 can be suitably controlled. In this embodiment, by making the flow resistance of the peripheral portion 44 larger than the flow resistance of the central portion 43, the porous member 41 and the resin member 42 can be bonded only at the peripheral portion 44.

[0095] (9) The fan member 40 includes a porous member 41 and a resin member 42 molded integrally with the porous member 41. The porosity of the porous member 41 is 20% or more and 90% or less, and the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less. With this configuration, the porosity of the porous member 41 is 20% or more and 90% or less, and the pore diameter of the porous member 41 is 50 μm or more and 500 μm or less, so that the number of pores in the porous member 41 filled with the resin 42A can be reduced. Therefore, the porous member 41 and the resin member 42 can be suitably molded integrally while maintaining the noise reduction effect of the porous member 41.

[0096] (10) The fan 30 is made up of the fan components 40. According to this configuration, the fan 30 made up of the fan components 40 can be provided.

[0097] (11) The fan unit 20 includes a fan 30 and a bellmouth 21. According to this configuration, a fan unit 20 including the fan 30 and the bellmouth 21 can be provided.

[0098] (12) The air conditioner 10A includes a fan unit 20. According to this configuration, an air conditioner 10A including a fan unit 20 can be provided.

[0099] (13) The method of manufacturing the fan member 40 includes a step of insert-molding the porous member 41 having a plurality of pores with the resin 42A having an MFR of 2 g / 10 min or more and 45 g / 10 min or less. According to this configuration, since the MFR of the resin 42A is 2 g / 10 min or more and 45 g / 10 min or less, when the porous member 41 is insert-molded, the resin 42A is unlikely to flow into the pores of the porous member 41. Since the resin 42A is unlikely to flow into the pores of the porous member 41, the pores of the porous member 41 are likely to be maintained. By using the resin member 42 having such an MFR, the porous member 41 can be preferably insert-molded while maintaining the noise reduction effect of the porous member 41.

[0100] <Modification> In addition to the above-described embodiments, the air conditioner, fan unit, fan, fan component, and method for manufacturing a fan component of the present disclosure may be configured in the following manner, or in a form that combines at least two of the modified examples that are not mutually contradictory.

[0101] The air conditioner 10A may be an air purifier. The fan unit 20 may constitute an inlet or an outlet of the air purifier. The air purifier, for example, treats the sucked air using a filter, a UV device, an ionizer device, a virus removal spray device, a streamer device, or the like, and then blows out the air. The air purifier is configured to treat the air in an indoor space such as a home or an office. The air purifier may be configured to treat the air in an indoor space such as a space in a warehouse where goods are stored, or a work space where goods are handled.

[0102] The fan unit 20 may be provided in a heat pump device. The heat pump device of this modified example includes the fan unit 20. The heat pump device is, for example, a device having a refrigerant circuit. The heat pump device is, for example, an air conditioner or a water heater. With this configuration, a heat pump device including the fan unit 20 can be provided.

[0103] The member constituted by the fan member 40 is not limited to the fan 30. The bellmouth 21 may be constituted by the fan member 40, and the fan casing 23 may be constituted by the fan member 40. When the fan casing 23 is constituted by the fan member 40, the air outlet 23A or the support portion 23B may be constituted by the fan member 40.

[0104] The predetermined conditions may be test conditions conforming to ISO 1133-1 or ISO 1133-2. The predetermined conditions may be test conditions conforming to JIS K7210-1, JIS K7210-2, or ASTM D1238.

[0105] The MFR may be a melt volume-flow rate (MVR). The MVR is, for example, the product of the melt mass-flow rate of the resin 42A and the melt density of the resin 42A.

[0106] The flow resistance of the peripheral portion 44 may be smaller than the flow resistance of the central portion 43. With this configuration, the resin 42A can easily permeate the peripheral portion 44, improving the bonding strength between the porous member 41 and the resin member 42.

[0107] This specification discloses the following techniques. (C1) A fan member (40) including a porous member (41) and a resin member (42) molded integrally with the porous member (41), the porous member (41) having a central portion (43) and a peripheral portion (44) located around the central portion (43). The flow resistance of the peripheral portion (44) is different from the flow resistance of the central portion (43). (C2) The fan member (40) according to (C1), wherein the porosity of the porous member (41) is not less than 20% and not more than 90%, and the pore diameter of the porous member (41) is not less than 50 μm and not more than 500 μm.

[0108] The above describes embodiments and variations of fan components, fans, fan units, air conditioners, heat pump devices, and methods for manufacturing fan components. However, it will be understood that various changes in form and details are possible without departing from the spirit and scope of the fan components, fans, fan units, air conditioners, heat pump devices, and methods for manufacturing fan components described in the claims. [Explanation of symbols]

[0109] 10A...air conditioner, 10...outdoor unit, 20...fan unit, 21...bell mouth, 30...fan, 40...fan component, 41...porous component, 42...resin component, 42A...resin, 43...central portion, 44...periphery, 45...hole filling portion.

Claims

1. A fan member (40) comprising a porous member (41) having a plurality of pores and a resin member (42) integrally molded with the porous member (41), The melt flow rate (MFR) of the resin (42A) constituting the resin member (42) is 5 g / 10 min or more and 40 g / 10 min or less, The flow resistance of the porous member (41) is 0.5 kPa or more and 1.1 kPa or less, A part of the plurality of pores is filled with the resin (42A). Fan parts.

2. The melt flow rate (MFR) of the resin (42A) is 5 g / 10 min or more and 35 g / 10 min or less. The fan component according to claim 1 .

3. The porosity of the porous member (41) is 20% or more and 90% or less, The pore diameter of the porous member (41) is 50 μm or more and 500 μm or less. The fan component according to claim 1 .

4. The porosity of the porous member (41) is 30% or more and 90% or less, The pore diameter of the porous member (41) is 90 μm or more and 300 μm or less. The fan component according to claim 3 .

5. The porous member (41) has a hole filling portion (45), In the hole filling portion (45), the plurality of pores of the porous member (41) are filled with the resin (42A). The fan component according to claim 1 .

6. The porous member (41) has a central portion (43) and a peripheral portion (44) located around the central portion (43), the flow resistance of said peripheral portion (44) is different from the flow resistance of said central portion (43); The fan component according to claim 1 .

7. A fan member (40) comprising a porous member (41) having a plurality of pores and a resin member (42) integrally molded with the porous member (41), The melt flow rate (MFR) of the resin (42A) constituting the resin member (42) is 2 g / 10 min or more and 45 g / 10 min or less, The porous member (41) has a central portion (43) and a peripheral portion (44) located around the central portion (43), The flow resistance of the peripheral portion (44) is different from the flow resistance of the central portion (43), A part of the plurality of pores is filled with the resin (42A). Fan parts.

8. A fan member (40) comprising a porous member (41) and a resin member (42) integrally molded with the porous member (41), The porosity of the porous member (41) is 20% or more and 90% or less, The pore diameter of the porous member (41) is 50 μm or more and 500 μm or less, The melt flow rate (MFR) of the resin (42A) constituting the resin member (42) is 5 g / 10 min or more and 40 g / 10 min or less, The flow resistance of the porous member (41) is 0.5 kPa or more and 1.1 kPa or less. Fan parts.

9. The fan member (40) according to any one of claims 1 to 8, fan.

10. The fan (30) according to claim 9; A bell mouth (21); Fan unit.

11. The fan unit (20) according to claim 10, Air conditioner.

12. The fan unit (20) according to claim 10, Heat pump equipment.

13. A method for manufacturing a fan member (40) including a porous member (41) having a plurality of pores and a resin member (42) integrally molded with the porous member (41), comprising the steps of: The method includes insert molding the porous member (41) with a resin (42A) having a melt flow rate (MFR) of 5 g / 10 min or more and 40 g / 10 min or less, The flow resistance of the porous member (41) is 0.5 kPa or more and 1.1 kPa or less. Manufacturing method.

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