Air conditioner indoor unit

Abstract

This indoor unit for an air conditioner comprises a heat exchanger, a blower, and a casing. The casing is configured in a box shape that opens toward the indoors, the casing accommodating the heat exchanger and the blower. The shape of the casing is also defined by a structure having an inner layer part that is not exposed to the exterior and an outer layer part that is exposed to the exterior and is arranged adjacent to the inner layer part. The structure is configured such that a first portion and a second portion are present alongside one another. The first portion has a plurality of voids in the inner layer part and the outer layer part. The second portion has voids in the inner layer part and the outer layer part, the density of voids per unit volume in the second portion being lower than that in the first portion. The second portion is arranged at a location to which is applied external force greater than that at the location in the casing where the first portion is arranged.

Description

[Technical field]

[0001] An embodiment of the present invention relates to an indoor unit of an air conditioner. [Background technology]

[0002] For example, in a ceiling-embedded air conditioner, the indoor unit is suspended above the ceiling. The indoor unit has a box-shaped housing (casing) that houses a blower and a heat exchanger, and the bottom end of the housing is closed with a drain pan that catches condensation water that drips from the heat exchanger.

[0003] The drain pan has a bellmouth attachment hole located directly below the blower, and a bellmouth is attached to the bellmouth attachment hole. The bellmouth is an element for straightening the flow of air sucked in by the blower, and its outer periphery is removably fixed to the drain pan. The bellmouth is covered with a panel. The panel is an element that covers the indoor unit from the indoor side, and is disposed in a position along the ceiling. The panel is provided with a grill that shields the intake port that sucks in indoor air, and a louver that changes the blowing direction of air blown into the room from the outlet that blows out the air that has been heat exchanged in the heat exchanger into the room.

[0004] When installing or maintaining an indoor unit, it is necessary to perform tasks such as attaching and removing the housing, panels, etc. Because such work is performed in high places such as the ceiling or above the attic, there is a demand for improving workability by shortening the work time and improving work efficiency. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 3-122425 Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention has been made in light of the above, and an object of the present invention is to provide an indoor unit for an air conditioner that enables improved workability in installation, maintenance, and the like. [Means for solving the problem]

[0007] According to an embodiment, an indoor unit of an air conditioner includes a heat exchanger, a blower, and a housing. The heat exchanger exchanges heat between indoor air and a refrigerant. The blower draws in indoor air and blows the air that has been heat exchanged by the heat exchanger into the room. The housing is configured in a box shape that opens toward the room, and houses the heat exchanger and the blower. The shape of the housing is defined by a structure having an inner layer that is not exposed to the outside, and an outer layer that is disposed adjacent to the inner layer and is exposed to the outside. The outer layer portions form a pair with the inner layer portion sandwiched therebetween in the thickness direction of the structure, and cover the entire inner layer portion to form a surface portion of the structure. The inner layer portions are sandwiched between the pair of surface portions of the structure to form the inside of the structure. The structure is configured by mixing a first portion and a second portion. The first portion is the inner layer portion and the outer layer portion. and the inner layer and the outer layer each have The second portion has a plurality of voids. The inner layer portion and the outer layer portion are both included, The density of the voids per unit volume is lower than that of the first portion. Applicable Inner layer and Applicable On the outer layer Each of them has multiple The first portion has the gap and is disposed at a location on the housing where a larger external force acts than at a location on the housing where the first portion is disposed. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of an indoor unit of a ceiling-embedded type air conditioner. [Diagram 2] FIG. 2 is a plan view showing the state in which the drain pan and the bell mouth are assembled into the housing of the unit body. [Diagram 3] FIG. 3 is a plan view showing a state in which the drain pan and the bell mouth have been removed from the housing of the unit body. [Figure 4] FIG. 4 is a cross-sectional view taken along line A2-A2 in FIG. [Diagram 5] FIG. 5 is a cross-sectional view that diagrammatically shows the internal structure of a structure that defines the shapes of at least some of the components that make up the indoor unit according to the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view that diagrammatically shows the internal structure of a structure that defines the shapes of at least some of the components that make up the indoor unit according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. (First embodiment) Figures 1 to 4 show the configuration of an indoor unit of an air conditioner according to this embodiment. Figure 1 is a perspective view of an indoor unit of a ceiling-embedded type air conditioner. Figure 2 is a plan view showing a state in which a drain pan and a bell mouth are incorporated into a housing of a unit body, which will be described later. Figure 3 is a plan view showing a state in which the drain pan and the bell mouth are removed from a housing of a unit body, which will be described later. Figure 4 is a cross-sectional view taken along line A2-A2 in Figure 2.

[0010] As shown in Figures 1 and 2, an indoor unit 1 of an air conditioner comprises, as its main elements, a unit body 2 installed above the ceiling, and a panel (hereinafter referred to as a ceiling panel) 3 attached to the lower end of the unit body 2. The unit body 2 comprises a housing 4. The housing 4 is a box-shaped element that opens downward, and is suspended from a beam above the ceiling via, for example, four suspension bolts (not shown).

[0011] The housing 4 includes a top plate portion 4a and a side portion 4b. The side portion 4b is continuous in the circumferential direction of the housing 4 and has four outer peripheral corners 4c. As shown in Fig. 4, the inner surfaces of the top plate portion 4a and the side portion 4b are covered with a heat insulating material 5 made of, for example, polystyrene foam. The heat insulating material 5 defines an opening 6 at the lower end of the housing 4.

[0012] Hanging metal fittings 7 are fixed to the outer circumferential corners 4c of the housing 4. The hanging metal fittings 7 protrude horizontally toward all four sides of the housing 4, and the lower ends of the hanging bolts are connected to the hanging metal fittings 7.

[0013] Furthermore, four brackets 8 are fixed to the housing 4. The brackets 8 are located at the lower ends of the outer circumferential corners 4c of the housing 4 so as to be located directly below the hanging metal fittings 7. The brackets 8 protrude horizontally towards all four sides of the housing 4.

[0014] As shown in FIG. 2, FIG. 3, and FIG. 4, the housing 4 houses a blower 10 and a heat exchanger 11. The blower 10 draws in air from the space to be air-conditioned, that is, the room, and blows the air that has been heat-exchanged by the heat exchanger 11 into the room. A so-called centrifugal fan that draws in air from the axial direction and blows it out in the circumferential direction is used as the blower 10. The blower 10 has a fan drive unit 10a and a fan unit 10b. The fan drive unit 10a is, for example, a motor, and is fixed to the top plate unit 4a of the housing 4 via a heat insulating material 5, and rotates the rotating shaft 10c. The fan unit 10b has a plurality of blades 10d arranged at a predetermined pitch in the circumferential direction, and is attached concentrically to the tip of the rotating shaft 10c to rotate together with the rotating shaft 10c. The upper end of the fan unit 10b is covered by the top plate unit 4a of the housing 4, so that the lower end of the fan unit 10b is the suction side.

[0015] The heat exchanger 11 exchanges heat between the air in the space to be air-conditioned, that is, the air in the room, and the refrigerant, thereby air-conditioning the room. The heat exchanger 11 stands upright inside the housing 4 so as to surround the blowing side of the blower 10. The heat exchanger 11 includes a plurality of heat dissipation fins 12 and a plurality of heat transfer tubes 13 through which the refrigerant flows. The heat dissipation fins 12 are elongated plates extending in the height direction of the housing 4, and are arranged at intervals from each other in the circumferential direction of the housing 4. The heat transfer tubes 13 are arranged at intervals from each other in the height direction and the lateral direction of the housing 4, and are connected in series to each other to form a plurality of flow paths. Furthermore, the heat transfer tubes 13 are thermally connected to the heat dissipation fins 12 by penetrating the heat dissipation fins 12.

[0016] 3, refrigerant pipes 14 connected to heat exchanger 11 are concentrated in a space between one outer circumferential corner 4c of housing 4 and heat exchanger 11. Refrigerant pipes 14 are connected to a pair of connection ports 16a, 16b. Connection ports 16a, 16b protrude from one outer circumferential corner 4c of housing 4 to the outside of housing 4, and are connected to an outdoor unit of an air conditioner via liquid pipes and gas pipes.

[0017] Furthermore, a drain pump 17 is housed inside the housing 4. The drain pump 17 is an element for discharging condensation water generated by the heat exchange action of the heat exchanger 11 to the outside of the unit body 2 when the indoor unit 1 is in cooling operation. The drain pump 17 is disposed at the lower end of the housing 4, near the outer circumferential corner 4c adjacent to the other outer circumferential corner 4c where the connection ports 16a, 16b are provided. A drain pipe 18 connected to the drain pump 17 is routed above the drain pump 17 through the inside of the housing 4.

[0018] As shown in Figs. 2 and 4, the opening 6 at the bottom end of the housing 4 is closed by a drain pan 20. The drain pan 20 is an element for receiving condensation water generated by the heat exchange action of the heat exchanger 11. The drain pan 20 includes a main body 21 having thermal insulation properties and a sheet material 22 laminated integrally on the surface of the main body 21. The main body 21 is an element that defines the shape of the drain pan 20. The sheet material 22 is made of a synthetic resin material having a thickness of, for example, several millimeters, and has higher rigidity than the main body 21. The synthetic resin material that makes up the sheet material 22 is, for example, ABS resin.

[0019] Drain pan 20 is configured, for example, in a square frame shape corresponding to heat exchanger 11, and is fitted inside opening 6 defined by insulating material 5 of housing 4. Drain pan 20 has a circular bell-mouth mounting hole 23 located directly below the suction side of blower 10, and a peripheral portion 24 surrounding bell-mouth mounting hole 23. Peripheral portion 24 of drain pan 20 is fitted inside opening 6 of housing 4.

[0020] The peripheral portion 24 of the drain pan 20 is formed with four notches 26 and a recess 27 into which the lower end of the heat exchanger 11 fits. The notches 26 each have an elongated shape extending along the four sides of the peripheral portion 24 of the drain pan 20. The notches 26 adjacent to each other in the circumferential direction of the drain pan 20 are maintained in a positional relationship such that they are perpendicular to each other. The peripheral portion 24 of the drain pan 20 is fitted inside the opening 6 defined by the insulating material 5, so that the area surrounded by the notches 26 and the insulating material 5 forms a plurality of communication ports 28 into which the air that has passed through the heat exchanger 11 is guided.

[0021] Recessed portion 27 is a groove-like element that continues in the circumferential direction of drain pan 20, and is located more inward of drain pan 20 than cutout portion 26. Recessed portion 27 is defined by an inner circumferential wall 29a, an outer circumferential wall 29b, and a bottom wall 29c. Inner circumferential wall 29a stands up from bottom wall 29c so as to surround bellmouth mounting hole 23. In other words, inner circumferential wall 29a can be said to be a partition wall interposed between bellmouth mounting hole 23 and recessed portion 27.

[0022] Furthermore, a bulging portion 31 that bulges toward the lower end of the heat exchanger 11 is formed in the center of the bottom wall 29c. The bulging portion 31 is formed continuously in the circumferential direction of the drain pan 20 so as to follow the lower end of the heat exchanger 11. A cushioning material 32 that supports the lower end of the heat exchanger 11 is layered on the upper surface of the bulging portion 31.

[0023] Such a drain pan 20 is removably supported at the bottom end of the housing 4 via four drain pan fixing metal fittings 38 as shown in Fig. 2. The drain pan fixing metal fittings 38 are screwed to the bottom surface of the bracket 8. The drain pan fixing metal fittings 38 protrude horizontally from the outer peripheral corners 4c of the housing 4 toward the four corners of the drain pan 20, and the corners of the drain pan 20 are placed on the drain pan fixing metal fittings 38. In this way, the drain pan 20 is held at the bottom end of the housing 4 so as not to fall out of the opening 6 of the housing 4.

[0024] 1 and 2, an electrical component unit 40 is supported on the front surface of the side portion 4b of the housing 4. The electrical component unit 40 includes an electric component box 41 exposed to the outside of the housing 4, and a control board 42 housed in the electric component box 41. The control board 42 has various electric components 43, such as a wiring board on which a plurality of IC chips are mounted, a reactor, and a terminal block. The control board 42 is electrically connected to the blower 10, the heat exchanger 11, the drain pump 17, and the like, via a plurality of lead wires.

[0025] 2 and 4, a bell mouth 53 is removably fitted into the bell mouth mounting hole 23 of the drain pan 20. The bell mouth 53 is an element for rectifying the flow of air sucked in by the blower 10.

[0026] The bellmouth 53 has a bellmouth body 54 having a shape that expands in a trumpet shape downward, for example, and a flange portion 55 that projects horizontally radially outward from the lower end of the bellmouth body 54 and defines the maximum diameter of the bellmouth body 54. The flange portion 55 is formed continuously in the circumferential direction of the bellmouth body 54. Furthermore, at the tip of the flange portion 55, an outer circumferential wall 56 is formed that is bent downward at a right angle.

[0027] The ceiling panel 3 of the indoor unit 1 is disposed so as to follow the ceiling (not shown) of the space to be air-conditioned, and covers the opening 6 at the lower end of the housing 4 from the inside of the room. As shown in Fig. 1, the ceiling panel 3 includes a grill (hereinafter referred to as an intake grill) 80 and a frame 81.

[0028] The intake grille 80 is located in the center of the ceiling panel 3, rotatably supported by a frame body 81, and is an element that shields an intake port (a working opening 87 described below) that draws indoor air into the housing 4. The intake grille 80 comprises a square outer frame portion 82 and a lattice portion 83 surrounded by the outer frame portion 82. The lattice portion 83 is located directly below the bellmouth 53, and has a removable filter (not shown).

[0029] The frame 81 of the ceiling panel 3 is, for example, a square-shaped element that surrounds the intake grille 80, and has first to fourth sides 85a, 85b, 85c, and 85d and four corners 86a, 86b, 86c, and 86d.

[0030] The first to fourth side portions 85a, 85b, 85c, and 85d each extend along the outer peripheral edge of the outer frame portion 82 of the intake grille 80. The corner portions 86a, 86b, 86c, and 86d are located at the four corners of the ceiling panel 3, and integrally connect the first to fourth side portions 85a, 85b, 85c, and 85d adjacent to each other in the circumferential direction of the frame body 81. A square area surrounded by the inner peripheral edges of the first to fourth side portions 85a, 85b, 85c, and 85d defines a work opening 87. The work opening 87 is an opening portion that exposes the inside of the housing 4 to the room and allows easy cleaning and maintenance of the blower 10 and the heat exchanger 11, for example. The work opening 87 corresponds to an intake port that draws indoor air into the housing 4.

[0031] The ceiling panel 3 is detachably connected to the bracket 8 of the housing 4 at four corners 86a, 86b, 86c, and 86d of the frame 81. As a result, the lower end of the unit body 2, including the drain pan 20 and the bell mouth 53, is covered by the ceiling panel 3.

[0032] The ceiling panel 3 has four air outlets 88 that blow out the air that has been heat exchanged in the heat exchanger 11 into the room. The air outlets 88 are formed in the first to fourth side portions 85a, 85b, 85c, and 85d of the frame body 81 so as to face the four cutout portions 26 of the drain pan 20.

[0033] Four louvers 89 are rotatably supported on the frame body 81 of the ceiling panel 3. The louvers 89 are elements that change the blowing direction of air blown into the room from the air outlet 88, and are formed in the shape of a flat, elongated plate. The louvers 89 are rotatable between a closed position that closes the air outlet 88 and an open position that is inclined so as to open the air outlet 88. When the louvers 89 are rotated to the closed position, the louvers 89 are horizontal and completely cover the first to fourth sides 85a, 85b, 85c, and 85d of the frame body 81.

[0034] For example, the suction grill 80 of the ceiling panel 3 has one side of the outer frame 82 selectively rotatably connected to any one of the first to fourth sides 85a, 85b, 85c, and 85d of the frame body 81. Therefore, the suction grill 80 is rotatable between a first position that closes the above-mentioned working opening and a second position that opens the working opening. Furthermore, when the suction grill 80 is rotated to the second position, the suction grill 80 can be removed from the frame body 81.

[0035] Among the various components constituting the indoor unit 1 described above, the shapes of at least some of the components are determined by the following structures. In other words, such components are shaped by the structures.

[0036] FIG. 5 is a cross-sectional view showing a schematic internal structure of the structure of some of the components. For example, the structure 90 shown in FIG. 5 defines the shape of the housing 4. As shown in FIG. 5, the structure 90 of the housing 4 has an inner layer 90a and an outer layer 90b. The inner layer 90a is a portion of the structure 90 that is not exposed to the outside, and corresponds to the inside of the structure 90. The outer layer 90b is disposed adjacent to the inner layer 90a and is a portion of the structure 90 that is exposed to the outside, and corresponds to the surface of the structure 90. That is, the outer layer 90b covers the entire inner layer 90a. FIG. 5 shows a schematic internal layer 90a and an outer layer 90b in a portion of the structure 90, and in the illustrated example, the outer layer 90b is disposed in a pair with the inner layer 90a sandwiched therebetween.

[0037] Thus, the structure 90 having the inner layer portion 90a and the outer layer portion 90b is configured by mixing the first portion 91 and the second portion 92. The first portion 91 has a plurality of voids 93 in each of the inner layer portion 90a and the outer layer portion 90b. Similarly, the second portion 92 has a plurality of voids 93 in each of the inner layer portion 90a and the outer layer portion 90b. The voids 93 are gaps between the walls (solid portions) 94 of the inner layer portion 90a and the outer layer portion 90b, that is, regions where no walls 94 exist. For example, the voids 93 are bubbles filled with air. The voids 93 in the outer layer portion 90b are partially open to the outside and correspond to depressions in the surface portion of the structure 90.

[0038] In the example shown in FIG. 5, the multiple voids 93 are all the same in size and shape, but they may be different. The multiple voids 93 may be arranged regularly or irregularly. In the example shown in FIG. 5, the multiple voids 93 in the first portion 91 are arranged regularly, and the voids 93 in the second portion 92 are arranged irregularly. Note that the inside of some of the voids 93 may be substantially vacuum or may be filled with liquid. Alternatively, the inside of the voids 93 may be filled with a mixture of air and liquid.

[0039] The structure 90 is formed, for example, by foaming a material obtained by adding a reinforcing material to a synthetic resin as a base material during the injection molding process. The reinforcing material reinforces the wall portions 95 that partition the air bubbles that are the voids 93, in other words, the area surrounding the voids 93 in the solid portion 94. For example, the reinforcing material is ultrafine fibers. The wall portions 95 of the voids 93 are reinforced by adding the reinforcing material, so that the bubbles are prevented from breaking during molding. Therefore, for example, finer voids 93 can be formed and the density of the voids 93 (foaming ratio) can be increased. Furthermore, the strength (rigidity) of the structure 90 is increased by reinforcing the wall portions 95.

[0040] The first portion 91 and the second portion 92 have different densities of voids 93 per unit volume. As shown in FIG. 5, specifically, the second portion 92 has a lower density of voids 93 per unit volume than the first portion 91. That is, the second portion 92 has voids 93 at a lower density per unit volume than the first portion 91. In this way, the first portion 91 is a region where the voids 93 are dense (dense void portion), and the second portion 92 is a region where the voids 93 are sparse (sparse void portion). For example, when the multiple voids 93 have almost the same shape, the density of the voids 93 is taken as the number of voids 93 per given volume. The ratio of the densities of the voids 93 in the first portion 91 and the second portion 92 per unit volume can be expressed as the ratio of the numbers of the voids 93 in these portions 91 and 92.

[0041] The first portion 91 and the second portion 92 are disposed in a mixed manner in various portions of the structure 90, i.e., the housing 4. The second portion 92 is disposed in a location on the housing 4 where a larger external force acts than the location of the first portion 91. In this embodiment, the second portion 92 is disposed in a specific location on the housing 4 where a relatively large external force acts. In contrast, the first portion 91 is disposed in a location on the housing 4 other than the specific location.

[0042] The specific location is, for example, a location where the heat exchanger 11 is fixed to the housing 4 shown in FIG. 4, and a location where the fan drive unit 10a of the blower 10 is fixed to the housing 4. Specifically, the fixing parts 4d and 4e of the top plate part 4a correspond to the specific location. The fixing part 4d is located continuously near the outer periphery of the top plate part 4a in correspondence with the arrangement of the heat exchanger 11. The external force acting on the fixing part 4d is, for example, a force applied by the weight of the heat exchanger 11. The fixing part 4e is located near the center of the top plate part 4a in correspondence with the arrangement of the fan drive unit 10a. The external force acting on the fixing part 4e is, for example, a force applied by the weight of the blower 10 including the fan drive unit 10a and vibration during driving of the fan drive unit 10a. That is, the fixing parts 4d and 4e are directly subjected to external forces such as the force due to the weight of the heat exchanger 11 and the blower 10, and the force due to the vibration of the fan drive part 10a when it is driven. Therefore, the influence of the external force on the fixing parts 4d and 4e is relatively large compared to other parts.

[0043] The non-specific locations are, for example, locations where the heat exchanger 11 is fixed to the housing 4 shown in FIG. 4 and locations where the fan drive unit 10a of the blower 10 is fixed to the housing 4. Specifically, locations of the top plate 4a other than the fixed parts 4d and 4e (non-fixed parts indicated by reference numeral 4f in FIG. 4), the side parts 4b, and the outer circumferential corners 4c (see FIGS. 1 to 3) correspond to the non-specific locations. The non-fixed parts 4f are not directly subjected to, for example, forces due to the weight of the heat exchanger 11 and the blower 10, and forces due to vibrations during the operation of the fan drive unit 10a, as opposed to the fixed parts 4d and 4e. Therefore, the influence of external forces on the non-fixed parts 4f, the side parts 4b, and the outer circumferential corners 4c is relatively smaller than that on the fixed parts 4d and 4e.

[0044] Thus, according to this embodiment, the fixed parts 4d and 4e in the housing 4, which are subjected to a relatively large external force, can be made into areas with dense gaps 93 (dense gap parts), and the non-fixed parts 4f, the side parts 4b, and the outer peripheral corner parts 4c, which are subjected to a relatively small external force, can be made into areas with sparse gaps 93 (sparse gap parts). In other words, the solid parts 94 can be reduced by the amount of the gaps 93 while maintaining strength (rigidity) against external forces, thereby reducing the weight of the housing 4. As a result, even when the indoor unit 1 is installed at a high place such as a ceiling or a space above the ceiling, the lightweight housing 4 can reduce the work time and improve the work efficiency, thereby making it possible to improve workability.

[0045] Here, the components other than the housing 4 of the indoor unit 1, such as the drain pan 20, the bell mouth 53, the panel 3, the grill 80, and the louvers 89, are not subjected to external forces acting on the fixed parts 4d and 4e of the housing 4. Therefore, the shapes of some or all of the components other than the housing 4 may be defined as a structure having a gap 93 similar to the first part (gap-tight part) 91 arranged in the non-fixed part 4f of the housing 4. This allows the drain pan 20, the bell mouth 53, the panel 3, the grill 80, the louvers 89, etc. to be reduced in weight while maintaining their strength (rigidity). Therefore, the reduced weight makes it easier to perform, for example, maintenance of these components. This in turn makes it possible to shorten the work time and improve the work efficiency, thereby improving the workability.

[0046] In this embodiment, as shown in the example of FIG. 5, in the first portion 91 and the second portion 92, the air bubbles, which are the multiple voids 93, do not communicate with each other between the inner layer portion 90a and the outer layer portion 90b, but exist independently of each other. However, as shown in FIG. 6, these voids may communicate with each other between the inner layer portion 100a and the outer layer portion 100b. Hereinafter, a form in which the voids communicate with each other in this way will be described as the second embodiment. The basic configuration of the indoor unit of the air conditioner according to the second embodiment is the same as the indoor unit 1 according to the first embodiment (FIGS. 1 to 4). Therefore, in the following, the description of the basic configuration of the indoor unit will be omitted or simplified, and the differences from the first embodiment, which are the characteristics of the second embodiment, will be described in detail. In this case, the same reference symbols will be used for components that are the same or similar to those in the first embodiment, and the description will be omitted or simplified.

[0047] Second embodiment FIG. 6 is a cross-sectional view showing the internal structure of at least some of the components constituting the indoor unit 1 in the structure 100. For example, the housing 4, the drain pan 20, the bell mouth 53, the panel 3, the grill 80, and the louvers 89 can be used as the structure 100. The structure 100 has an inner layer portion 100a and an outer layer portion 100b, similar to the structure 90 (FIG. 5). The inner layer portion 100a is a portion of the structure 100 that is not exposed to the outside, and corresponds to the inside of the structure 100. The outer layer portion 100b is disposed adjacent to the inner layer portion 100a, and is a portion of the structure 100 that is exposed to the outside, and corresponds to the surface portion of the structure 100. Similarly to the structure 90, the structure 100 is configured by mixing a first portion 91 and a second portion 92.

[0048] As shown in FIG. 6, in this embodiment, the multiple voids 96 of the structure 100 communicate with each other between the inner layer portion 100a and the outer layer portion 100b. The voids 96 are voids relative to the meat (solid portion) 97, that is, regions where the meat 94 does not exist, and are, for example, bubbles filled with air. In this embodiment, the multiple voids 96, that is, the bubbles, communicate with each other to form an aggregate (hereinafter, referred to as a void group) 98. The void group 98 is formed by each wall portion 99 that partitions the multiple bubbles, that is, the regions surrounding the multiple voids 96 in the solid portion 97, which are continuously formed. As a result, the void group 98 is configured as a space larger than each of the voids 96 partitioned from the solid portion 97 by the multiple wall portions 99, that is, as multiple continuous bubbles.

[0049] Among the voids 96 forming the void group 98, the voids 96 in the outer layer portion 100b are partially open to the outside, and serve as a communication opening 98a to the void group 98 in the surface portion of the structure 100. The communication opening 98a is an inlet leading to the multiple voids 96 forming the void group 98, that is, multiple continuous bubbles. That is, in the example shown in FIG. 6, the multiple voids 96 are in a state of communication from one outer layer portion 100b through the inner layer portion 100a to the other outer layer portion 100b. In other words, the void group 98 is in a state in which the multiple voids 96 are in communication from both the outer layer portions 100b to the inner layer portion 100a. As a result, in the structure 100, the wall portions 99 of each void 96 are exposed to the outside through the communication opening 98a in the outer layer portion 100b and the inner layer portion 100a. Thus, structure 100 has an expanded exterior exposed surface area as compared to structure 90 (FIG. 5).

[0050] In the structure 100, such a configuration of the voids 96 can be applied to both the first portion 91 and the second portion 92. As an example, Fig. 6 shows the configuration of the voids 96 in the first portion (void-dense portion) 91. Although not shown, the configuration of the voids 96 in the second portion (void-sparse portion) 92 is such that the voids 96 are interconnected, similar to the first portion 91, except that the density of the voids 96 is low.

[0051] Thus, the structure 100 having the void group 98 can achieve the following effects while reducing the weight of the structure 100. That is, moisture and water can be caused to flow and be absorbed from the outer layer portion 100b to the inner layer portion 100a through the void group 98. In addition, the moisture and water absorbed in the void group 98 can be evaporated through the voids 96 in the outer layer portion 100b, i.e., the communication openings 98a to the void group 98.

[0052] Therefore, by forming the structural elements that are relatively prone to condensation, such as the housing 4, the drain pan 20, the bell mouth 53, the panel 3, the grill 80, and the louvers 89, with the structure 100, the area of ​​each of these structural elements exposed to the outside can be expanded. As a result, even if condensation occurs in the housing 4, the drain pan 20, the bell mouth 53, the panel 3, the grill 80, and the louvers 89, the condensed water can be appropriately stored in the gap group 98 and can be appropriately evaporated. As a result, leakage of condensed water from the indoor unit 1 can be suppressed, and the air conditioning capacity can be improved. For example, the growth of mold caused by condensation on the louvers 89 can be suppressed.

[0053] Furthermore, according to structure 100, the area exposed to the outside is expanded compared to structure 90 (FIG. 5), so that not only moisture and water but also odors, harmful substances, dirt, and the like contained in the indoor air can be adsorbed into void group 98. Therefore, in addition to reducing the weight of structure 100, it is possible to improve the indoor air purification effect, for example, and keep the air quality clean.

[0054] Here, similar to the structure 90, the structure 100 is formed by foaming a material obtained by adding a reinforcing material to a synthetic resin as a base material during the injection molding process. In this embodiment, the base material of the structure 100 is made of a material having a high affinity for water. For example, the affinity of the base material for water may be higher than the components of the indoor unit 1 other than the structure 100 having the void group 98, that is, higher than the base material of the structure that defines the shape of the components.

[0055] For example, the base material of the structure 100 may be a material having a hydrophilic functional group such as a hydroxyl group (-OH group) or an amino group (-NH3), specifically, diatomaceous earth having the functional group. The structure 100 may be formed by foaming a material obtained by adding a reinforcing material to a synthetic resin as the base material during the injection molding process. The reinforcing material may be, for example, ultrafine fibers, and reinforces the wall portion 99 that divides the air bubbles that are the voids 96, in other words, the area surrounding the void group 98 in the solid portion 97. Since the wall portion 99 of the voids 96 is reinforced by adding the reinforcing material, the destruction of the air bubbles during molding is suppressed, as in the first embodiment. Note that the surface of the structure 100 after molding may be subjected to a hydrophilic treatment such as a plasma treatment.

[0056] Alternatively, an organic material may be used as the material contained in the base material of the structure 100. Many of the substances that cause odors, harmful substances, and dirt contained in indoor air are thought to be organic substances. For this reason, these substances are compatible with organic molecules that have a carbon skeleton, such as activated carbon, and are easily bonded to them. Therefore, by using an organic material as the material of the structure 100, it becomes easier to adsorb odors, harmful substances, dirt, and the like contained in the indoor air. As a result, it becomes possible to further enhance the indoor air purification effect and keep the air quality cleaner.

[0057] For example, the bellmouth 53, panel 3, grille 80, louvers 89, etc. can adsorb odors, harmful substances, dirt, etc. contained in the air in the room, thereby improving the indoor air purification effect and maintaining clean air quality. In addition, because these are lighter than before, they can be more easily removed, replaced, and so on. As a result, it is possible to improve the indoor air purification effect and air quality over the long term.

[0058] Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0059] 1... Indoor unit of air conditioner, 2... Unit body, 3... Panel (ceiling panel), 4... Housing, 4a... Top plate portion, 4b... Side portion, 4c... Outer peripheral corner portion, 4d, 4e... Fixed portion, 4f... Non-fixed portion, 6... Opening, 10... Blower, 10a... Fan drive portion, 10b... Fan portion, 10c... Rotating shaft, 10d... Blade, 11... Heat exchanger, 20... Drain pan, 21... Body, 22... Sheet material, 23... Bell mouth mounting hole, 53... Bell mouth, 54... Bell mouth Main body, 55...flange portion, 80...grill (suction grill), 81...frame body, 82...outer frame portion, 83...lattice portion, 87...work opening (suction port), 88...blowout port, 89...louver, 90,100...structural body, 90a,100a...inner layer portion, 90b,100b...outer layer portion, 91...first portion (tight gap portion), 92...second portion (sparse gap portion), 93,96...gap, 94,97...body (solid portion), 95,99...wall portion, 98...group of gaps, 98a...communicating port.

Claims

1. a heat exchanger that exchanges heat between indoor air and a refrigerant; a blower that draws in air from within the room and blows the air that has been heat exchanged in the heat exchanger into the room; a housing having a box shape that opens toward the room and that houses the heat exchanger and the blower; The shape of the housing is defined by a structure having an inner layer portion that is not exposed to the outside and an outer layer portion that is disposed adjacent to the inner layer portion and is exposed to the outside, the outer layer portion forms a pair with the inner layer portion sandwiched therebetween in the thickness direction of the structure, covers the entire inner layer portion, and constitutes a surface portion of the structure; the inner layer portion is sandwiched between the pair of surface portions of the structure to constitute the interior of the structure; the structure is configured by mixing a first portion having both the inner layer portion and the outer layer portion, and a plurality of voids in the inner layer portion and the outer layer portion, and a second portion having both the inner layer portion and the outer layer portion, and a plurality of voids in the inner layer portion and the outer layer portion, with the voids having a lower existence density per same volume than in the first portion; The second portion is disposed at a location on the housing where a larger external force acts than at a location on the housing where the first portion is disposed. Air conditioner indoor unit.

2. A drain pan for receiving condensation water generated by the heat exchange action of the heat exchanger; A bell mouth that is removably fitted into an attachment hole formed in the drain pan and straightens the air drawn by the blower; a panel that has an intake port for drawing in air from within the room and an outlet port for blowing out the air that has been heat exchanged in the heat exchanger, the panel covering an opening of the housing from the inside of the room; a grille rotatably supported on the panel and configured to cover the air inlet; A louver that is rotatably supported on the panel and changes the blowing direction of the air blown out from the air outlet, at least one of the housing, the drain pan, the bell mouth, the panel, the grille, and the louver has a shape defined by the structure constituted by a mixture of the first portion and the second portion; In the structure of the member, the plurality of voids in the first portion communicate with each other between the inner layer portion and the outer layer portion, and the plurality of voids in the second portion communicate with each other between the inner layer portion and the outer layer portion. An indoor unit for an air conditioner according to claim 1.

3. The structure of the member is made of a material having a higher affinity for water than the structure of members other than the member. An indoor unit for an air conditioner according to claim 2.

4. The structure of the member is made of an organic material. An indoor unit for an air conditioner according to claim 2.

5. The material constituting the structure of the member includes a reinforcing agent that reinforces the wall portion that defines the gap.

5. An indoor unit for an air conditioner according to claim 3 or 4.

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