Method for manufacturing component, component, and fan including component

Abstract

To simplify manufacturing of a constituent member provided with a porous member.SOLUTION: A constituent member constitutes an air passage (S2) formed inside a predetermined device (20) and contacts air flowing through the air passage (S2). A method for manufacturing the constituent member includes: a first step for forming an assembly (51) of a plate-shaped porous member (53) and a frame member (52) by fixing the porous member (53) to an inner frame of the frame member (52); and a second step for integrating the assembly (51) and constituent members (41, 62) by providing the assembly (51) in a first region (R) of the constituent members (41, 62).SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a component, the component, and a fan including the component. [Background technology]

[0002] It is known that a porous material is provided on the blades of a propeller fan as a noise reduction measure for a blower. By providing a porous material on the blades, separation of air from the negative pressure surface of the blade is prevented, suppressing the generation of noise. Patent Document 1 discloses a manufacturing method for a propeller fan having such blades. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 4-12199 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, a resin sintering material is filled into a mold that matches the blade surface shape, and sintered to form a porous member, and then the porous member is molded integrally with the blade by injection molding. In this way, since the porous member needs to be sintered to match the blade surface shape, manufacturing the porous member requires a lot of work.

[0005] An object of the present disclosure is to simplify the manufacture of components provided with a porous member. [Means for solving the problem]

[0006] The first aspect is A method for manufacturing a component that constitutes an air passage (S2) formed inside a predetermined device (20) and that comes into contact with air flowing through the air passage (S2), comprising the steps of: a first step of forming an assembly (51) of a plate-shaped porous member (53) and a frame member (52) by fixing the plate-shaped porous member (53) to an inner frame of the frame member (52); The manufacturing method includes a second step of integrating the assembly (51) with the components (41, 62) by providing the assembly (51) in the first region (R) of the components (41, 62).

[0007] In the first aspect, a plate-shaped porous member (53) is used, and there is no need to take the trouble of forming the porous member (53) to match the shape of the first region (R) of the component. This reduces the number of steps required to manufacture the component, and also reduces manufacturing costs.

[0008] The second aspect is the first aspect, The method further includes a third step of forming the frame member (52) to fit the shape of the first region (R).

[0009] In the second aspect, since it is easier to process the frame member to fit the shape of the first region (R) than to process the porous member (53) to fit the first region (R), it is possible to facilitate the manufacture of the components and to reduce variation in the shapes of the components.

[0010] The third aspect is the first or second aspect, The first region (R) is an opening formed in the component (41, 62), The second step is a step of fixing the assembly (51) to the opening.

[0011] In the third embodiment, a component can be created simply by fitting the outer periphery of the assembly (51) into the opening.

[0012] The fourth aspect is the first or second aspect, The second step is a step of integrating the assembly (51) with the components by insert molding.

[0013] In the fourth aspect, the structural member can be easily formed by insert molding.

[0014] A fifth aspect is any one of the first to fourth aspects, The frame member (52) is configured to sandwich the plate-shaped porous member (53) from both sides of the porous member (53).

[0015] In the fifth embodiment, the porous member (53) can be fixed to the inner frame of the frame member (52) by sandwiching the porous member (53) between the frame members (52) from both sides thereof.

[0016] A sixth aspect is any one of the first to fourth aspects, The frame member (52) is configured to cover the outer peripheral edge of the porous member (53).

[0017] In the sixth aspect, since the frame member (52) is formed so as to surround the outer periphery of the porous member (53), the porous member (53) can be stably held within the frame member (52).

[0018] A seventh aspect is any one of the first to fourth aspects, The frame member (52) has a portion formed so as to contact only the side surface of the porous member (53).

[0019] In the seventh embodiment, the frame member (52) has a portion that contacts only the side surfaces of the porous member (53), thereby increasing the surface area of ​​the porous member (53). Furthermore, the larger the portion of the frame member (52) that contacts only the side surfaces of the porous member (53), the larger the surface area of ​​the porous member (53) can be secured.

[0020] The eighth aspect is any one of the first to fourth aspects, The frame member (52) is configured to be fixed to one surface of the plate-shaped porous member (53).

[0021] In the eighth aspect, for example, the porous member (53) and the frame member (52) can be bonded together by applying an adhesive to one side of the porous member (53). Also, the frame member (52) can be fixed to one side of the porous member (53) by a fastening member such as a screw.

[0022] A ninth aspect is any one of the first to seventh aspects, The frame member (52) is made of resin.

[0023] In the ninth embodiment, the frame member (52) can be easily molded.

[0024] A tenth aspect is the eighth aspect, The material from which the frame member (52) is made has the same material as the component member (41).

[0025] In the tenth aspect, the frame member 52 is made of the same material as the component member 41, thereby increasing the strength of adhesion between the frame member 52 and the component member 41. This not only enables the assembly 51 to be stably fixed to the component member 41, but also prevents the assembly 51 from falling off the component member 41.

[0026] An eleventh aspect is any one of the first to tenth aspects, The components (41, 62) are rotor blades (41) or stator blades (62) which constitute the fan (26).

[0027] In the eleventh aspect, by providing the moving blade (41) or the stationary blade (62) with a porous member (53), it is possible to reduce noise caused by airflow generated by the rotation of the blade.

[0028] A twelfth aspect is A component that constitutes an air passage (S2) formed inside a specific device (20) and comes into contact with air flowing through the air passage (S2), The assembly (51) includes a frame member (52) and a porous member (53) fixed to an inner frame of the frame member (52), The assembly (51) is a component provided so as to be integrated with the component in a first region (R) of the component.

[0029] In the twelfth aspect, the component members can suppress the generation of noise caused by the air flowing through the air passage (S2).

[0030] A thirteenth aspect is A fan including the rotor blade (41) or the stator blade (62) according to a twelfth embodiment of the present invention. [Brief description of the drawings]

[0031] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of an air conditioner. [Diagram 2] FIG. 2 is a piping diagram of a refrigerant circuit of the air conditioner. [Diagram 3] FIG. 3 is a cross-sectional view showing the configuration of the outdoor unit. [Figure 4] FIG. 4 is a front view of the fan. [Diagram 5] FIG. 5 is a side view of the fan. [Figure 6] FIG. 6 is a perspective view of the assembly. [Figure 7] FIG. 7 is an exploded perspective view of the assembly. [Figure 8] 8A and 8B are diagrams illustrating the shape of a porous member fixed to a frame member. (a) shows the shape of a porous member without a second short side. (b) shows the shape of a porous member with a second short side. [Figure 9] FIG. 9 is a cross-sectional view taken along line IX-IX in FIG. 4 and an enlarged view of the first region. [Figure 10] FIG. 10 is a perspective view showing a stationary guide of an outdoor unit according to a modified example. [Figure 11] FIG. 11 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. [Figure 12] FIG. 12 is a view corresponding to the enlarged view shown in FIG. 9 of an assembly according to another embodiment. [Figure 13] FIG. 13 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. [Figure 14] FIG. 14 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. [Figure 15] 15 is a cross-sectional view of the assembly shown in FIG. 14 taken along the line XV-XV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Note that the following embodiment is essentially a preferred example, and is not intended to limit the scope of the present invention, its applications, or its uses. Also, each configuration of each embodiment, modification, other example, etc. described below can be combined or partially substituted within the scope in which the present invention can be implemented. Note that "front", "rear", "right", and "left" shown below refer to the directions indicated by the arrows shown in FIG. 3.

[0033] (1) Air conditioning equipment As shown in Figures 1 and 2, the air conditioner (10) includes an outdoor unit (20), an indoor unit (30), a liquid connection pipe (12), and a gas connection pipe (13). The outdoor unit (20) and the indoor unit (30) are connected to each other via the liquid connection pipe (12) and the gas connection pipe (13). These are connected to form a refrigerant circuit. The refrigerant circuit (11) is filled with refrigerant.

[0034] (1-1) Outdoor unit The outdoor unit (20) is installed outdoors. The outdoor unit (20) includes a compressor (21), an outdoor heat exchanger (22), an expansion valve (23), a four-way switching valve (25), and an outdoor fan (26). The outdoor unit (20) is an example of a specified device (20) of the present disclosure.

[0035] The compressor (21) draws in and compresses a low-pressure gas refrigerant. The compressor (21) discharges the compressed refrigerant. The compressor (21) is a variable displacement compressor.

[0036] The outdoor fan (26) delivers outdoor air passing through the outdoor heat exchanger (22). The outdoor heat exchanger (22) exchanges heat between the outdoor air delivered by the outdoor fan (26) and a refrigerant.

[0037] The expansion valve (23) reduces the pressure of the refrigerant and is an electrically operated expansion valve whose opening is adjustable.

[0038] The four-way switching valve (25) switches the flow of refrigerant in the refrigerant circuit (11). Depending on the switching of the four-way switching valve (25), the refrigerant circuit (11) performs a first refrigeration cycle or a second refrigeration cycle.

[0039] (1-2) Indoor unit The indoor unit (30) is installed in a room, which is a space to be air-conditioned. The indoor unit (30) has an indoor heat exchanger (31) and an indoor fan (32). The indoor heat exchanger (31) exchanges heat between the refrigerant and the indoor air. The indoor heat exchanger (31) is a fin-and-tube type air heat exchanger.

[0040] (2) Operation of air conditioning equipment (2-1) Cooling operation In the cooling operation, the four-way switching valve (25) is set to a state in which the refrigerant circuit (11) performs a first refrigeration cycle. In the refrigerant circuit (11), the outdoor heat exchanger (22) functions as a condenser, and the indoor heat exchanger (31) functions as an evaporator. The indoor unit (30) cools air sucked from the indoor space in the indoor heat exchanger (31) and blows the cooled air into the indoor space.

[0041] (2-2) Heating operation In the heating operation, the four-way switching valve (25) is set to a state in which the refrigerant circuit (11) performs the second refrigeration cycle. In the refrigerant circuit (11), the indoor heat exchanger (31) functions as a condenser, and the outdoor heat exchanger (22) functions as an evaporator. The indoor unit (30) heats air drawn from the indoor space in the indoor heat exchanger (31) and blows the heated air into the indoor space.

[0042] (3) Outdoor unit configuration As shown in Fig. 3, the outdoor unit (20) includes a rectangular parallelepiped casing (35). The casing (35) has an inlet (36) and an outlet (37). The inlet (36) is formed on the back and left side surface of the casing (35), and the outlet (37) is formed on the front surface of the casing (35). An outlet grill (38) is provided on the front surface of the casing (35). The outlet grill (38) covers the outlet (37).

[0043] A partition plate (39) is provided in the internal space of the casing (35). The partition plate (39) divides the internal space of the casing (35) into an equipment chamber (S1) on the right side and an air passage (S2) in the remaining portion. The equipment chamber (S1) accommodates the compressor (21) and the like. The air passage (S2) connects the suction port (36) and the air outlet (37). The outdoor heat exchanger (22) and the outdoor fan (26) are disposed in the air passage (S2). In this manner, the air passage (S2) is formed inside the outdoor unit (20).

[0044] The outdoor heat exchanger (22) is formed in an L-shape in a plan view. The outdoor heat exchanger (22) is provided along the back surface and left side surface of the casing (35) and faces the suction port (36). The outdoor fan (26) is provided downstream of the outdoor heat exchanger (22) in the air passage (S2). The outdoor fan (26) is rotatably connected to a fan motor (34) disposed behind the outdoor fan (26).

[0045] (4) Outdoor fan configuration As shown in FIGS. 4 and 5, the outdoor fan (26) is a propeller fan. The outdoor fan (26) is an example of the fan (26) of the present disclosure. The outdoor fan (26) of the present embodiment has one first hub (42) and three rotor blades (41). The number of the rotor blades (41) is an example, and is not limited. The rotor blades (41) form the air passage (S2) and come into contact with the air flowing through the air passage (S2). The rotor blades (41) are an example of the components (41, 62) of the present disclosure. The rotor blades (41) are made of resin. The rotor blades (41) are made of a resin material.

[0046] The first hub (42) is a cylindrical member whose front end is closed. The first hub (42) is disposed coaxially with the drive shaft of the fan motor (34). A boss portion (not shown) is formed at the rear end of the first hub (42). The drive shaft of the motor is connected to the boss portion.

[0047] The three rotor blades (41) are connected to the outer circumferential surface of the first hub (42) and are disposed at equal intervals in the circumferential direction. The three rotor blades (41) are formed so that, when the first hub (42) rotates in the direction of the arrow in FIG. 4, air flows from the back of the page to the front of the page. Specifically, each rotor blade (41) has four edges (41a, 41b, 41c, 41d) each having a different shape. The four edges (41a, 41b, 41c, 41d) are an inner edge (41a), an outer edge (41b), a leading edge (41c), and a trailing edge (41d).

[0048] The inner edge portion (41a) is an edge of the rotor blade (41) that is in contact with the outer circumferential surface of the first hub (42). The inner edge portion (41a) is provided so as to be inclined with respect to the direction of the rotation axis of the first hub (42) from the front end to the rear end of the first hub (42).

[0049] The outer edge portion (41b) is an edge facing the inner edge portion (41a). Like the inner edge portion (41a), the outer edge portion (41b) is also inclined with respect to the rotation axis direction of the first hub (42). The length of the outer edge portion (41b) is longer than the length of the inner edge portion (41a). One end P1 of the outer edge portion (41b) in the rotation direction is located forward of one end Q1 of the inner edge portion (41a). One end P1 of the outer edge portion (41b) is located rearward of the rear end of the first hub (42). The other end P2 of the outer edge portion (41b) in the rotation direction and the other end Q2 of the inner edge portion (41a) in the rotation direction are located on approximately the same radial direction of the hub when the outdoor fan (26) is viewed from the front.

[0050] The leading edge portion (41c) is the edge on the front side in the direction of rotation of the rotor blade (41). The leading edge portion (41c) connects one end P1 of the outer edge portion (41b) and one end Q1 of the inner edge portion (41a). The leading edge portion (41c) is formed so as to curve rearward in the direction of rotation. The trailing edge portion (41d) is the edge on the rear side in the direction of rotation of the rotor blade (41). The trailing edge portion (41d) connects the other end P2 of the outer edge portion (41b) and the other end Q2 of the inner edge portion (41a). The trailing edge portion (41d) is formed so as to curve rearward in the direction of rotation.

[0051] (5) Porous part Each rotor blade 41 is provided with a porous portion 50. The porous portion 50 is made of a porous material having a plurality of continuous fine pores. In this embodiment, the porous material is a resin.

[0052] The porous portion (50) is provided so as to penetrate the rotor blade (41) in the thickness direction. The porous portion (50) is provided in a first region (R) of the rotor blade (41). The first region (R) is a predetermined region of the blade surface. In other words, the porous portion (50) is provided in a part of the rotor blade (41). Specifically, when the outdoor fan (26) rotates, air flows toward the front of the paper. As a result, one surface of the rotor blade (41) becomes a negative pressure surface. The speed of the air flowing along the negative pressure surface becomes slower closer to the rotor blade (41), and the speed distribution becomes non-uniform. This can cause air separation from the rotor blade (41) and generate noise. The first region (R) of this embodiment is provided at a position that can cause the separation. That is, by providing the porous portion (50) in the first region (R), non-uniformity in the speed distribution of the air on the blade surface is suppressed, and separation of the air from the rotor blade (41) is suppressed, and as a result, the generation of noise is suppressed.

[0053] (6) Manufacturing method of outdoor fan Next, a method for manufacturing the outdoor fan (26) will be described. The method for manufacturing the outdoor fan includes a first step of forming an assembly (51) of the porous member (53) and the frame member (52) by fixing the plate-shaped porous member (53) to the inner frame of the frame member (52), and a second step of providing the assembly (51) in the first region (R) of the rotor blade (41) to integrate the assembly (51) with the rotor blade (41). The method for manufacturing the outdoor fan (26) further includes a third step, prior to the first step, of forming the frame member (52) to fit the shape of the first region (R).

[0054] The assembly (51) constitutes the porous section (50). The assembly (51) has a plate-shaped porous member (53) and a frame member (52). The plate-shaped porous member (53) is made of an elastically deformable resin material. The porous member (53) is made of a porous material having a large number of continuous fine pores. The average diameter of the pores (voids) in the porous member (53) is, for example, in the range of 15 μm to 300 μm. The porosity of the porous member (53) (= volume of voids / total volume of the porous member) is, for example, in the range of 35% to 90%.

[0055] 6 to 7, the frame member (52) has a first frame (52a) and a second frame (52b). The first frame (52a) and the second frame (52b) form a pair. Since the first frame (52a) and the second frame (52b) have the same shape, in the following description, the first frame (52a) and the second frame (52b) may not be distinguished from each other and may be simply referred to as the frame member (52).

[0056] The frame member (52) is formed in a generally rectangular shape. Specifically, the frame member (52) has a first long side (54a), a second long side (54b), a first short side (55a), a second short side (55b), and a third short side (55c). The lengths of the first long side (54a) and the second long side (54b) are equal to each other. The lengths of the first short side (55a), the second short side (55b), and the third short side (55c) are equal to each other. The first long side (54a) is longer than the second short side (55b).

[0057] The first short side (55a) connects one ends of the two opposing long sides (54a, 54b). The second short side (55b) connects the midpoints of the two opposing long sides (54a, 54b). The third short side (55c) connects the other ends of the two opposing long sides (54a, 54b).

[0058] The frame member (52) is made of resin. The frame member (52) has the same material as the rotor blade (41). In other words, each of the frames (52a, 52b) is made of the same material as the rotor blade (41). Strictly speaking, the frame member (52) has the same matrix resin as the rotor blade (41). The matrix resin is a resin component that forms the matrix of the frame member (52) and the rotor blade (41). More strictly, the frame member (52) is made of the same resin material as the rotor blade (41). For example, when the rotor blade (41) is made of ASG (glass fiber reinforced styrene-acrylonitrile resin) or ABS resin, each of the frames (52a, 52b) is also made of ASG or ABS, and is not made of PP resin or the like. Specifically, when the rotor blade (41) is made of ABS, each of the frames (52a, 52b) is made of styrene-based rubber.

[0059] Each frame (52a, 52b) is made of a non-porous synthetic resin. Each frame (52a, 52b) is formed to fit the shape of the first region (R) of the rotor blade (41). Therefore, each long side (54a, 54b) and each short side (55a, 55b, 55c) is formed to be curved. Each frame (52a, 52b) is also formed by injection molding. Specifically, each frame (52a, 52b) can be obtained by pouring molten synthetic resin into a mold that matches the shape of the first region (R) and then cooling it. In this manner, the third step is performed.

[0060] Next, the plate-shaped porous member (53) is sandwiched between the first frame (52a) and the second frame (52b) (see FIG. 6). The first frame (52a) and the second frame (52b) may be configured to fit into each other. This allows the porous member (53) to be fixed to the frame member (52) simply by sandwiching the porous member (53) between the first frame (52a) and the second frame (52b). In this way, the assembly (51) can be assembled manually without insert molding. Since each frame (52a, 52b) is formed to have a shape that matches the first region (R), the porous member (53) sandwiched between the pair of frames (52a, 52b) is deformed to have a shape that matches the first region. More specifically, since the outer edge of the porous member (53) is fixed to the frame member (52), normally, as shown in the cross-sectional view of Fig. 8(a), the porous member (53) is supported at two points at both ends and is formed to stretch between the two points, but since the frame member (52) of this embodiment has the second short side (55b), the porous member (53) is supported at three points as shown in the cross-sectional view of Fig. 8(b), and can be formed into a shape that is more suited to the first region (R). That is, the second short side (55b) functions as a support part that supports the porous member (53) inside the frame member (52) and also functions as a shape adjustment part that adjusts the shape of the porous member (53). In this manner, the first step is carried out.

[0061] Finally, the assembly (51) and the outdoor fan (26) are integrated together, as shown in Fig. 9. Specifically, the assembly (51) is attached to the first region (R) of the rotor blade (41) so that the assembly (51) constitutes a part of the rotor blade (41). Since the thickness of the assembly (51) is the same as the thickness of the rotor blade (41) in the first region (R), the rotor blade (41) and the assembly (51) can be made flush with each other (see the enlarged view in Fig. 9). Furthermore, since the assembly (51) is formed in the same shape as the first region (R), it is possible to prevent the assembly (51) from creating a ventilation resistance to the air flowing over the blade surface, and to suppress separation of the air.

[0062] (7) Features (7-1) Feature 1 The manufacturing method for the outdoor fan of this embodiment includes a first step of forming an assembly (51) of the porous member (53) and the frame member (52) by fixing the plate-shaped porous member (53) to the inner frame of the frame member (52), and a second step of integrating the assembly (51) and the components (41, 62) by providing the assembly (51) in the first region (R) of the components (41, 62).

[0063] According to the present embodiment, it is sufficient to use a plate-shaped porous member (53), and there is no need to take the trouble of forming the porous member (53) to fit the shape of the first region (R) of the outdoor fan (26). This reduces the number of steps in manufacturing the outdoor fan (26) and reduces manufacturing costs.

[0064] (7-2) Feature 2 The method of manufacturing the outdoor fan of this embodiment further includes a third step of forming the frame member (52) to fit the shape of the first region (R).

[0065] According to this embodiment, it is easier to process the frame member to fit the shape of the first region (R) than to process the porous member (53) to fit the first region (R). This makes it easier to manufacture the outdoor fan and reduces variation in the shape of each outdoor fan (26).

[0066] (7-3) Feature 3 The second step in this embodiment is a step of fixing the assembly (51) to the opening, which is the first region (R). In this way, the outdoor fan (26) can be produced by simply fitting the outer periphery of the assembly (51) into the opening.

[0067] (7-4) Feature 4 In the present embodiment, the frame member (52) is configured to sandwich the plate-shaped porous member (53) from both sides of the porous member (53). In this way, by sandwiching the porous member (53) from both sides with the frame member (52), the porous member (53) can be fixed to the inner frame of the frame member (52).

[0068] (8) Variations As shown in Fig. 10, the outdoor unit (20) of this modification includes a stationary guide (60). The stationary guide (60) is disposed between the outdoor fan (26) and the inlet (36). The stationary guide (60) has one second hub (61), eleven stator vanes (62), and one peripheral ring (63). The stator vanes (62) are an example of components (41, 62) of the present disclosure.

[0069] The second hub (61) is a cylindrical portion with closed ends. The second hub (61) is disposed substantially coaxially with the first hub (42). The second hub (61) is made of a non-porous resin.

[0070] The outer circumferential ring (63) is a ring-shaped or short cylindrical portion. The outer circumferential ring (63) is disposed substantially coaxially with the second hub (61). The inner diameter of the outer circumferential ring (63) is larger than the outer diameter of the outdoor fan (26). The outer circumferential ring (63) is made of a non-porous resin.

[0071] Each stator vane (62) protrudes from the outer circumferential surface of the second hub (61) and extends radially outward from the second hub (61). Each stator vane (62) is provided from the outer circumferential surface of the second hub to the inner circumferential surface of the outer circumferential ring (63). An inner edge of each stator vane (62) is fixed to the second hub (61), and an outer edge of each stator vane (62) is fixed to the outer circumferential ring. Each stator vane is arranged at regular angular intervals in the circumferential direction of the second hub (61).

[0072] The first region (R) is formed in a part of the stator vane (62). Specifically, an opening is formed in the first region (R) of the stator vane (62). In this modified example, as in the above embodiment, the assembly (51) formed to match the shape of the first region (R) is fitted into the first region (R) (opening), thereby integrating the stator vane (62) and the assembly (51).

[0073] (9) Other embodiments The above embodiment may be configured as follows.

[0074] As shown in FIG. 11, the frame member (52) may have one frame (52a, 52b) instead of a pair of frames (52a, 52b). That is, the frame member (52) may be configured to be fixed to one side of a plate-shaped porous member (53). In this case, for example, the porous member (53) and the frame member (52) can be fixed by applying an adhesive to one side of the plate-shaped porous member (53). Also, the frame member (52) may be fixed to one side of the porous member (53) by a fastening member such as a screw.

[0075] The predetermined device (20) may be any device having an air passage (S2) formed therein. When the predetermined device (20) is, for example, a ceiling-mounted indoor unit (30), the components (41, 62) may be a bellmouth disposed in the air passage, or an indoor fan that is a centrifugal fan. In this manner, the components may be any components that constitute the air passage (S2) and come into contact with the air flowing through the air passage (S2). The components may also be any components that constitute the air passage (S2) or come into contact with the air flowing through the air passage (S2).

[0076] The second step may be a step of integrating the assembly (51) and the fan (26) by insert molding. Specifically, the assembly (51) is placed at a predetermined position in a mold, and the mold is filled with resin. The predetermined position is a position corresponding to the first region (R) of the rotor blade (41). By removing the solidified resin from the mold, the fan (26) having the assembly (51) provided in the first region (R) of the rotor blade (41) can be obtained. In this way, the fan (26) can be easily formed by insert molding.

[0077] The first region (R) is not limited to a location where air separation occurs, but may be any location where noise generation can be suppressed by the assembly (51).

[0078] 12, the assembly (51) may be attached so as to fit into the opening of the first region (R). In this case, for example, the assembly (51) may be provided with a fitting structure (K) in which the outer circumferential surface of the assembly (51) and the inner circumferential surface of the opening fit together. Due to the fitting structure, for example, if the porous member (53) is damaged, only the assembly needs to be replaced, which can reduce costs compared to replacing the entire fan.

[0079] As shown in FIG. 13, the frame member (52) does not have to have the second short side (55b). In this case, for example, the frame member (52) is configured to cover the outer peripheral edge of the porous member (53). The assembly (51) is formed, for example, by insert molding. This makes it possible to easily manufacture the assembly (51) since it is not necessary to manufacture the assembly (51) by sandwiching the porous member between the two frames (52a, 52b) as in the above embodiment. In addition, since the outer peripheral edge of the porous member (53) is covered by the frame member (52), the porous member (53) can be stably fixed inside the frame member (52).

[0080] 14 and 15, the frame member (52) may have a portion formed so as to contact only the side surface of the porous member (53). The side surface of the porous member (53) is a surface that surrounds the surface facing the porous member (53) in the thickness direction. In other words, the side surface of the porous member (53) is the outer circumferential surface of the porous member (53). The side surface of the porous member (53) may be flat or curved.

[0081] In this case, the assembly 51 is formed by, for example, insert molding, which ensures a larger surface area for the porous member 53 compared to the structure in which the outer periphery of the porous member is covered by the frame member 52 as in the above embodiment.

[0082] As shown in FIG. 14, the frame member (52) may be provided with an edge portion (59) for insert molding with the rotor blade (41). The edge portion (59) is formed as a protrusion extending along the outer periphery of the frame member (52). The edge portion (59) is provided so as to protrude outward from the frame member (52) when the assembly (51) is viewed in cross section (see FIG. 15). The edge portion (59) may be provided on a part of the outer periphery of the frame member (52) or over the entire periphery. The frame member (52) may be formed so as to contact only the side surface of the porous member (53). In other words, the frame member (52) may be formed so as not to contact any part of the porous member (53) other than the side surface.

[0083] The edge portion 59 is formed so that the surface of the porous member 53 is flush with the surface of the frame member 52. In other words, the connection portion between the porous member 53 and the frame member 52 is flat. This can improve the effects of suppressing the ventilation resistance of air on the blade surface and suppressing air separation.

[0084] Although the embodiments and modifications have been described above, it will be understood that various modifications of form and details are possible without departing from the spirit and scope of the claims. Furthermore, the above embodiments and modifications may be appropriately combined or substituted as long as the functions of the subject of the present disclosure are not impaired. The descriptions "first" and "second" described above are used to distinguish the words to which these descriptions are attached, and do not limit the number or order of the words. [Industrial Applicability]

[0085] INDUSTRIAL APPLICABILITY As described above, the present disclosure is useful for a method for manufacturing a component, a component, and a fan having a component. [Explanation of symbols]

[0086] 26 Outdoor fan (fan) 41 Blade (component) 51 Assembly 52 Frame members 53 Porous Materials 62 Stator blade (component) R 1st area S2 Air passage

Claims

1. A method for manufacturing a component (41, 62) that constitutes an air passage (S2) formed inside a predetermined device (20) and that comes into contact with air flowing through the air passage (S2), comprising the steps of: a first step of forming an assembly (51) of a plate-shaped porous member (53) made of an elastically deformable resin material to an inner frame of a frame member (52) by fixing the porous member (53) and the frame member (52); a second step of providing the assembly (51) in a first region (R) of the component (41, 62) to integrate the assembly (51) with the component (41, 62).

2. The method further includes a third step of forming the frame member (52) to match the shape of the first region (R). The method of claim 1 .

3. the first region (R) is an opening formed in the component (41, 62), The second step is a step of fixing the assembly (51) to the opening. The method according to claim 1 or 2.

4. The second step is a step of integrating the assembly (51) with the components by insert molding. The method according to claim 1 or 2.

5. The frame member (52) is configured to sandwich the porous member (53) from both sides of the porous member (53). The method according to claim 1 or 2.

6. The frame member (52) is configured to cover the outer peripheral edge of the porous member (53). The method according to claim 1 or 2.

7. The frame member (52) has a portion formed so as to contact only the side surface of the porous member (53). The method according to claim 1 or 2.

8. The frame member (52) is configured to be fixed to one side of the porous member (53). The method according to claim 1 or 2.

9. The frame member (52) is made of resin. The method according to claim 1 or 2.

10. The frame member (52) is made of the same material as the component member (41). The method of claim 9.

11. The components (41, 62) are rotor blades (41) or stator blades (62) that constitute the fan (26). The method according to claim 1 or 2.

12. A component that constitutes an air passage (S2) formed inside a predetermined device (20) and comes into contact with air flowing through the air passage (S2), The method includes the steps of: providing an assembly (51) having a frame member (52) and a plate-shaped porous member (53) made of an elastically deformable resin material and fixed to an inner frame of the frame member (52); The assembly (51) is a component provided so as to be integrated with the component in a first region (R) of the component.

13. A fan comprising the component member of claim 12, said component being a rotor blade (41) or a stator blade (62).

Images