Turbo fan

Abstract

To provide a turbo fan of which blade member having a curved shape can be molded while being positioned in a mold jig and fixed when being integrally molded with a main plate, thereby maintaining fluidity of a resin at integral molding and ensuring an air flow rate.SOLUTION: In a turbo fan, a blade member 27 includes blade body parts 42, 48 and a flange part 43, the flange part 43 is formed while extending on an outside more than projection surfaces of the blade body parts 42, 48 and a positioning part 80 for positioning the blade member 27 relative to a main plate 24 is formed in the flange part 43.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a turbofan, and more particularly to a turbofan that can stably support a blade member and is less likely to cause misalignment between a main board and the blade member even when distorted in the centrifugal direction.

Background Art

[0002] Conventionally, a turbofan composed of a fan body in which a main board and a plurality of blades are integrally formed and a shroud, which is mounted on an indoor unit of an air conditioner or the like, is known.

[0003] Conventionally, for such a turbofan, for example, since the blades are erected on the main board and joined to the shroud with almost no curvature formation, when integrally molding the blades and the main board, the base of the blade fixed to the jig can be held by the jig without forming it large, and a technique has been disclosed in which the fan body is integrally molded with a thermoplastic resin (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in recent turbofans, in order to ensure the air volume, the blades are curved and the blade members tend to be inclined with respect to the main board. For this reason, the blade members may be formed in a twisted shape so that the attachment angles of the main board and the shroud to the blade members are different.

[0006] Therefore, when integrally molding the blade member and the main board, the flange portion of the blade member fixed to the mold jig needs to be formed to protrude beyond the curved projection surface. As a result, the flange portion becomes large, the gap formed between the flange portions of adjacent blade members becomes narrow, and there is a risk that the fluidity of the thermoplastic resin injected during the integral molding decreases when flowing through this gap.

[0007] In addition, in the previous process of integral molding, there is a problem of holding the angle of the blade member fixed to the main board so that it does not shift, and positioning the blade member so as not to cause further air volume resistance.

[0008] The present invention has been made in view of the above points, and when integrally molding a blade member having a curved shape with a main board, it can be positioned and fixed to a mold jig for molding. Therefore, an object of the present invention is to provide a turbo fan that maintains the fluidity of the resin during integral molding and ensures the air volume.

Means for Solving the Problems

[0009] To achieve the above object, the present invention provides a turbo fan including a main board, a shroud, and a plurality of blade members having a curved shape between the main board and the shroud. The blade member has a blade body portion and a flange portion. The flange portion is formed to extend outside the projection surface of the blade body portion, and a positioning portion for positioning the blade member with respect to the main board is formed on the flange portion. The positioning portion has a function of preventing the blade member from rotating and moving.

[0010] Further, the blade member is formed of a positive pressure side blade member and a negative pressure side blade member. The positive pressure side blade member has a positive pressure surface portion of the blade body portion and the flange portion. The negative pressure side blade member has a negative pressure surface portion of the blade body portion. The blade body portion arranges the positive pressure surface portion and the negative pressure surface portion to face each other. The flange portion extends in a direction opposite to the rotation direction on the negative pressure surface portion side, and the positioning portion is formed at an end portion of the flange portion.

[0011] Further, the positioning portion is a hole portion, and the anti-rotation function is characterized in that the hole portion is formed in a non-circular irregular shape.

[0012] Also, a gap portion formed between the flange portions of the adjacent blade members is formed to be larger toward the outside from the rotation axis, and the gap portion is covered with resin and integrally molded.

[0013] Further, the positioning portion is fixed to a positioning pin provided on a jig for integrally molding the main board.

Advantages of the Invention

[0014] According to the present invention, the blade member can be molded without displacement with respect to the main board, and low noise can be achieved.

Brief Description of the Drawings

[0015]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Modes for Carrying Out the Invention

[0016] Hereinafter, embodiments of the turbo fan according to the present invention will be described with reference to the drawings.

[0017] FIG. 1 is a longitudinal sectional view showing an embodiment of a ceiling-embedded air conditioner to which a turbo fan according to the present invention is applied. FIG. 2 is a perspective view of the ceiling-embedded air conditioner.

[0018] In this embodiment, as shown in FIG. 1, the indoor unit 10 is installed in a ceiling space 13 between a ceiling 11 of a building and a ceiling board 12 installed below the ceiling 11.

[0019] As shown in FIG. 1, this indoor unit 10 includes an air conditioner main body 14 formed in a box shape with an open bottom surface, and suspension fittings 18 are attached to the outer corner portions of the air conditioner main body 14. The air conditioner main body 14 is installed in a state of being suspended from the ceiling 11 by a suspension bolt 15 connected to the suspension fittings 18. Inside the air conditioner main body 14, a heat insulating member 16 made of foamed polystyrene is disposed in contact with the inner surface of a side plate 17 of the air conditioner main body 14 to prevent dew condensation on the side plate 17.

[0020] A fan motor 21 is attached to the lower surface of the upper plate of the air conditioner main body 14, and a rotary shaft 22 that is rotationally driven by the drive of the fan motor 21 is provided so as to extend downward. A turbo fan 23 is attached to the lower end portion of the rotary shaft 22, and the fan motor 21 and the turbo fan 23 constitute a blower device 20.

[0021] The turbo fan 23 includes a main plate 24 formed in an annular plate shape. A reverse frustum-shaped motor housing portion 25 that extends downward is formed at the central portion of the main plate 24.

[0022] The fan motor 21 is housed in the motor housing portion 25, and the rotary shaft 22 of the fan motor 21 extends downward and is connected to the bottom surface of the motor housing portion 25. By rotationally driving the fan motor 21, the turbo fan 23 is configured to be rotationally operated via the rotary shaft 22.

[0023] Below the main board 24, a shroud 26 is provided. The shroud 26 is formed in an annular shape with an arcuate peripheral surface. Between the main board 24 and the inner peripheral surface of the shroud 26, there are a plurality of curved blade members 27 arranged at predetermined intervals in the circumferential direction, and the blade members 27 are integrally formed with the main board 24.

[0024] Below the shroud 26, an orifice 28 is arranged. The orifice 28 is formed in an annular shape with an arcuate peripheral surface.

[0025] Between this blower device 20 and the heat insulation member 16, a heat exchanger 30 that is bent in a substantially rectangular shape in plan view so as to surround the side of the blower device 20 is arranged.

[0026] The heat exchanger 30 is a heat exchanger 30 that functions as an evaporator of the refrigerant during the cooling operation and functions as a condenser of the refrigerant during the heating operation. The heat exchanger 30 is configured to perform heat exchange between the indoor air sucked into the air conditioner main body 14 and the refrigerant, and can cool the air in the air-conditioned room during the cooling operation and heat the indoor air during the heating operation.

[0027] Also, below the heat exchanger 30, a drain pan 31 is arranged so as to correspond to the lower surface of the heat exchanger 30. This drain pan 31 is for receiving the drain water generated by the heat exchanger 30. Also, a suction port 32 of the blower device 20 is formed in the central portion of the drain pan 31.

[0028] Also, on the lower surface of the air conditioner main body 14, as shown in FIGS. 1 and 2, a substantially rectangular decorative panel 33 is attached so as to cover the lower opening of the air conditioner main body 14.

[0029] In the central portion of the decorative panel 33, a suction port 34 communicating with the suction port 32 of the drain pan 31 is formed. A suction grill 35 covering the suction port 34 is detachably attached to the suction port 34 portion of the decorative panel 33. A filter 36 for removing dust in the air is provided on the air conditioner main body 14 side of the suction grill 35.

[0030] Outside the suction port 34 of the decorative panel 33 and at positions along each side of the decorative panel 33, air outlets 37 for sending the conditioned air into the room are respectively formed. Each air outlet 37 is provided with a flap 38 for changing the wind direction. Then, by rotating the rotary shaft 22 by the fan motor 21 to rotate the turbo fan 23, the indoor air is sucked in from the suction ports 32 and 34, passes through the filter 36, then passes through the heat exchanger 30 for heat exchange, and the conditioned air is sent into the room from the air outlets 37.

[0031] Next, the turbo fan will be described in more detail.

[0032] FIG. 3 is a bottom view of the turbo fan. FIG. 4 is a perspective view of the turbo fan. FIG. 5 is an exploded perspective view of the turbo fan.

[0033] The turbo fan 23 is formed by integrally molding in advance a shroud 26, a main board 24, and a plurality of curved blade members 27. After manufacturing these respectively, assembly is performed to form the turbo fan 23.

[0034] FIG. 4 shows a state in which the thermoplastic resin 50 is injected integrally with the main board 24 between the flange portions 43 of the plurality of blade members 27. The outer peripheral shape of the flange portion 43 is configured to be curved in a substantially arc shape in the direction opposite to the fan rotation direction. The gap portion 44 formed between the flange portions 43 of the adjacent blade members 27 during injection molding is also configured in the direction opposite to the fan rotation direction and is formed to expand greatly in the direction away from the rotation axis 45.

[0035] In this embodiment, as shown in FIG. 5, the blade member 27 includes a positive-pressure-side blade member 40 located on the positive-pressure side and a negative-pressure-side blade member 41 located on the negative-pressure side, and these two blade members are brought into contact with each other to form a single blade member 27.

[0036] The positive-pressure-side blade member 40 includes a blade body 42 that constitutes the positive-pressure-side surface and a flange portion 43 that extends from the bottom plate of the blade body 42. The flange portion 43 is formed toward the negative-pressure surface side so as to receive the bottom plate of the negative-pressure-side blade member 41 from below, and is further formed to extend in a direction opposite to the rotation direction of the fan.

[0037] A hole portion serving as a positioning portion 80 is formed at the end of the flange portion 43 that extends in a direction opposite to the rotation direction of the fan. The positioning portion 80 is disposed at approximately the center of the positive-pressure-side blade member 40 of the adjacent blade members 27 on the main board 24.

[0038] In addition, on the upper portion of the positive-pressure-side blade member 40, a stepped welding support portion 46 formed at different heights is formed. The upper surfaces of each step of the welding support portion 46 are flat surfaces, and welding pins 47 are protruding from these respective welding support portions 46 as shown in FIG. 5.

[0039] The blade member 27 is integrally formed with the main board 24 via the flange portion 43.

[0040] The negative-pressure-side blade member 41 includes a blade body 48 that constitutes the negative-pressure-side surface. Engagement pins (not shown) are formed on the inner surface of the blade body 42 of the positive-pressure-side blade member 40, and engagement recesses (not shown) into which the engagement pins are engaged are formed on the inner surface of the blade body 48 of the negative-pressure-side blade member 41.

[0041] FIG. 6 shows a state before fixing a plurality of blade members 27 to the mold jig 81. The blade body portions 42 and 48 of the blade member 27 are inserted into predetermined positions of the mold jig, and the flange portion 43 is fixed to a predetermined position of the mold jig 81.

[0042] At this time, the positioning portion 80 provided at the end of the flange portion 43 engages with the positioning pin 82 provided on the mold jig 81, and the blade member 27 can be fixed to a predetermined position on the mold jig 81.

[0043] As shown in FIG. 7, when attached to the positioning pin 82 of the mold jig 81, the positioning portion 80 is configured with a rotation prevention function so that the blade member 27 does not rotate and is maintained at a predetermined position to prevent rotational movement.

[0044] Specifically, the positioning portion 80 is configured with a non-circular irregular shape. In the case of the embodiment, specifically, it is a substantially D-shaped hole portion. By inserting it into the positioning pin 82 of the same shape, it can be arranged at a predetermined position on the mold jig 81 without deviation. Also, by providing only one positioning portion 80 on the flange portion 43, even in the vertically placed mold jig 81 as shown in FIG. 6, the blade member 27 can be prevented from rotating and rotational movement can be suppressed.

[0045] Then, by injecting a thermoplastic resin into the mold jig 81, so-called insert molding is performed, and the resin flows in the gap portion 44 formed between the flange portions 43 of the plurality of blade members 27, connecting the adjacent flange portions 43 to form the main board 24. Therefore, the blade member 27 can be integrally molded with respect to the main board 24 without deviation by the positioning portion 80.

[0046] Also, the gap portion 44 widens outward from the central rotation axis 45, and it is possible to suppress a decrease in the fluidity of the resin during molding.

[0047] Then, after integrally molding the blade member 27 and the main board 24, by joining the shroud 26, it is possible to suppress variations in the air volume due to variations during integral molding and provide a turbo fan 23 that ensures a predetermined air volume.

[0048] Also, when the turbofan 23 is operated, the hole portion that constitutes the positioning portion 80 formed in the flange portion 43 does not protrude from the flange portion 43, and since there is only one positioning portion 80, the air volume can be ensured without disturbing the air fluidity, and the wind noise can also be suppressed.

[0049] Note that the positioning portion 80 is a substantially D-shaped hole portion, but it only needs to be prevented from rotating, and it may be formed with a rectangular cross-section or a notch shape.

[0050] Also, although the positioning portion 80 is a hole portion, it may be a protrusion portion. In this case, since the protrusion portion protrudes on the side opposite to the side where the blade member of the main board is formed, the air volume can be ensured without disturbing the air fluidity due to the rotation of the fan, and the wind noise can also be suppressed.

[0051] Note that the embodiments of the present invention have been described with reference to the drawings, but the present invention is not limited to the above embodiments and can be changed without departing from the gist of the invention.

Explanation of Reference Numerals

[0052] 10 Indoor unit 14 Air conditioner main body 24 Main board 23 Turbofan 26 Shroud 27 Blade member 40 Positive pressure side blade member 41 Negative pressure side blade member 42, 48 Blade body 43 Flange portion 80 Positioning portion

Claims

【Claim 1】 In a method for manufacturing a turbo fan including a main board, a shroud, and a plurality of curved blade members between the main board and the shroud, the blade member has a blade body portion and a flange portion, the flange portion is formed to extend outside the projection plane of the blade body portion, one positioning portion formed by a non-circular hole portion is provided in the flange portion, the plurality of blade members are fixed to a predetermined position of the mold jig by engaging the positioning portion with a positioning pin provided in the mold jig, and insert molding is performed on the mold jig to connect the adjacent flange portions and form a main board A method for manufacturing a turbo fan, characterized by the above.

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