Method for manufacturing constituent member, constituent member, and fan provided with constituent member

Abstract

Provided is a method for manufacturing a constituent member that constitutes an air passage (S2) formed inside a predetermined device (20) and that contacts air flowing through the air passage (S2). The method 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).

Description

Method for manufacturing component, component, and fan including component

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

[0002] One known approach to reducing noise from blowers is to provide a porous material on the blades of a propeller fan. Providing a porous material on the blades prevents air from separating from the negative pressure surface of the blade, thereby suppressing noise generation. Patent Document 1 discloses a method for manufacturing a propeller fan with such blades.

[0003] Japanese Patent Application Publication No. 4-12199

[0004] In Patent Document 1, a porous member is formed by filling a mold that matches the blade surface shape with a resin sintering material and sintering it, and then the porous member is integrally formed with the blade by injection molding. As such, since the porous member needs to be sintered to match the blade surface shape, manufacturing the porous member is time-consuming.

[0005] An object of the present disclosure is to simplify the manufacture of components that are provided with porous members.

[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), the method including: a first step of 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 of integrating the assembly (51) with the component members (41, 62) by providing the assembly (51) in a first region (R) of the component members (41, 62).

[0007] In the first aspect, a plate-shaped porous member (53) can be 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, which reduces the number of steps required to manufacture the component and reduces manufacturing costs.

[0008] The second embodiment is the same as the first embodiment, further comprising a third step of forming the frame member (52) to fit the shape of the first region (R).

[0009] In the second aspect, 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), which makes it easier to manufacture the components and reduces variation in the shapes of the components.

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

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

[0012] A fourth aspect is the first or second aspect, wherein the second step is a step of integrating the assembly (51) and the component members by insert molding.

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

[0014] A fifth aspect is the porous member according to any one of the first to fourth aspects, wherein 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 aspect, 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 the fuel cell device according to any one of the first to fourth aspects, wherein the frame member (52) is configured to cover the outer periphery of the porous member (53).

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

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

[0019] In the seventh aspect, the frame member (52) has a portion that contacts only the side surface 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 surface of the porous member (53), the larger the surface area of ​​the porous member (53) that can be ensured.

[0020] An eighth aspect is the porous member according to any one of the first to fourth aspects, wherein 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 surface of the porous member (53). Also, the frame member (52) can be fixed to one surface of the porous member (53) by a fastening member such as a screw.

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

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

[0024] A tenth aspect is the eighth aspect, wherein the frame member (52) is made of 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 (41), thereby increasing the strength of adhesion between the frame member (52) and the component (41), thereby enabling the assembly (51) to be stably fixed to the component (41) and preventing the assembly (51) from falling off the component (41).

[0026] An eleventh aspect is the air conditioner according to any one of the first to tenth aspects, wherein the component (41, 62) is a rotor blade (41) or a stator blade (62) that constitutes a fan (26).

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

[0028] A twelfth aspect is 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), and includes an assembly (51) having a frame member (52) and a porous member (53) fixed to an inner frame of the frame member (52), and the assembly (51) is a component that is 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) which is the component of the twelfth aspect.

[0031] FIG. 1 is a schematic diagram showing the configuration of an air conditioner. FIG. 2 is a piping diagram of a refrigerant circuit of the air conditioner. FIG. 3 is a cross-sectional view showing the configuration of an outdoor unit. FIG. 4 is a front view of a fan. FIG. 5 is a side view of the fan. FIG. 6 is a perspective view of an assembly. FIG. 7 is an exploded perspective view of the assembly. FIG. 8 is a diagram explaining the shape of a porous member fixed to a frame member. (a) shows the shape of a porous member when there is no second short side. (b) shows the shape of a porous member with a second short side. FIG. 9 is a cross-sectional view taken along line IX-IX in FIG. 4 and an enlarged view centered on the first region. FIG. 10 is a perspective view showing a stationary guide of an outdoor unit according to a modified example. FIG. 11 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. FIG. 12 is a view corresponding to the enlarged view shown in FIG. 9 of an assembly according to another embodiment. FIG. 13 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. FIG. 14 is a perspective view corresponding to FIG. 6 of an assembly according to another embodiment. FIG. 15 is a cross-sectional view taken along line XV-XV of the assembly of FIG. 14.

[0032] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the following embodiments are essentially preferred examples and are not intended to limit the scope of the present invention, its applications, or its uses. Furthermore, each configuration of the embodiments, modifications, other examples, etc. described below can be combined or partially substituted within the scope of the present invention. Note that "front," "rear," "right," and "left" shown below refer to the directions indicated by the arrows in FIG. 3.

[0033] (1) Air Conditioning Apparatus As shown in Figures 1 and 2, an 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 predetermined device (20) of the present disclosure.

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

[0036] The outdoor fan (26) transports outdoor air passing through the outdoor heat exchanger (22). The outdoor heat exchanger (22) exchanges heat between the outdoor air transported by the outdoor fan (26) and the 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 selector valve (25) switches the flow of refrigerant in the refrigerant circuit (11). Depending on the switching of the four-way selector valve (25), the refrigerant circuit (11) operates in 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 air heat exchanger.

[0040] (2) Operation of the Air Conditioning Apparatus (2-1) Cooling Operation In cooling operation, the four-way selector valve (25) is set to a state in which the refrigerant circuit (11) performs the 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 drawn in 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 heating operation, the four-way selector 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 in from the indoor space in the indoor heat exchanger (31) and blows the heated air into the indoor space.

[0042] (3) Configuration of the Outdoor Unit As shown in Fig. 3, the outdoor unit (20) includes a rectangular parallelepiped casing (35). The casing (35) is formed with an inlet (36) and an outlet (37). The inlet (36) is formed on the back and left side of the casing (35), and the outlet (37) is formed on the front of the casing (35). An outlet grill (38) is provided on the front 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) for the remaining part. The equipment chamber (S1) accommodates the compressor (21) and the like. The air passage (S2) connects the intake port (36) with the outlet port (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 L-shaped in plan view. The outdoor heat exchanger (22) is provided along the rear surface and left side surface of the casing (35) and faces the air inlet (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) located behind the outdoor fan (26).

[0045] (4) Configuration of the Outdoor Fan 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 this embodiment has one first hub (42) and three rotor blades (41). The number of 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 with a closed front end. 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 peripheral surface of the first hub (42) and are arranged 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 edge portions (41a, 41b, 41c, 41d) each having a different shape. The four edge portions (41a, 41b, 41c, 41d) are an inner edge portion (41a), an outer edge portion (41b), a leading edge portion (41c), and a trailing edge portion (41d).

[0048] The inner edge portion (41 a) is an edge of the rotor blade (41) that is in contact with the outer peripheral surface of the first hub (42). The inner edge portion (41 a) 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 rotational 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 rotational direction is located forward of one end Q1 of the inner edge portion (41a) in the rotational direction. 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 rotational direction and the other end Q2 of the inner edge portion (41a) in the rotational 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 backward 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 backward in the direction of rotation.

[0051] (5) Porous Part Each rotor blade (41) is provided with a porous part (50). The porous part (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 page. As a result, one surface of the rotor blade (41) becomes a negative pressure surface. The speed of air flowing along the negative pressure surface decreases toward the rotor blade (41), resulting in a non-uniform speed distribution. This can cause air separation from the rotor blade (41), generating noise. The first region (R) of this embodiment is provided at a position that can cause this separation. That is, by providing the porous portion (50) in the first region (R), non-uniformity in the speed distribution of air on the blade surface is suppressed, and air separation from the rotor blade (41) is suppressed, resulting in reduced noise.

[0053] (6) Manufacturing Method of Outdoor Fan Next, a manufacturing method of the outdoor fan (26) will be described. The manufacturing method of 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 manufacturing method of 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 portion (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) (= void volume / total volume of the porous member) is, for example, in the range of 35% to 90%.

[0055] 6 and 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. Because 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 end of each of the two opposing long sides (54a, 54b), the second short side (55b) connects the midpoints of each of the two opposing long sides (54a, 54b), and the third short side (55c) connects the other ends of each 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 frame (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 precisely, the frame member (52) is made of the same resin material as the rotor blade (41). For example, if the rotor blade (41) is made of ASG (glass fiber reinforced styrene-acrylonitrile resin) or ABS resin, each frame (52a, 52b) is also made of ASG or ABS, and is not made of PP resin or the like. Specifically, if the rotor blade (41) is made of ABS, each frame (52a, 52b) is made of styrene-based rubber.

[0059] Each frame (52a, 52b) is molded from 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 molded by injection molding. Specifically, each frame (52a, 52b) is obtained by pouring molten synthetic resin into a mold that fits 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 together. 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 manner, the assembly (51) can be manually assembled without insert molding. Since each frame (52a, 52b) is formed to fit the shape of the first region (R), the porous member (53) sandwiched between the pair of frames (52a, 52b) deforms to fit the shape of the first region. More specifically, because the outer edge of the porous member (53) is fixed to the frame member (52), the porous member (53) is normally supported at two points on both ends, as shown in the cross-sectional view of FIG. 8( a), and is formed so as to stretch between the two points. However, because the frame member (52) of this embodiment has the second short side (55 b), 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 more closely matches the first region (R). In other words, the second short side (55 b) functions as a support portion that supports the porous member (53) inside the frame member (52) and also functions as a shape adjuster that adjusts the shape of the porous member (53). In this manner, the first step is performed.

[0061] Finally, the assembly (51) and the outdoor fan (26) are integrated as shown in Figure 9. Specifically, the assembly (51) is attached to the first region (R) of the rotor blade (41) so that the assembly (51) forms part of the rotor blade (41). The thickness of the assembly (51) is the same as the thickness of the rotor blade (41) in the first region (R), and therefore the rotor blade (41) and the assembly (51) can be made flush with each other (see the enlarged view in Figure 9). Furthermore, because the assembly (51) is formed in the same shape as the first region (R), the assembly (51) is prevented from creating a ventilation resistance to the air flowing over the blade surface, and air separation can be suppressed.

[0062] (7) Features (7-1) Feature 1 The method for manufacturing 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 component members (41, 62) by providing the assembly (51) in the first region (R) of the component members (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 required to manufacture the outdoor fan (26), and also reduces manufacturing costs.

[0064] (7-2) Feature 2 The method for 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] In 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), which 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 of the present embodiment is a step of fixing the assembly (51) to the opening, which is the first region (R). This makes it possible to create the outdoor fan (26) simply by 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) between the frame members (52) from both sides, the porous member (53) can be fixed to the inner frame of the frame member (52).

[0068] (8) Modification 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 air inlet (36). The stationary guide (60) includes one second hub (61), eleven stationary vanes (62), and one outer ring (63). The stationary vane (62) is an example of a component (41, 62) of the present disclosure.

[0069] The second hub (61) is a cylindrical part 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 peripheral surface of the second hub (61) and extends radially outward from the second hub (61). Each stator vane (62) is provided from the outer peripheral surface of the second hub to the inner peripheral surface of the outer peripheral ring (63). The inner edge of each stator vane (62) is fixed to the second hub (61), and the outer edge of each stator vane (62) is fixed to the outer peripheral ring. The stator vanes are 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 modification, as in the above embodiment, the assembly (51) formed to fit 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 a single 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 surface of the 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 surface of the plate-shaped porous member (53). Alternatively, the frame member (52) may be fixed to one surface 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. If the predetermined device (20) is, for example, a ceiling-mounted indoor unit (30), the component (41, 62) may be a bell mouth disposed in the air passage, or an indoor fan that is a centrifugal fan. In this manner, the component may be any component that constitutes the air passage (S2) and comes into contact with the air flowing through the air passage (S2). Alternatively, the component may be any component that constitutes the air passage (S2) or that comes 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 corresponds 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) attached to 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] As shown in Fig. 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) fits into the inner circumferential surface of the opening. Due to the fitting structure, if the porous member (53) is damaged, for example, only the assembly needs to be replaced, which reduces 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 eliminates the need to manufacture the assembly (51) by sandwiching the porous member between two frames (52a, 52b) as in the above embodiment, and therefore allows the assembly (51) to be manufactured easily. Furthermore, because 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] As shown in Figures 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 that faces 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 allows the porous member (53) to have a larger surface area than in the structure in which the outer periphery of the porous member is covered with 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 portion of the outer periphery of the frame member (52) or along the entire periphery. Furthermore, 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 portion 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 airflow resistance and air separation on the blade surface.

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

[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.

[0086] 26 Outdoor fan (fan) 41 Rotor blade (component) 51 Assembly 52 Frame member 53 Porous member 62 Stationary blade (component) R First region S2 Air passage

Claims

1. A manufacturing method for a component (41, 62) that constitutes an air passage (S2) formed inside a specified device (20) and that comes into contact with air flowing through the air passage (S2), the manufacturing method comprising: a first step of 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 of integrating the assembly (51) and the component (41, 62) by providing the assembly (51) in a first region (R) of the component (41, 62).

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

3. A manufacturing method as described in claim 1 or 2, wherein the first region (R) is an opening formed in the component member (41, 62), and the second step is a step of fixing the assembly (51) to the opening.

4. A manufacturing method according to any one of claims 1 to 3, wherein the second step is a step of integrating the assembly (51) and the component members by insert molding.

5. The manufacturing method according to any one of claims 1 to 4, wherein the frame member (52) is configured to sandwich the porous member (53) from both sides of the porous member (53).

6. The manufacturing method according to any one of claims 1 to 5, wherein the frame member (52) is configured to cover the outer peripheral edge of the porous member (53).

7. The manufacturing method according to any one of claims 1 to 6, wherein the frame member (52) has a portion formed so as to contact only the side surface of the porous member (53).

8. The manufacturing method according to any one of claims 1 to 7, wherein the frame member (52) is configured to be fixed to one side of the porous member (53).

9. The manufacturing method according to any one of claims 1 to 8, wherein the frame member (52) is made of resin.

10. The manufacturing method according to claim 9, wherein the material constituting the frame member (52) is the same as the material constituting the component member (41).

11. The manufacturing method according to any one of claims 1 to 10, wherein the component (41, 62) is a moving blade (41) or a stationary blade (62) that constitutes a fan (26).

12. A component that constitutes an air passage (S2) formed inside a specified device (20) and that comes into contact with air flowing through the air passage (S2), comprising an assembly (51) having a frame member (52) and a porous member (53) fixed to the inner frame of the frame member (52), the assembly (51) being provided so as to be integrated with the component in a first region (R) of the component.

13. A fan comprising a rotor blade (41) or a stator blade (62) which is the component of claim 12.

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