Indoor unit of air conditioner

Abstract

An indoor unit (100) of an air conditioner comprises: a housing (10); a fan plate (20); a sensor (51); and a control box (60). The housing has a first side wall (11) and a second side wall (12). The first side wall and the second side wall are disposed to face each other with a gap therebetween in a first direction (DR1). The fan plate extends toward the second side wall from the first side wall along the first direction in the housing, and separates the inner space of the housing into a first space in which a fan (30A) is displaced and a second space in which a heat exchanger (40) is displaced. The first side wall has formed therein an opening (11a) which is contiguous to the first space. The control box has a control substrate (62) and a support plate (61) which supports the control substrate and is detachably attached to the first side wall to cover the opening. The sensor has a detection port (51e) for detecting a refrigerant in air and is attached to the fan plate from the first space side to expose the detection port to the second space.

Description

Air conditioner indoor unit

[0001] The present disclosure relates to an indoor unit of an air conditioner.

[0002] Japanese Patent Laid-Open Publication No. 2021-14962 (Patent Document 1) describes an indoor unit of an air conditioner (hereinafter referred to as the “indoor unit”). The indoor unit described in Patent Document 1 has a housing, a partition plate, a fan, a heat exchanger, a sensor, and an electrical component box.

[0003] The housing has a first side plate and a second side plate. The first side plate and the second side plate are arranged opposite each other with a gap in the first direction. The partition plate extends along the first direction within the housing and divides the housing into an internal space, a first space, and a second space. A fan is arranged in the first space, and a heat exchanger is arranged in the second space. A sensor is attached to the partition plate within the second space. The sensor detects flammable refrigerant in the air. An electrical component box is arranged within the first space. A control board is arranged inside the electrical component box.

[0004] Japanese Patent Application Laid-Open No. 2021-14962

[0005] In the indoor unit described in Patent Document 1, an opening communicating with the second space is formed in the first side panel, and sensor replacement work is performed through this opening. Also, in the indoor unit described in Patent Document 1, because the electrical equipment box is located in the second space, maintenance of the control board located in the electrical equipment box cannot be performed through the above-mentioned opening. In other words, the indoor unit described in Patent Document 1 requires both an opening for sensor replacement and an opening for maintenance of the control board.

[0006] The present disclosure has been made in consideration of the above-mentioned problems of the conventional technology. More specifically, the present disclosure provides an indoor unit of an air conditioner that allows both sensor replacement and control board maintenance to be performed through a single opening.

[0007] The indoor unit of an air conditioner disclosed herein includes a housing, a fan plate, a sensor, and a control box. The housing has a first side wall and a second side wall. The first side wall and the second side wall are arranged opposite each other with a gap in a first direction. The fan plate extends from the first side wall toward the second side wall along the first direction within the housing and divides the interior space of the housing into a first space in which a fan is arranged and a second space in which a heat exchanger is arranged. An opening communicating with the first space is formed in the first side wall. The control box includes a control board and a support plate that supports the control board and is detachably attached to the first side wall to cover the opening. The sensor has a detection port that detects refrigerant in the air and is attached to the fan plate from the first space side so that the detection port is exposed to the second space.

[0008] According to the air conditioner indoor unit of the present disclosure, it is possible to perform both sensor replacement and control board maintenance through a single opening.

[0009] 1. A plan view of the indoor unit 100. A side view of the indoor unit 100. A side view of the sensor unit 50. A rear view of the sensor unit 50. A front view of the sensor unit 50. A cross-sectional view taken along line IV-IV in FIG. 1. A plan view of the indoor unit 100 with the support plate 61 open.

[0010] The details of the embodiments of the present disclosure will be described with reference to the drawings. In the following drawings, the same or corresponding parts are designated by the same reference numerals, and redundant descriptions will not be repeated.

[0011] Embodiment 1 An indoor unit of an air conditioner according to embodiment 1 will be described below. The indoor unit of the air conditioner according to embodiment 1 is designated as indoor unit 100.

[0012] (Configuration of indoor unit 100) The configuration of the indoor unit 100 will be described below.

[0013] Fig. 1 is a plan view of the indoor unit 100. An upper wall 13 is not shown in Fig. 1. Fig. 2 is a side view of the indoor unit 100. A cover 63 is not shown in Fig. 2. As shown in Figs. 1 and 2, the indoor unit 100 has a housing 10, a fan plate 20, a fan 30, a fan motor 31, a heat exchanger 40, a sensor unit 50, and a control box 60.

[0014] The housing 10 has a side wall 11 and a side wall 12. The side wall 11 and the side wall 12 are arranged facing each other with a gap between them. The direction in which the side wall 11 and the side wall 12 face each other is defined as a first direction DR1. The direction perpendicular to the first direction DR1 is defined as a second direction DR2. Each of the side wall 11 and the side wall 12 extends along the second direction DR2.

[0015] The housing 10 further has a top wall 13 (see FIG. 5 ) and a bottom wall 14. The direction perpendicular to the first direction DR1 and the second direction DR2 is defined as a third direction DR3. The top wall 13 and the bottom wall 14 are disposed opposite each other with a gap in between in the third direction DR3. One end and the other end of the side wall 11 in the third direction DR3 are defined as the upper end and the lower end of the side wall 11, respectively, and one end and the other end of the side wall 12 in the third direction DR3 are defined as the upper end and the lower end of the side wall 12, respectively. The top wall 13 is continuous with the upper end of the side wall 11 and the upper end of the side wall 12. The bottom wall 14 is continuous with the lower end of the side wall 11 and the lower end of the side wall 12.

[0016] An intake port 15 is defined by one end of the side wall 11 in the second direction DR2 (the right end in FIG. 1 ), one end of the side wall 12 in the second direction DR2 (the right end in FIG. 1 ), the top wall 13, and the bottom wall 14. An exhaust port 16 is defined by the other end of the side wall 11 in the second direction DR2, the other end of the side wall 12 in the second direction DR2, the top wall 13, and the bottom wall 14.

[0017] The fan plate 20 extends in the housing 10 from the side wall 11 to the side wall 12 along the first direction DR1. This divides the internal space of the housing 10 into a first space and a second space. The air inlet 15 and the air outlet 16 communicate with the first space and the second space, respectively. The fan plate 20 has a first surface 20a (see FIG. 4) and a second surface 20b (see FIG. 4). The first surface 20a faces the first space. The second surface 20b faces the second space and is the surface opposite the first surface 20a. The first surface 20a and the second surface 20b form end surfaces of the fan plate 20 in the second direction DR2.

[0018] The fans 30 are disposed in the first space. In the example shown in FIG. 1 , there are two fans 30. The two fans 30 are designated as fan 30A and fan 30B. Fan 30A is located closer to the side wall 11 than fan 30B. Fans 30A and 30B are aligned along the first direction DR1. The fans 30 are disposed in a fan case 32. The fan case 32 is attached to the fan plate 20, and the interior space of the fan case 32 communicates with the second space through an opening (not shown) formed in the fan plate 20. The fan motor 31 is disposed between fans 30A and 30B in the first direction DR1 and is connected to fans 30A and 30B. The fan motor 31 rotates the fans 30 (fans 30A and 30B) around a rotation axis along the first direction DR1.

[0019] The heat exchanger 40 is disposed in the second space. More specifically, the heat exchanger 40 is disposed on a drain pan 17 disposed on the bottom wall 14 in the second space. The heat exchanger 40 has a first end 40a and a second end 40b in the second direction DR2. The second end 40b is the end opposite the first end 40a and is farther from the fan plate 20 in the second direction DR2 than the first end 40a. The heat exchanger 40 is installed at an angle so that the first end 40a is located closer to the top wall 13 than the second end 40b.

[0020] The heat exchanger 40 has a plurality of heat transfer tubes 41. The heat transfer tubes 41 extend along a first direction DR1. One end and the other end of the heat transfer tubes 41 in the first direction DR1 are located on the side wall 11 side and the side wall 12 side, respectively. Two adjacent ones of the plurality of heat transfer tubes 41 are connected at one end in the first direction DR1 by a connecting tube 42. However, some of the plurality of heat transfer tubes 41 are connected at one end in the first direction DR1 to a refrigerant pipe 43 (shown by a dotted line in FIG. 1 ). Two adjacent ones of the plurality of heat transfer tubes 41 are connected at the other end in the first direction DR1 by the connecting tube 42.

[0021] A refrigerant flows through the refrigerant pipe 43. The refrigerant is, for example, a flammable refrigerant or a slightly flammable refrigerant. A specific example of the refrigerant is R32 refrigerant (CH ２ F ２ A refrigerant is supplied to the heat transfer tube 41 from a refrigerant pipe 43. The refrigerant flows through the heat transfer tube 41 and then returns to the refrigerant pipe 43.

[0022] When the fan motor 31 rotates the fan 30, air is drawn into the first space through the suction port 15. The air drawn in through the suction port 15 is drawn into the internal space of the fan case 32 and flows into the second space through the internal space of the fan case 32 and openings formed in the fan plate 20. The air that flows into the second space exchanges heat with the refrigerant flowing through the heat transfer tube 41, and is then blown out through the outlet 16. In this manner, the indoor unit 100 operates.

[0023] Fig. 3A is a side view of the sensor unit 50. Fig. 3B is a rear view of the sensor unit 50. Fig. 3C is a front view of the sensor unit 50. As shown in Figs. 3A to 3C, the sensor unit 50 includes a sensor 51, a mounting bracket 52, and a screw 53.

[0024] The sensor 51 has a detection element 51a therein. The detection element 51a is configured to output a signal when it detects refrigerant in the air. The sensor 51 has a first surface 51b and a second surface 51c. The second surface 51c is the surface opposite to the first surface 51b. The sensor 51 has a protrusion 51d on the first surface 51b. A detection opening 51e is formed on the top surface of the protrusion 51d, exposing the detection element 51a. Therefore, the sensor 51 can detect refrigerant in the air at the detection opening 51e.

[0025] Fig. 4 is a cross-sectional view taken along line IV-IV in Fig. 1. As shown in Fig. 4, the sensor 51 is attached to the fan plate 20 from the first space side so that the detection port 51e is exposed to the second space.

[0026] More specifically, an opening 20c is formed in the fan plate 20. The opening 20c penetrates the fan plate 20 in the second direction DR2, connecting the first space and the second space. A protrusion 51d is inserted into the opening 20c from the first surface 20a side. The protrusion 51d protrudes from the second surface 20b.

[0027] A through hole 20d is formed in the fan plate 20 along the second direction DR2, and a weld nut 21 is attached to the second surface 20b so that its screw hole overlaps with the through hole 20d. Through holes 52a are formed at the upper and lower ends of the mounting bracket 52. The mounting bracket 52 is attached to the fan plate 20 by passing a screw 53 through the through hole 52a and the through hole 20d from the first surface 20a side and threading it into the weld nut 21, with the sensor 51 sandwiched between the mounting bracket 52 and the second surface 20b. In this way, the sensor 51 is attached to the fan plate 20 from the first space side so that the detection port 51e is exposed to the second space.

[0028] 1, the sensor 51 is disposed in the second direction DR2 between the fan 30A and the side wall 11. The sensor 51 may also be disposed in the second direction DR2 between the fan 30A and the fan 30B.

[0029] An opening 11a is formed in the side wall 11. The opening 11a penetrates the side wall 11 along the first direction DR1 and communicates with the first space. The control box 60 has a support plate 61, a control board 62, and a cover 63. The support plate 61 is detachably attached to the side wall 11 so as to cover the opening 11a. A through-hole 61a is formed in the support plate 61. The through-hole 61a penetrates the support plate 61 along the first direction DR1 and communicates with the first space. The control board 62 is supported by the support plate 61. The cover 63 is attached to the support plate 61 so as to cover the control board 62.

[0030] Claw portions 11b are formed on the side wall 11. Through holes 61b are formed on the support plate 61. The through holes 61b penetrate the support plate 61 along the first direction DR1. When the support plate 61 is attached to the side wall 11, the claw portions 11b are inserted through the through holes 61b and are thereby engaged with the support plate 61.

[0031] The wiring 54 is passed through the through hole 61a. One end of the wiring 54 is connected to the sensor 51, and the other end is connected to the control board 62. As described above, the sensor 51 (detection element 51a) outputs a signal when it detects refrigerant in the air, and this signal is transmitted to the control board 62 by the wiring 54. The control board 62 performs necessary control based on this signal. For example, the control board 62 performs control to stop the circulation of the refrigerant or to notify the user that a refrigerant leak has occurred.

[0032] (Method of Replacing Sensor 51 in Indoor Unit 100) Hereinafter, a method of replacing the sensor 51 in the indoor unit 100 will be described.

[0033] When replacing the sensor 51 in the indoor unit 100, first, the cover 63 is removed from the support plate 61. Second, the support plate 61 is opened so that the opening 11a is exposed. FIG. 5 is a plan view of the indoor unit 100 with the support plate 61 open. As shown in FIG. 5, the claws 11b are passed through the through-holes 61b and engaged with the support plate 61, so the support plate 61 can be opened without being removed from the side wall 11. Third, a tool is inserted through the opening 11a and used to unscrew the screws 53, thereby removing the sensor unit 50 from the housing 10 through the opening 11a. After replacing the sensor 51, the replacement of the sensor 51 is completed by performing the above steps in reverse.

[0034] (Effects of the indoor unit 100) The effects of the indoor unit 100 will be described below.

[0035] When a flammable or slightly flammable catalyst is used as the refrigerant, it is required by law to quickly detect refrigerant leakage using a sensor within a specified time. In this regard, in the indoor unit 100, the detection port 51e is attached to the fan plate 20 so that it is exposed to the second space where the heat exchanger 40 is located, so even if refrigerant leaks from the heat exchanger 40 into the second space, it is possible to quickly detect it.

[0036] Furthermore, when a flammable or slightly flammable catalyst is used as the refrigerant, the sensor that detects refrigerant leaks is required by law to be replaced periodically. In the indoor unit 100, an opening 11a communicating with the first space is formed in the sidewall 11 to accommodate the control box 60. The sensor 51 is attached to the fan plate 20 from the first space side, allowing for sensor 51 replacement through the opening 11a. This eliminates the need to form a separate opening for sensor 51 replacement from the opening 11a. Furthermore, if the sensor replacement must be performed in the second space, the second space contains many components, such as the piping, pump, and drain pan of the heat exchanger 40, limiting the space available for the sensor 51. This makes the sensor replacement process cumbersome because many components must be removed.

[0037] When an air conditioner indoor unit is installed on the ceiling of a building, an inspection hatch is provided in the ceiling. The inspection hatch is usually provided next to the side wall of the housing where the control box is installed. In the indoor unit 100, the sensor 51 can be replaced using this inspection hatch, eliminating the need to provide a new inspection hatch in the ceiling.

[0038] If the sensor 51 is disposed between the fan 30 and the side wall 11 in the first direction DR1, the sensor 51 can be more easily reached by a tool inserted through the opening 11a or by an operator's hand, making it even easier to replace the sensor 51. If the opening 11a can be opened to expose the support plate 61 while it remains attached to the side wall 11, the sensor 51 can be replaced without removing the wiring 54 from the control board 62, making it even easier to replace the sensor 51. In this case, the operator does not need to support the support plate 61, and can therefore use both hands to replace the sensor 51, making it even easier.

[0039] The embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of this application is defined by the claims, not the above description, and is intended to include all modifications within the meaning and scope of the claims.

[0040] 100 Indoor unit, 10 Housing, 11 Side wall, 12 Side wall, 11a Opening, 11b Claw portion, 13 Upper wall, 14 Bottom wall, 15 Intake port, 16 Outlet port, 17 Drain pan, 20 Fan plate, 20a First surface, 20b Second surface, 20c Opening, 20d Through hole, 21 Weld nut, 30, 30A, 30B Fan, 31 Fan motor, 32 Fan case, 40 Heat exchanger, 40a First end, 40b Second end, 41 Heat transfer tube, 42 Connecting tube, 43 Refrigerant piping, 50 Sensor unit, 51 Sensor, 51a Detection element, 51b First surface, 51c Second surface, 51d Protrusion, 51e Detection port, 52 Mounting bracket, 52a Through hole, 53 Screw, 54 Wiring, 60 Control box, 61 support plate, 61a, 61b through holes, 62 control board, 63 cover, DR1 first direction, DR2 second direction, DR3 third direction.

Claims

1. An indoor unit for an air conditioner comprising: a housing; a fan plate; a sensor; and a control box; wherein the housing has a first side wall and a second side wall, the first side wall and the second side wall being arranged opposite each other with a gap in a first direction; the fan plate extends within the housing from the first side wall towards the second side wall along the first direction and divides the internal space of the housing into a first space in which a fan is arranged and a second space in which a heat exchanger is arranged; an opening is formed in the first side wall that communicates with the first space; the control box has a control board and a support plate that supports the control board and is detachably attached to the first side wall so as to cover the opening; and the sensor has a detection port that detects refrigerant in the air, and is attached to the fan plate from the first space side so that the detection port is exposed to the second space.

2. The indoor unit of an air conditioner according to claim 1, wherein the sensor is disposed between the first side wall and the fan in the first direction.

3. An indoor unit of an air conditioner as described in claim 1 or claim 2, further comprising wiring connecting the sensor and the control board, wherein a through hole communicating with the first space is formed in the support plate, and the wiring is passed through the through hole and is connected to the sensor at one end and to the control board at the other end.

4. An indoor unit for an air conditioner as described in any one of claims 1 to 3, wherein the support plate can be opened to expose the opening while remaining attached to the first side wall.

5. An indoor unit of an air conditioner as described in any one of claims 1 to 4, further comprising a mounting bracket and a screw, wherein the mounting bracket is attached to the fan plate from the first space side by the screw with the sensor sandwiched between the mounting bracket and the fan plate.

6. An indoor unit for an air conditioner according to any one of claims 1 to 5, wherein the control box further has a cover detachably attached to the support plate so as to cover the control board.

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