Refrigerant flow path module and method for manufacturing same

Abstract

This refrigerant flow path module (40) comprises: a flow path part (32) in which a first refrigerant flow path (R1) and a second refrigerant flow path (R2) through which a refrigerant flows are formed; and a casing (33) that accommodates the flow path part (32). The flow path part (32) is formed from a synthetic resin or a material containing aluminum as a main component, and the casing (33) is formed from a steel material.

Description

Refrigerant Flow Path Module and Manufacturing Method Thereof

[0001] The present disclosure relates to a refrigerant flow path module and a manufacturing method thereof.

[0002] In Patent Document 1 below, a flow rate adjustment valve that adjusts the fluid flow rate by rotating a cylindrical valve body housed in a valve case is disclosed. Both the valve case and the valve body in this flow rate adjustment valve are formed of resin.

[0003] Japanese Utility Model Publication No. 61-23567

[0004] Since the flow rate adjustment valve described in Patent Document 1 has a valve case and a valve body made of resin, it can be formed by die molding or the like, and the manufacturability and workability can be improved. However, using the flow rate adjustment valve described in Patent Document 1 for flowing a refrigerant that is pressurized by a compressor, such as in an air conditioner, is disadvantageous in terms of pressure resistance.

[0005] An object of the present disclosure is to provide a refrigerant flow path module and a manufacturing method thereof that can enhance pressure resistance.

[0006] (1)The refrigerant flow path module of the present disclosure includes a flow path portion in which a first refrigerant flow path and a second refrigerant flow path through which the refrigerant flows are formed, and a casing that houses the flow path portion, wherein the flow path portion is formed of a synthetic resin or a material mainly composed of aluminum, and the casing is formed of a steel material.

[0007] According to the above configuration, since the flow path portion having the first and second refrigerant flow paths is formed of a synthetic resin or a material mainly composed of aluminum, its manufacturability and workability can be improved. Since the flow path portion is housed in a casing formed of a steel material having higher rigidity than this flow path portion, even if a high-pressure refrigerant flows through the first refrigerant flow path and the second refrigerant flow path and a high pressure is applied to the flow path portion, the pressure resistance of the flow path portion can be enhanced by the casing.

[0008] (2)In the refrigerant flow path module of (1) above, an opening communicating with the first refrigerant flow path and the second refrigerant flow path is formed in the casing, and the refrigerant flow path module further includes a pipe joined to the casing at the periphery of the opening.

[0009] With the above configuration, since the pipe is joined to the casing, it is possible to suppress the leakage of refrigerant from the gap between the casing and the pipe.

[0010] (3) In the refrigerant flow path module of (1) or (2) above, the casing is made of stainless steel.

[0011] The above configuration makes it possible to improve the corrosion resistance of the casing.

[0012] (4) In any one of the refrigerant flow path modules described in (1) to (3) above, the flow path portion has a hollow portion that communicates with the first refrigerant flow path, and the refrigerant flow path module further comprises a valve body housed in the hollow portion.

[0013] With the above configuration, since the flow path is formed from a material mainly composed of synthetic resin or aluminum, a hollow section can be easily formed. With the above configuration, since the refrigerant flow path module is equipped with a valve body, the refrigerant flow path module can be used as a valve for controlling the flow of refrigerant, such as a flow path switching valve.

[0014] (5) In the refrigerant flow path module of (4) above, the valve body has a passage that can communicate with the first refrigerant flow path.

[0015] (6) In the refrigerant flow path module of (4) or (5) above, the valve body is made of synthetic resin or a material mainly composed of aluminum.

[0016] The above configuration improves the manufacturability and processability of the valve body. If the valve body has a passage, the manufacturability and processability of the valve body can be further improved.

[0017] (7) In any one of the refrigerant flow path modules described in (4) to (6) above, the second refrigerant flow path does not communicate with the hollow portion but penetrates the flow path portion.

[0018] According to the above configuration, a refrigerant flow that is not controlled by a valve can be formed in the refrigerant flow path module.

[0019] (8) A method for manufacturing a refrigerant flow path module as described in any one of (1) to (7) above, comprising, in this order, a first step of molding the flow path portion and a second step of housing the flow path portion in the casing.

[0020] According to the above configuration, in the first step, the first refrigerant flow path and the second refrigerant flow path can be easily formed in the flow path section.

[0021] (9) A method for manufacturing the refrigerant flow path module described in (2) above, comprising, in this order: a first step of inserting the pipe into the opening and welding it to the casing; and a second step of housing the flow path portion in the casing and connecting the pipe to the first refrigerant flow path and the second refrigerant flow path.

[0022] According to the above configuration, the first step of welding the pipe to the casing is performed before the second step of housing the flow path section in the casing, so that the heat generated during welding is not transferred to the flow path section.

[0023] (10) A method for manufacturing a refrigerant flow path module as described in any one of (1) to (7) above, wherein the casing of the refrigerant flow path module is composed of a plurality of components, and the method includes, in this order, a first step of housing the flow path portion in the casing, and a second step of joining the plurality of components by welding, wherein in the second step, a gap is formed between the flow path portion housed in the casing and the joint portion of the plurality of components.

[0024] According to the above configuration, it is possible to suppress the transfer of heat to the flow path section when welding the multiple components that make up the casing.

[0025] This figure shows the refrigerant circuit of a refrigeration cycle device including a refrigerant flow path module according to the first embodiment of this disclosure. This is a plan view showing the interior of the outdoor unit. This is a front view showing the machine room of the outdoor unit. This is a perspective view of the refrigerant flow path module. This is an exploded perspective view of the refrigerant flow path module. This is a schematic cross-sectional view showing the structure of the refrigerant flow path module. This is a perspective view of a divided part of the flow path section of the refrigerant flow path module. This is a perspective view of the valve body of the refrigerant flow path module. This is a cross-sectional view of the refrigerant flow path module along the line IX-IX in Figure 4. This is a cross-sectional view illustrating the operation of the refrigerant flow path module in the first embodiment. This is a cross-sectional view illustrating the operation of the refrigerant flow path module in the second embodiment. This is an enlarged cross-sectional view of part XII in Figure 10. This is a perspective view of the refrigerant flow path module according to the second embodiment of this disclosure. This is an exploded perspective view of the refrigerant flow path module. This is a cross-sectional view illustrating the structure of the refrigerant flow path module according to the third embodiment of this disclosure. This is a cross-sectional view illustrating the structure of the refrigerant flow path module according to the fourth embodiment of this disclosure. This is a cross-sectional view illustrating the structure of the refrigerant flow path module according to the fifth embodiment of this disclosure.

[0026] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the attached drawings. [First Embodiment] Figure 1 is a diagram showing the refrigerant circuit of a refrigeration cycle device including a refrigerant flow path module according to the first embodiment of the present disclosure. The refrigeration cycle device 10 is equipped with a refrigerant circuit 30 that performs vapor compression type refrigeration cycle operation. The refrigeration cycle device 10 of this embodiment is an air conditioner. As shown in Figure 1, this air conditioner 10 has an outdoor unit (heat source unit) 11 and an indoor unit (utilization unit) 12. The outdoor unit 11 and the indoor unit 12 are connected by connecting pipes 13 and 14, respectively. The refrigerant circuit 30 is formed by the outdoor unit 11, the indoor unit 12 and the connecting pipes 13 and 14. In the outdoor unit 11, shut-off valves 23 and 24 are provided at the connection parts of the connecting pipes 13 and 14. Note that the refrigeration cycle device 10 is not limited to an air conditioner, but may be a refrigerator, freezer, water heater, ventilation device, etc.

[0027] (Refrigerant Circuit Configuration) As shown in Figure 1, the outdoor unit 11 is equipped with a compressor 15, an accumulator 25, an outdoor heat exchanger (heat source heat exchanger; second heat exchanger) 16, an expansion valve 17, and a four-way switching valve (flow path switching valve) 18, which constitute the refrigerant circuit 30. The outdoor unit 11 is also equipped with an outdoor fan 19. The indoor unit 12 is equipped with an indoor heat exchanger (utilizing heat exchanger; first heat exchanger) 21, which constitutes the refrigerant circuit 30. The indoor unit 12 is also equipped with an indoor fan 22. In this embodiment, the four-way switching valve 18 is configured as a modularized or integrated refrigerant flow path module 40, which includes the refrigerant flow paths 51b, 52b, 53b, 56b, and other refrigerant flow paths 57, 58, 59 connected to these. Details of this will be described later.

[0028] The compressor 15 is a positive displacement compressor, such as a scroll type or rotary type, and has a built-in compressor motor. The compressor 15 compresses the refrigerant drawn in from the suction pipe 52a and then discharges it from the discharge pipe 51a. In the outdoor unit 11, the discharge side of the compressor 15 is connected to port A of the four-way switching valve 18 via the discharge pipe 51a, which is a refrigerant pipe, and the refrigerant flow path 51b in the refrigerant flow path module 40. The refrigerant flow path 51b is provided with a check valve 71 to suppress backflow of refrigerant.

[0029] The suction side of the compressor 15 is connected to port B of the four-way switching valve 18 via the suction pipe 52a, which is a refrigerant pipe, and the refrigerant flow path 52b in the refrigerant flow path module 40. An accumulator 25 is provided in the middle of the suction pipe 52a.

[0030] The outdoor heat exchanger 16 is composed of a cross-fin type fin-and-tube heat exchanger or a microchannel type heat exchanger, etc. The gas side end of the outdoor heat exchanger 16 is connected to port C of the four-way switching valve 18 via refrigerant piping 53a and refrigerant flow path 53b in the refrigerant flow path module 40. The liquid side end of the outdoor heat exchanger 16 is connected to one end of the expansion valve 17 via refrigerant piping 54, 73 and refrigerant flow path 57 in the refrigerant flow path module 40. A strainer (filter) 72 for removing foreign matter from the refrigerant is provided in this refrigerant flow path 57.

[0031] The expansion valve 17 is, for example, an electrically operated valve with adjustable opening. The other end of the expansion valve 17 is connected to the liquid-side shut-off valve 23 via a refrigerant flow path 58 and refrigerant piping 55 in the refrigerant flow path module 40. The refrigerant flow path 58 is provided with a strainer (filter) 72 for removing foreign matter from the refrigerant.

[0032] The indoor heat exchanger 21 is composed of a cross-fin type fin-and-tube heat exchanger or a microchannel type heat exchanger, etc. The liquid side end of the indoor heat exchanger 21 is connected to the liquid side shut-off valve 23 via the liquid side connecting pipe 14. The gas side end of the indoor heat exchanger 21 is connected to the gas side shut-off valve 24 via the gas side connecting pipe 13. The gas side shut-off valve 24 is connected to port D of the four-way switching valve 18 via the refrigerant pipe 56a and the refrigerant flow path 56b in the refrigerant flow path module 40.

[0033] The four-way switching valve 18 switches the flow path between a first mode (shown by a solid line in Figure 1) in which ports A and C are in communication with each other and ports B and D are in communication with each other, and a second mode (shown by a dotted line in Figure 1) in which ports A and D are in communication with each other and ports B and C are in communication with each other. In the first mode, the refrigerant discharged from the compressor 15 flows to the outdoor heat exchanger 16, and in the second mode, the refrigerant discharged from the compressor 15 flows to the indoor heat exchanger 21.

[0034] The outdoor fan 19 is positioned near the outdoor heat exchanger 16. The outdoor fan 19 is driven to rotate by a motor and blows air onto the outdoor heat exchanger 16. The refrigerant flowing through the outdoor heat exchanger 16 exchanges heat with the outdoor air supplied by the outdoor fan 19, causing it to evaporate or condense.

[0035] The indoor fan 22 is positioned near the indoor heat exchanger 21. The indoor fan 22 is driven by a motor to rotate and blow air into the indoor heat exchanger 21. The refrigerant flowing through the indoor heat exchanger 21 exchanges heat with the indoor air supplied by the indoor fan 22, and condenses or evaporates.

[0036] The air conditioner 10 switches the four-way diverter valve 18 to a first mode when performing cooling operation, and switches the four-way diverter valve 18 to a second mode when performing heating operation. In cooling operation, the gaseous refrigerant discharged from the compressor 15 flows into the outdoor heat exchanger 16, which functions as a condenser, via the four-way diverter valve 18, and is condensed into liquid refrigerant. This liquid refrigerant is depressurized in the expansion valve 17 to become a gas-liquid two-phase refrigerant and flows into the indoor heat exchanger 21, which functions as an evaporator. The gas-liquid two-phase refrigerant exchanges heat with the air supplied by the indoor fan 22 and evaporates, becoming a gaseous refrigerant. The air cooled by heat exchange is supplied to the room. The gaseous refrigerant flowing out of the indoor heat exchanger 21 is drawn into the compressor 15 via the four-way diverter valve 18.

[0037] During heating operation, the gaseous refrigerant discharged from the compressor 15 flows into the indoor heat exchanger 21, which functions as a condenser, via the four-way switching valve 18. The gaseous refrigerant exchanges heat with the air supplied by the indoor fan 22 and condenses to become liquid refrigerant. The air heated by the heat exchange is supplied to the room. The liquid refrigerant flowing out of the indoor heat exchanger 21 is depressurized in the expansion valve 17 to become a gas-liquid two-phase refrigerant and flows into the outdoor heat exchanger 16, which functions as an evaporator. The gas-liquid two-phase refrigerant evaporates in the outdoor heat exchanger 16 and becomes gaseous refrigerant. The gaseous refrigerant is drawn into the compressor 15 via the four-way switching valve 18.

[0038] (Outdoor Unit Structure) Figure 2 is a plan view showing the interior of the outdoor unit. Figure 3 is a front view showing the machine room of the outdoor unit. In the following description, the direction indicated by arrow X in Figures 2 and 3 (first direction X) is the left-right direction, the direction indicated by arrow Y (second direction Y) is the front-back direction, and the direction indicated by arrow Z (third direction Z) is the up-down direction. However, these directions are merely examples and can be changed as appropriate.

[0039] The outdoor unit 11 is equipped with a casing 91. The casing 91 is formed in a rectangular parallelepiped shape and is rectangular in plan view. The interior of the casing 91 is divided into a machine room S1 and a heat exchange room S2 by a partition wall 92. The machine room S1 houses the compressor 15. In addition to the compressor 15, the machine room S1 also houses an accumulator 25, a refrigerant flow path module 40, and the like.

[0040] The heat exchange chamber S2 of the casing 91 houses an outdoor heat exchanger 16 and an outdoor fan 19, etc. The outdoor heat exchanger 16 is formed in an L-shape in plan view. The outdoor heat exchanger 16 is positioned along two adjacent side walls (rear side wall 91a, left side wall 91b) of the casing 91 which is located on the heat exchange chamber S2 side. Air intakes 91a1 and 91b1 are formed in these side walls 91a and 91b. The outdoor fan 19 is positioned opposite the other side wall (front side wall) 91c which is adjacent to the side wall (left side wall) 91b on which the air intake 91b1 is formed. An air outlet 91c1 is formed in this side wall 91c.

[0041] When the outdoor fan 19 is activated, air is drawn into the casing 91 from the air intakes 91a1 and 91b1 and discharged from the air outlet 91c1. The arrow a in Figure 2 indicates the direction of the airflow drawn into the casing 91.

[0042] As shown in Figures 2 and 3, the refrigerant flow path module 40 is located in the machine room S1 of the casing 91 of the outdoor unit 11. Specifically, the refrigerant flow path module 40 is located in the vicinity of the adjacent side walls (front side wall) 91c and side wall (right side wall) 91d in the machine room S1. In other words, the refrigerant flow path module 40 is located in the corner between the side walls 91c and 91d.

[0043] The refrigerant flow path module 40 is fixed to the casing 91 by mounting members 93 and 94. Mounting member 93 is formed, for example, in the shape of a strip, with one end in the longitudinal direction fixed to the refrigerant flow path module 40 and the other end fixed to the partition wall 92 of the casing 91. Mounting member 94 is fixed, for example, with one end fixed to the side wall (right side wall) 91d of the casing 91 and the other end fixed to the refrigerant flow path module 40. Therefore, the refrigerant flow path module 40 is mounted between the side wall 91d and the partition wall 92 of the casing 91 via mounting members 93 and 94. The refrigerant flow path module 40 is located to the right of the compressor 15 (one side in the first direction X) and in front of the accumulator 25 (one side in the second direction Y).

[0044] In the refrigerant flow path module 40 of the present embodiment, for example, refrigerant pipes 51a, 52a, 53a, and 56a are connected. Among these, the other end of the refrigerant pipe (discharge pipe) 51a is connected to the discharge side of the compressor 15. The other end of the refrigerant pipe (suction pipe) 52a is connected to the accumulator 25. The other end of the refrigerant pipe 53a is connected to the outdoor heat exchanger 16. The other end of the refrigerant pipe 56a is connected to the shut-off valve 24.

[0045] (Refrigerant Flow Path Module) FIG. 4 is a perspective view of the refrigerant flow path module. FIG. 5 is an exploded perspective view of the refrigerant flow path module. FIG. 6 is a cross-sectional view schematically showing the structure of the refrigerant flow path module. FIG. 7 is a perspective view of a divided body of the flow path portion of the refrigerant flow path module. FIG. 8 is a perspective view of the valve body of the refrigerant flow path module. FIG. 9 is a cross-sectional view of the refrigerant flow path module taken along the line IX-IX in FIG. 4.

[0046] As shown in FIG. 4, the refrigerant flow path module 40 has a module main body 40A and a drive mechanism 40B. The module main body 40A is formed in a substantially cylindrical shape as a whole. The central axis C1 of the cylindrical shape of the module main body 40A is directed in the vertical direction. Therefore, the "vertical direction" in the following description of the module main body 40A means the direction along the central axis C1. The drive mechanism 40B is provided on the outer peripheral surface of the module main body 40A. [[ID=​​​​Of the plurality of refrigerant flow paths, the refrigerant flow paths 51b, 52b, 53b, and 56b have one end communicating with the hollow portion 31A and the other end communicating with the outside of the flow path body 31. The other refrigerant flow paths 57 and 58 do not communicate with the hollow portion 31A and penetrate the flow path body 31. Still other refrigerant flow path 59 has one end communicating with the refrigerant flow path 56b and the other end communicating with the outside of the flow path body 31.

[0049] In this specification, any one of the plurality of refrigerant flow paths may be referred to as a first refrigerant flow path, and any other one may be referred to as a second refrigerant flow path. In particular, in the present embodiment, the refrigerant flow paths 51b, 52b, 53b, and 56b that communicate with the hollow portion 31A are referred to as first refrigerant flow paths, and a common reference numeral R1 is assigned to them in a generalized manner. Also, in the present embodiment, the other refrigerant flow paths 57, 58, and 59 that do not communicate with the hollow portion 31A are referred to as second refrigerant flow paths, and a common reference numeral R2 is assigned to them in a generalized manner. Details of these refrigerant flow paths R1 and R2 will be described later.

[0050] As shown in FIG. 5, the flow path portion 32 of the present embodiment is composed of a plurality of members (divided bodies) 32A and 32B. The flow path portion 32 is divided by a plane that intersects (is orthogonal to) the central axis C1. More specifically, the flow path portion 32 is divided into two by a plane that intersects the central axis C1 at a position offset to one side from the center in the vertical direction. Therefore, the flow path portion 32 is composed of two divided bodies 32A and 32B.

[0051] In the present embodiment, the vertical length of the lower divided body 32B is smaller than the vertical length of the upper divided body 32A. However, the vertical lengths of the upper and lower divided bodies 32A and 32B may be made the same, or the upper and lower divided bodies 32A and 32B may be composed of the same part. The flow path portion 32 may be composed of a plurality of divided bodies divided by a plane on the central axis C1 or a plane parallel to the central axis C1.

[0052] As shown in Figures 5 and 9, the two divided bodies 32A and 32B are assembled with their one end faces 32A1 and 32B1 facing each other in the vertical direction. Hemispherical recesses 32A2 and 32B2 are formed on one end face 32A1 and 32B1 of each divided body 32A, and a spherical hollow portion 31A is formed by combining the two recesses 32A2 and 32B2. Therefore, the hollow portion 31A is formed slightly above the center in the vertical direction within the flow channel portion 32.

[0053] As shown in Figures 5 and 9, the flow path section 32 has a plurality of cylindrical pipe sections 81 and a spherical housing section 82. Coolant flow paths R1 and R2 are formed inside each of the plurality of pipe sections 81. A hollow section 31A is formed inside the housing section 82.

[0054] Furthermore, the flow channel section 32 has a plurality of ribs 83 that protrude from the outer surfaces of the pipe section 81 and the housing section 82. The plurality of ribs 83 are formed in a plate shape and have plate surfaces that are aligned in the vertical direction. The plurality of ribs 83 are arranged in a grid pattern. The outer circumferential surfaces of the plurality of ribs 83 are formed in a cylindrical shape as a whole so as to conform to the inner surface of the casing 33, which will be described later.

[0055] The flow path section 32 of this embodiment includes a pipe section 81 and a housing section 82 that form the refrigerant flow paths R1 and R2 and the hollow section 31A, and ribs 83 that protrude from the outer surfaces thereof, with a gap S between adjacent ribs 83. Therefore, the flow path section 32 can be made lightweight and the amount of material used can be reduced. In addition, the ribs 83 can support the pipe section 81 against the pressure from the refrigerant flowing through the refrigerant flow paths R1 and R2.

[0056] The flow channel section 32 is formed of, for example, a synthetic resin. The flow channel section 32 is formed by mold molding (mold molding) such as injection molding. As the material of the flow channel section 32, PA66 (polyamide 66), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), etc. can be used. However, the flow channel section 32 may also be formed of a material mainly composed of aluminum, such as an aluminum alloy or pure aluminum, and may be formed by die casting.

[0057] As shown in Figures 5 and 6, the casing 33 covers the outside of the flow path 32. The casing 33 is formed in a substantially cylindrical shape. As shown in Figure 5, the casing 33 has a cylindrical body portion 33A and ends 33B located at both ends of the body portion 33A in the axial direction. The body portion 33A and one end 33B (the lower end in the example of Figure 5) are formed integrally. Therefore, the casing 33 is composed of two components 33D and 33E: a component 33D consisting of the body portion 33A and one end 33B, and a component 33E consisting of the other end 33B.

[0058] The casing 33 is formed from a steel material. For example, the casing 33 is made of stainless steel. Each component 33D, 33E of the casing 33 is formed by metalworking such as sheet metal processing or press working. For example, each component 33D, 33E is formed by deep drawing. However, the material and manufacturing method of the casing 33 are not limited to those described above. For example, the casing 33 may be made from other steel materials such as iron.

[0059] The two components 33D and 33E of the casing 33 are joined by welding. Specifically, the two components 33D and 33E of the casing 33 are joined by welding that involves melting the base material. The two components 33D and 33E are tightly joined to prevent refrigerant leakage between them. The casing 33 protects the flow path section 32 by covering the outside of the flow path section 32. The casing 33 reinforces the pressure resistance of the flow path section 32 against the pressure applied by the refrigerant in the refrigerant flow paths R1 and R2 and the refrigerant in the hollow section 31A of the flow path section 32. The casing 33 suppresses the leakage of refrigerant that has leaked from the flow path section 32 to the outside.

[0060] As mentioned above, the valve body 60 of the four-way switching valve 18 is housed within the flow path body 31. Therefore, the flow path body 31 also functions as the casing for the valve body 60 in the four-way switching valve 18. More specifically, the flow path portion 32 of the flow path body 31 functions as the inner casing for the valve body 60, and the casing 33 functions as the outer casing for the valve body 60.

[0061] (Four-way switching valve (switching mechanism) 18) As shown in Figure 9, the hollow portion 31A (housing portion 82) that houses the valve body 60 of the four-way switching valve 18 is spherical in shape. Multiple ports (openings) A, B, C, and D are formed on the inner surface of the hollow portion 31A. These ports A to D correspond to the ports A to D described with reference to Figure 1. Two ports B and C are located on the upper side of the hollow portion 31A, and two ports A and D are located on the lower side of the hollow portion 31A.

[0062] The main flow path body 31 has refrigerant flow paths R1 (51b, 52b, 53b, 56b) that communicate with ports A to D. The refrigerant flow path 51b that communicates with port A extends approximately downward from port A. The lower end of the refrigerant flow path 51b communicates with an opening 51c formed on the lower surface of the casing 33. The main flow path body 31 has a fitting pipe 51d that is inserted into the opening 51c and attached to the casing 33. The end (upper end) of the fitting pipe 51d is also inserted into the refrigerant flow path 51b.

[0063] The refrigerant flow path 51b has a stepped section 51e in its middle. The inner diameter of the refrigerant flow path 51b above the stepped section 51e (valve body 60 side) is larger than the inner diameter of the refrigerant flow path 51b below the stepped section 51e (joint pipe 51d side). A check valve 71 is housed in the refrigerant flow path 51b above the stepped section 51e. The check valve 71 is a non-electric component incorporated into the refrigerant flow path 51b. The check valve 71 has a spherical valve body 71a and a retaining member 71b that covers the valve body 71a from above and restricts the upward movement of the valve body 71a. The valve body 71a restricts the flow of refrigerant from top to bottom (from the valve body 60 side to the joint pipe 51d side) by contacting the stepped section 51e, and allows the flow of refrigerant in the reverse direction. The specific structure of the check valve 71 is not particularly limited, and a known structure can be adopted.

[0064] The refrigerant flow path 52b, which communicates with port B, extends approximately upward from port B. The upper end of the refrigerant flow path 52b communicates with an opening 52c formed on the upper surface of the casing 33. The flow path body 31 has a fitting pipe 52d that is inserted into the opening 52c and attached to the casing 33. The end (lower end) of the fitting pipe 52d is also inserted into the refrigerant flow path 52b.

[0065] The refrigerant flow path 53b, which communicates with port C, extends approximately upward from port C. The upper end of the refrigerant flow path 53b communicates with an opening 53c formed on the upper surface of the casing 33. The flow path body 31 has a fitting pipe 53d that is inserted into the opening 53c and attached to the casing 33. The end (lower end) of the fitting pipe 53d is also inserted into the refrigerant flow path 53b.

[0066] The refrigerant flow path 56b, which communicates with port D, extends approximately downward from port D. The lower end of the refrigerant flow path 56b communicates with an opening 56c formed on the lower surface of the casing 33. The flow path body 31 has a connecting pipe 56d attached to the opening 56c. The end (upper end) of the connecting pipe 56d is also inserted into the refrigerant flow path 56b.

[0067] In the following description, the joint pipes attached to the casing 33, such as the above-mentioned joint pipes 51d, 52d, 53d, 56d, and the joint pipes 57d1, 57d2, 58d1, 58d2 described later, may be denoted by a generalized common designation T. Similarly, the openings 51c, 52c, 53c, 56c, 57c1, 57c2, 58c1, 58c2 formed in the casing 33 may be denoted by a generalized common designation K.

[0068] As shown in Figure 9, the valve body 60 is positioned in the hollow portion 31A of the flow path body 31. The valve body 60 is formed in a spherical shape, as shown in Figure 8. The outer diameter of the valve body 60 is formed to be slightly smaller than the inner diameter of the inner surface of the hollow portion 31A.

[0069] The valve body 60 is made of synthetic resin or metal. The valve body 60 is formed, for example, by a mold such as injection molding or die casting. Examples of materials used for the valve body 60 include synthetic resins such as PA66 (polyamide 66) and PPS (polyphenylene sulfide), aluminum alloys, materials mainly composed of aluminum such as pure aluminum, and steel materials such as SUJ2 (high-carbon chromium bearing steel). However, the material and manufacturing method of the valve body 60 are not limited to these.

[0070] As shown in Figure 8, the valve body 60 rotates around a predetermined rotation axis C2. The rotation axis C2 of the valve body 60 passes through the spherical center P of the valve body 60. The rotation axis C2 is set to a fixed position, and the valve body 60 rotates at a fixed position. A drive shaft 66 is positioned on the rotation axis C2. As shown in Figure 4, the drive shaft 66 constitutes the drive mechanism 40B. The drive shaft 66 is positioned on the rotation axis C2 and one end is fixed to the valve body 60. The other end of the drive shaft 66 protrudes from the outer circumferential surface of the flow path body 31 of the module body 40A and is connected to the reduction unit 65 and the drive unit 64. In this embodiment, the drive shaft 66 is positioned horizontally perpendicular to the central axis C1 of the module body 40A. The reduction unit 65 and the drive unit 64 also constitute the drive mechanism 40B. The flow channel section 32 and casing 33 that constitute the flow channel body 31 have insertion holes 32C and 33C into which the drive shaft 66 is inserted (see Figures 5 and 7).

[0071] The drive unit 64 is, for example, an electric motor. The drive unit 64 generates and outputs rotational power. The drive unit 64 employs an electric motor with an adjustable rotation angle, such as a stepping motor. The reduction unit 65 reduces the rotational power of the drive unit 64 and transmits it to the drive shaft 66. The reduction unit 65 is composed of, for example, multiple reduction gears.

[0072] (Specific structure of valve body 60) Figure 8 shows a reference axis C3 perpendicular to the rotation axis C2 of the valve body 60, and a reference axis C4 perpendicular to both the rotation axis C2 and the reference axis C3. The rotation axis C2, the reference axis C3, and the reference axis C4 are perpendicular to each other at the spherical center P of the valve body 60.

[0073] The valve body 60 has a through hole 61 and a recess 62. Both the through hole 61 and the recess 62 constitute passages for the refrigerant. The through hole 61 is a hole that penetrates the valve body 60. In contrast, the recess 62 is formed by recessing the outer surface 60a of the valve body 60.

[0074] The through-hole 61 is formed at two locations on the outer surface 60a of the valve body 60. One opening 61a of the through-hole 61 is formed on the reference axis C3. The other opening 61b is formed on the reference axis C4. Therefore, as shown in Figure 9, the through-hole 61 is formed in a roughly L-shaped curve. The areas of both openings 61a and 61b are the same. The cross-sectional area of ​​the through-hole 61 (the area of ​​the cross section perpendicular to the center line of the through-hole 61; the cross-sectional area) is approximately the same as the area of ​​each opening 61a and 61b.

[0075] The recess 62 is formed on the outer surface 60a of the valve body 60 over a range (approximately 90° around the rotation axis C2) that spans from position G1, located on the opposite side of the reference axis C3 with respect to one opening 61a of the through hole 61, to position G2, located on the opposite side of the reference axis C4 with respect to the other opening 61b of the through hole 61.

[0076] The bottom surface 62a of the recess 62 is a single flat surface. This bottom surface 62a is formed across positions G1 and G2. The bottom surface 62a may be composed of multiple flat surfaces or of curved surfaces. The bottom surface 62a of the recess 62 and the openings 61a and 61b of the through hole 61 are positioned at an angle of approximately 45°.

[0077] The valve body 60 is not a perfect sphere because of the through hole 61 and the recess 62, and is a sphere with a portion of its spherical surface (outer surface 60a) missing. In Figure 9, the shape of a perfect sphere without any missing portion is shown by the dashed line L.

[0078] (Switching of flow path by valve body 60) Figure 10 is a cross-sectional view illustrating the operation of the refrigerant flow path module in the first embodiment. Figure 11 is a cross-sectional view illustrating the operation of the refrigerant flow path module in the second embodiment. In this embodiment, the valve body 60 is switched between the first embodiment (see Figure 10) and the second embodiment (see Figure 11) by rotating 90° around the rotation axis C2.

[0079] In the first embodiment shown in Figure 10, port B and port D are connected by a through-hole 61 in the valve body 60, and port A and port C are connected by a recess 62. Therefore, as shown by the solid arrows in Figure 1, the refrigerant discharged from the compressor 15 flows into the four-way diverter valve 18 from port A through the refrigerant piping 51a and refrigerant flow path 51b, flows out of the four-way diverter valve 18 from port C through the recess 62 of the valve body 60 (see Figure 10), and is supplied to the outdoor heat exchanger 16 through the refrigerant flow path 53b and refrigerant piping 53a. The refrigerant flowing out from the indoor heat exchanger 21 flows into the four-way diverter valve 18 from port D through the connecting piping 13, refrigerant piping 56a, and refrigerant flow path 56b, flows out of the four-way diverter valve 18 from port B through the through-hole 61 of the valve body 60 (see Figure 10), and is drawn into the compressor 15 through the refrigerant flow path 52b and refrigerant piping 52a. This enables the air conditioner 10 to perform cooling operation.

[0080] In the second embodiment shown in Figure 11, port B and port C are connected by a through-hole 61 in the valve body 60, and port A and port D are connected by a recess 62. Therefore, as shown by the dotted arrow in Figure 1, the refrigerant discharged from the compressor 15 flows into the four-way diverter valve 18 from port A through the refrigerant piping 51a and refrigerant flow path 51b, flows out to the outside of the four-way diverter valve 18 from port D through the recess 62 of the valve body 60 (see Figure 11), and is supplied to the indoor heat exchanger 21 through the refrigerant flow path 56b, refrigerant piping 56a, and connecting piping 13. The refrigerant flowing out from the outdoor heat exchanger 16 flows into the four-way diverter valve 18 from port C through the refrigerant piping 53a and refrigerant flow path 53b, flows out to the outside of the four-way diverter valve 18 from port B through the through-hole 61 of the valve body 60 (see Figure 11), and is drawn into the compressor 15 through the refrigerant flow path 52b and refrigerant piping 52a. This allows the air conditioner 10 to perform heating operation.

[0081] The through-hole 61 of the valve body 60 is always in communication with port B, and by rotating the valve body 60 90° around the rotation axis C2, it selectively communicates with port D and port C. Since port B is connected to the suction pipe 52a and refrigerant flow path 52b of the compressor 15, the through-hole 61, which is always in communication with port B, becomes a passage through which "low-pressure refrigerant" flows.

[0082] The recess 62 is always in communication with port A, and the valve body 60 selectively communicates with port C and port D by rotating 90° around the rotation axis C2. Since port A is connected to the discharge pipe 51a and refrigerant flow path 51b of the compressor 15, the recess 62, which is always in communication with port A, becomes a passage through which "high-pressure refrigerant" flows.

[0083] As shown in Figures 7, 10, and 11, sealing portions 34a, 34b, 34c, and 34d are integrally formed on the inner surface of the hollow portion 31A of the flow path body 31, around each of the ports A to D. For example, the sealing portions 34a to 34d are integrally formed with the flow path 32 when the flow path 32 is molded using injection molding or die casting. The sealing portions 34a to 34d are annular projections that protrude from the inner surface of the hollow portion 31A. The tips of these sealing portions 34a to 34d are in contact with the outer surface 60a of the valve body 60. In this embodiment, the sealing portions 34a to 34d are formed in a circular annular shape substantially along the periphery of the cylindrical refrigerant flow paths 51b, 52b, 53b, and 56b. However, the sealing portions 34a to 34d may also be annular in shape, such as a rectangular shape.

[0084] Specifically, in the first embodiment shown in Figure 10, the sealing portion 34b formed around the port B on the inner surface of the hollow portion 31A is in contact with the area around the opening 61b of the through hole 61 on the outer surface 60a of the valve body 60. The sealing portion 34d formed around the port D on the inner surface of the hollow portion 31A is in contact with the area around the opening 61a of the through hole 61 on the outer surface 60a of the valve body 60.

[0085] Therefore, the sealing portions 34b and 34d can prevent the low-pressure refrigerant flowing through ports B, D, and the through-hole 61 from leaking into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A. Furthermore, the sealing portions 34b and 34d can prevent the refrigerant flowing through areas other than ports B, D, and the through-hole 61 (high-pressure refrigerant) from flowing into ports B, D, and the through-hole 61. This prevents the mixing of low-pressure and high-pressure refrigerants.

[0086] In contrast, the sealing portions 34a and 34c formed around ports A and C on the inner surface of the hollow portion 31A partially contact the area around the recess 62 on the outer surface 60a of the valve body 60, but other portions are located radially outside the recess 62 and do not contact the outer surface 60a of the valve body 60. Therefore, the high-pressure refrigerant leaks through ports A, C, and the recess 62 into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A.

[0087] When high-pressure refrigerant leaks into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A, the pressure of the high-pressure refrigerant is applied to most of the outer surface 60a of the valve body 60, excluding the through hole 61. The pressure of the high-pressure refrigerant is also applied to the recess 62 through which the high-pressure refrigerant passes. As a result, the outer surface 60a of the valve body 60 is strongly pressed against the seal portions 34b and 34d formed around ports B and D.

[0088] As a result, the sealing portions 34b and 34d can further suppress the leakage of low-pressure refrigerant flowing through ports B, D, and the through-hole 61 into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A. Furthermore, the sealing portions 34b and 34d can further suppress the flow of high-pressure refrigerant flowing through areas other than ports B, D, and the through-hole 61—in other words, high-pressure refrigerant flowing through ports A, C, and the recess 62, as well as high-pressure refrigerant leaking from these areas—into ports B, D, and the through-hole 61.

[0089] In the second embodiment shown in Figure 11, the sealing portion 34b formed around the port B on the inner surface of the hollow portion 31A is in contact with the area around the opening 61a of the through hole 61 on the outer surface 60a of the valve body 60. The sealing portion 34c formed around the port C on the inner surface of the hollow portion 31A is in contact with the area around the opening 61b of the through hole 61 on the outer surface 60a of the valve body 60.

[0090] Therefore, the sealing portions 34b and 34c can prevent the low-pressure refrigerant flowing through ports B, C, and the through-hole 61 from leaking into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A. Furthermore, the sealing portions 34b and 34c can prevent the refrigerant flowing through areas other than ports B, C, and the through-hole 61 (high-pressure refrigerant) from flowing into ports B, C, and the through-hole 61. This prevents the mixing of low-pressure and high-pressure refrigerants.

[0091] In contrast, the sealing portions 34a and 34d formed around ports A and D on the inner surface of the hollow portion 31A partially contact the area around the recess 62 on the outer surface 60a of the valve body 60, but other portions are located radially outside the recess 62 and do not contact the outer surface 60a of the valve body 60. Therefore, the refrigerant flowing through ports A, D, and the recess 62 leaks into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A.

[0092] When high-pressure refrigerant leaks into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A, the pressure of the high-pressure refrigerant is applied to most of the outer surface 60a of the valve body 60, excluding the through-hole 61, and to the recess 62 through which the high-pressure refrigerant passes. As a result, the valve body 60 is strongly pressed against the sealing portions 34b and 34c formed around ports B and C.

[0093] As a result, the sealing portions 34b and 34c can further suppress leakage of low-pressure refrigerant flowing through ports B, C, and the through-hole 61 into the gap between the outer surface 60a of the valve body 60 and the inner surface of the hollow portion 31A. Furthermore, the sealing portions 34b and 34c can further suppress the inflow of high-pressure refrigerant flowing through areas other than ports B, C, and the through-hole 61—in other words, high-pressure refrigerant flowing through ports A, D, and the recess 62, as well as high-pressure refrigerant leaking from these areas—into ports B, C, and the through-hole 61.

[0094] The sealing portions 34a to 34d are formed integrally with the flow channel portion 32. Therefore, the number of parts can be reduced compared to the case where the sealing portions 34a to 34d are formed separately from the flow channel portion 32. Furthermore, if the flow channel portion 32 is molded using synthetic resin or the like, the sealing portions 34a to 34d can be easily molded integrally.

[0095] Of the four ports A to D, only high-pressure refrigerant flows through port A, so the seal portion 34a formed around port A is not used in practice. Therefore, the seal portion 34a can be omitted.

[0096] As shown in Figure 5, the two divided parts 32A and 32B that constitute the flow path section 32 are only butted together at their end faces 32A1 and 32B1, and are not bonded together. Therefore, as indicated by arrow d in Figure 10, the high-pressure refrigerant leaks out of the flow path section 32 from between the end faces 32A1 and 32B1. The leaked high-pressure refrigerant flows into the space between the outer surface of the flow path section 32 and the inner surface of the casing 33, for example, into the gap S between the ribs 83 of the flow path section 32. Since the casing 33 has multiple components 33D and 33E tightly joined together by welding, leakage from between these components 33D and 33E to the outside of the casing 33 is suppressed.

[0097] As shown in Figure 9, the joint pipes T (51d, 52d, 53d, 56d) inserted into the refrigerant flow path R1 (51b, 52b, 53b, 56b) are inserted into openings K (51c, 52c, 53c, 56c) formed at the end 33B of the casing 33, and are joined and fixed to the casing 33 by welding at the periphery of the openings K. Specifically, the joint pipes T are joined to the casing 33 by brazing, a type of welding that does not involve melting the base material. Therefore, leakage of refrigerant from the outer surface of the joint pipes T to the outside of the casing 33 through the gap between the outer surface of the joint pipes T and the openings K of the casing 33 is suppressed.

[0098] The end of the joint pipe T is inserted into the refrigerant flow path R1 in the flow path section 32. In this embodiment, a seal portion 37 is provided between the outer circumferential surface of the joint pipe T and the refrigerant flow path R1. This seal portion 37 is formed annularly along the circumferential direction on the inner circumferential surface of the refrigerant flow path R1. The seal portion 37 is integrally formed on the inner circumferential surface of the refrigerant flow path R1.

[0099] Therefore, leakage from the end faces 32A1 and 32B1 of the flow channel section 32, and the refrigerant flowing between the outer surface of the flow channel section 32 and the inner surface of the casing 33 as shown by arrow d (see Figure 10), is prevented from entering the hollow section 31A through the refrigerant flow channel R1 and the joint pipe T. The seal section 37 can be integrally molded when the flow channel section 32 is molded, similar to the seal sections 34a to 34d formed on the inner surface of the hollow section 31A.

[0100] (Other refrigerant flow paths) As shown in Figure 6, the flow path section 32 of the refrigerant flow path module 40 has refrigerant flow paths R2 (57, 58, 59) formed therein that do not communicate with the hollow section 31A. Of these, refrigerant flow paths 57 and 58 both extend vertically between the upper and lower ends of the flow path section 32 and penetrate the flow path section 32.

[0101] The upper and lower ends of the refrigerant flow path 57 communicate with openings 57c1 and 57c2 formed on the upper and lower surfaces of the casing 33, respectively. Joint pipes 57d1 and 57d2 are inserted into these openings 57c1 and 57c2. For example, the joint pipes 57d1 and 57d2 are joined and fixed to the casing 33 by welding at the periphery of the openings 57c1 and 57c2. Specifically, the joint pipes 57d1 and 57d2 are joined to the casing 33 by brazing, a type of welding that does not involve melting the base material. The ends of the joint pipes 57d1 and 57d2 are also inserted into the interior of the refrigerant flow path 57.

[0102] The upper and lower ends of the refrigerant flow path 58 communicate with openings 58c1 and 58c2 formed on the upper and lower surfaces of the casing 33, respectively. Joint pipes 58d1 and 58d2 are inserted into these openings 58c1 and 58c2. For example, the joint pipes 58d1 and 58d2 are joined and fixed to the casing 33 by welding at the periphery of the openings 58c1 and 58c2. Specifically, the joint pipes 58d1 and 58d2 are joined to the casing 33 by brazing, a type of welding that does not involve melting the base material. The ends of the joint pipes 58d1 and 58d2 are also inserted into the interior of the refrigerant flow path 58.

[0103] Although not shown in the diagram, a sealing portion similar to the sealing portion 37 shown in Figure 9 is integrally formed on the inner circumferential surface of the refrigerant flow paths 57 and 58. This sealing portion contacts the outer circumferential surface of the joint pipes 57d1, 57d2, 58d1, and 58d2, suppressing refrigerant leakage from between the inner circumferential surface of the refrigerant flow paths 57 and 58 and the outer circumferential surface of the joint pipes 57d1, 57d2, 58d1, and 58d2.

[0104] As shown in Figure 6, strainers 72 are inserted into the refrigerant flow paths 57 and 58, respectively. The strainers 72 are non-electric components incorporated into the refrigerant flow paths 57 and 58. As also shown in Figures 1 and 4, one end of a refrigerant pipe 73 is connected to one joint pipe 57d1 of the refrigerant flow path 57, and the other end of the refrigerant pipe 73 is connected to one end of the expansion valve 17. The other joint pipe 57d2 of the refrigerant flow path 57 is connected to a refrigerant pipe 54 (see Figure 1) that is connected to the liquid side end of the outdoor heat exchanger 16.

[0105] The other end of the expansion valve 17 is connected to one joint pipe 58d1 of the refrigerant flow path 58. The other joint pipe 58d2 of the refrigerant flow path 58 is connected to a refrigerant pipe 55 (see Figure 1) that leads to the liquid side shut-off valve 23.

[0106] As shown in Figure 6, the other refrigerant flow path 59, which does not communicate with the hollow portion 31A of the flow path 32, extends vertically between the upper end of the flow path 32 and the refrigerant flow path 56b. The upper end of the refrigerant flow path 59 communicates with openings 59c formed on the upper and lower surfaces of the casing 33. A joint pipe 59d is inserted into these openings 59c. For example, the joint pipe 59d is joined and fixed to the casing 33 by welding at the periphery of the opening 59c. Specifically, the joint pipe 59d is joined to the casing 33 by brazing, a type of welding that does not involve melting the base material. The end of the joint pipe 59d is also inserted into the interior of the refrigerant flow path 59. A service port 75 is connected to the joint pipe 59d. Instruments such as pressure gauges and vacuum pumps can be connected to the service port 75.

[0107] In this embodiment, each of the fittings T described above is formed from a copper alloy or a material mainly composed of copper, such as pure copper. However, the material of the fittings T is not limited to this, and may be formed from other materials such as a material mainly composed of aluminum or stainless steel.

[0108] (Method for manufacturing the refrigerant flow path module 40) The refrigerant flow path module 40 is assembled as follows. As shown in Figure 5, first, the joint pipes T are inserted into the openings K formed in each component 33D, 33E of the casing 33, and the joint pipes T are joined to the casing 33 by brazing. In this embodiment, the casing 33 is made of stainless steel and the joint pipes T are made of copper, and the two are made of different materials. Therefore, the casing 33 and each joint pipe T are joined by furnace brazing. By performing furnace brazing in this way, brazing can be performed without using flux even when dissimilar materials are joined together, and sensitization of the stainless steel can also be suppressed.

[0109] Next, various components 60, 71, and 72 are placed inside the flow path section 32. Specifically, the valve body 60 is placed in the hollow section 31A between the two divided bodies 32A and 32B, the strainer 72 is placed in the refrigerant flow paths 57 and 58, and the check valve 71 is placed in the refrigerant flow path 51b. With this in place, the end faces 32A1 and 32B1 of the two divided bodies 32A and 32B are brought together. After that, the flow path section 32 is inserted into one of the components 33D of the casing 33, and the other component 33E completely covers the flow path section 32. At this time, the ends of each joint pipe T protruding to the inside of the casing 33 are inserted into the corresponding refrigerant flow paths R1 and R2.

[0110] Subsequently, the components 33D and 33E of the casing 33 are joined by welding. The flow channel section 32 is in contact with the inner surface of the casing 33 at the outer circumferential surface of the rib 83, but most of the other parts, namely the pipe section 81 and the housing section 82, are positioned away from the inner surface of the casing 33 with a gap t (see Figure 9). Therefore, the heat generated when joining the components 33D and 33E of the casing 33 by welding is suppressed from being transferred to the flow channel section 32. As shown in Figure 12, a groove 84 may be formed on the outer circumferential surface of the rib 83 of the flow channel section 32, forming a gap t between the joint between the components 33D and 33E. This gap t can be set according to the constituent material of the flow channel section 32, and is preferably 5 mm or more.

[0111] Subsequently, as shown in Figure 5, the drive shaft 66 (see Figure 4) of the drive mechanism 40B is inserted into the holes 33C and 32C formed in the casing 33 and the flow path section 32 and connected to the valve body 60, and the reduction unit 65 and drive unit 64 are attached to the drive shaft 66. A seal is provided between the drive shaft 66 and the casing 33 to prevent refrigerant leakage.

[0112] In the above assembly method, the joint pipe T is attached to the casing 33 by brazing before the flow path section 32 is housed inside the casing 33. Therefore, it is possible to suppress the transfer of heat from the joint pipe T to the flow path section 32 when attaching it to the casing 33.

[0113] The process of bonding the two divided parts 32A and 32B that constitute the flow path section 32 by welding or other means is unnecessary. Therefore, the assembly work of the refrigerant flow path module 40 can be easily performed. The seal between the outer surface 60a of the valve body 60 and the inner surface of the hollow section 31A can be performed by the sealing sections 34b to 34d simply by housing the valve body 60 in the hollow section 31A of the flow path section 32. Similarly, the seal between the joint pipe and the refrigerant flow path can be performed by the sealing section 37 simply by inserting the joint pipe fixed to the casing 33 into the refrigerant flow path. These also make the assembly work of the refrigerant flow path module 40 easy.

[0114] [Second Embodiment] Figure 13 is a perspective view of a refrigerant flow path module according to the second embodiment of the present disclosure. Figure 14 is an exploded perspective view of the refrigerant flow path module. In this embodiment, the refrigerant flow path module 40 has a module body 40A and a drive mechanism 40B. The module body 40A is formed in a substantially rectangular parallelepiped shape. The flow path section 32 and the casing 33 of the module body 40A are also formed in a substantially rectangular parallelepiped shape. The flow path section 32 has a plurality of refrigerant flow paths 52b, 53b, 51b and a hollow section 31A. A plurality of joint pipes 51d, 52d, 53d, 56d, 59d are connected to the upper surface, lower surface, and side surface of the casing 33. In Figures 13 and 14, refrigerant flow paths and joint pipes having functions common to the first embodiment are denoted by the same reference numerals as in the first embodiment, and other refrigerant flow paths and joint pipes are denoted by the generalized common reference numerals R1, R2, and T, respectively.

[0115] As shown in Figure 14, the flow path section 32 is composed of multiple (two) divided sections 32A and 32B. On the mutually opposing surfaces 32A1 and 32B1 of these two divided sections 32A and 32B, recesses 32A2 and 32B2 are formed, respectively, which form the hollow section 31A. The casing 33 is also composed of multiple constituent members 33G, 33H, 33I, and 33J. Each of the constituent members 33G to 33J is joined to a connecting pipe T (51d, 52, 53d, 56d, 59d). In other words, the casing 33 is divided into sections to which the connecting pipe T is joined.

[0116] The components 33G to 33J include a component 33H corresponding to the upper surface of the rectangular parallelepiped casing 33, components 33I and 33J corresponding to a portion of the side surface of the casing 33 to which the joint pipe T is connected, and a component 33G corresponding to the portion of the casing 33 other than components 33H to 33J.

[0117] The refrigerant flow path module 40 in this embodiment is assembled as follows. First, the joint pipes T are joined to the respective components 33G, 33H, 33I, and 33J of the casing 33 by brazing. Next, with the valve body 60 housed between the two divided bodies 32A and 32B that constitute the flow path section 32 (hollow section 31A), the end faces 32A1 and 32B1 are brought together. Then, the flow path section 32 is inserted into the component 33G of the casing 33. At this time, the ends of the joint pipes T (51d, 56d) protruding inward from the component 33G are inserted into the corresponding refrigerant flow paths.

[0118] Next, the other components 33H, 33I, and 33J of the casing 33 are superimposed on the outer surface of the flow path section 32. At this time, the ends of the joint pipes T that protrude inward from each component 33H, 33I, and 33J are inserted into the corresponding refrigerant flow paths R1 and R2. Then, the other components 33H, 33I, and 33J are joined to the component 33G of the casing 33 by welding. After that, the drive shaft 66 is attached to the valve body 60, and the drive unit 64 is connected to the drive shaft 66.

[0119] Subsequently, in order to suppress the transfer of heat from the joint to the flow channel 32, it is preferable to form the groove 84, as described with reference to Figure 12, on the outer surface of the flow channel 32.

[0120] [Third Embodiment] Figure 15 is a schematic cross-sectional view showing the structure of a refrigerant flow path module according to the third embodiment of the present disclosure. In the first embodiment described above, as shown in Figure 6, a refrigerant pipe 73 was connected to one end of the expansion valve 17, and a refrigerant flow path 58 (joint pipe 58d1) of the flow path body 31 was connected to the other end of the expansion valve 17. In this embodiment, as shown in Figure 15, a part of the expansion valve 17 is housed in the flow path body 31. Specifically, the expansion valve 17 includes a valve body 17a housed in the flow path body 31 and a drive unit 17b protruding from the flow path body 31. A valve element 17c driven by the drive unit 17b is built into the valve body 17a. The valve element 17c is formed in a needle shape and adjusts the flow rate of the refrigerant by moving up and down by the drive unit 17b. A hollow portion 321 for housing the valve body 17a is formed in the flow path portion 32 of the flow path body 31, and an opening 331 for inserting the valve body 17a is formed in the casing 33.

[0121] In this embodiment, the refrigerant flow path 58 formed in the flow path body 31 includes a flow path portion 581 to which the other end of the expansion valve 17 is connected, and a flow path portion 582 to which one end of the expansion valve 17 is connected. The lower end of the flow path portion 581 communicates with the opening 58c2 of the casing 33. The upper end of the flow path portion 582 communicates with the opening 58c1 of the casing 33.

[0122] Since the other configurations of this embodiment are the same as those of the first embodiment shown in Figure 6, a detailed explanation will be omitted.

[0123] [Fourth Embodiment] Figure 16 is a schematic cross-sectional view showing the structure of a refrigerant flow path module according to the fourth embodiment of the present disclosure. In the refrigerant flow path module 40 of the first embodiment, as shown in Figure 6, the plurality of refrigerant flow paths 51b, 52b, 53b, 56b, 57, 58, 59 formed in the flow path section 32 were broadly divided into those that communicate with the hollow section 31A (51b, 52b, 53b, 56b) and those that do not (57, 58, 59). In contrast, in the refrigerant flow path module 40 of this embodiment, all of the plurality of refrigerant flow paths 51b, 52b, 53b, 56b formed in the flow path section 32 communicate with the hollow section 31A. Therefore, the flow of refrigerant flowing through the refrigerant flow paths 51b, 52b, 53b, 56b of the flow path section 32 is switched by the valve body 60 in the hollow section 31A and the flow is controlled.

[0124] Since the configurations of the refrigerant flow paths 51b, 52b, 53b, 56b, the hollow section 31A, and the valve body 60 in this embodiment are the same as in the first embodiment, a detailed explanation will be omitted.

[0125] In the first embodiment, the refrigerant flow path communicating with the hollow section 31A was referred to as the first refrigerant flow path, and the refrigerant flow path not communicating with the hollow section 31A was referred to as the second refrigerant flow path. In this embodiment, since all refrigerant flow paths 51b, 52b, 53b, and 56b communicate with the hollow section 31A, unlike the first and second embodiments, one of the refrigerant flow paths is designated as the first refrigerant flow path, regardless of whether or not it communicates with the hollow section 31A, and one of the other refrigerant flow paths is designated as the second refrigerant flow path.

[0126] In this embodiment, since all refrigerant flow paths 51b, 52b, 53b, and 56b are in communication with the hollow section 31A, the refrigerant flow path module 40 itself is substantially configured as a four-way switching valve (flow path switching valve) 18.

[0127] [Fifth Embodiment] Figure 17 is a schematic cross-sectional view showing the structure of a refrigerant flow path module according to the fifth embodiment of the present disclosure. In the first embodiment described above, as shown in Figure 6, the valve body 60 of a four-way switching valve (flow path switching valve) 18 was housed in a hollow portion 31A formed in the flow path body 31 of the refrigerant flow path module 40. In this embodiment, a hollow portion 31A in which the valve body 60 is housed is not formed in the flow path body 31. In this embodiment, a plurality of refrigerant flow paths 101, 102, and 103 are formed in the flow path section 32. The refrigerant flow path 103 penetrates the flow path section 32 vertically, and its upper and lower ends communicate with openings K formed in the casing 33. A joint pipe T is joined to each opening K, and the end of the joint pipe T is inserted into the refrigerant flow path 103. A check valve 71 is provided in the refrigerant flow path 103.

[0128] In this embodiment, the refrigerant flow path module 40 is configured similarly to the third embodiment, with a portion of the expansion valve 17 housed in the flow path body 31. The expansion valve 17 includes a valve body 17a housed in the flow path body 31 and a drive unit 17b discharged from the flow path body 31. A valve element 17c, driven by the drive unit 17b, is built into the valve body 17a. The valve element 17c is needle-shaped and moves up and down by the drive unit 17b to adjust the flow rate of the refrigerant.

[0129] In this embodiment, the refrigerant passage 101 formed in the flow path body 31 is connected to one end of the expansion valve 17, and the refrigerant passage 102 is connected to the other end of the expansion valve 17. The upper end of the refrigerant passage 101 and the lower end of the refrigerant passage 102 are in communication with the opening K of the casing 33. A joint pipe T is joined to the opening K, and the ends of the joint pipe T are inserted into the refrigerant passages 101 and 102. Strainers 72 are inserted into the refrigerant passages 101 and 102, respectively.

[0130] In the first embodiment, the refrigerant flow path communicating with the hollow section 31A was referred to as the first refrigerant flow path, and the refrigerant flow path not communicating with the hollow section 31A was referred to as the second refrigerant flow path. In this embodiment, since all of the refrigerant flow paths 51b, 52b, 53b, and 56b do not communicate with the hollow section 31A, unlike the first and second embodiments, one of the refrigerant flow paths is designated as the first refrigerant flow path, regardless of whether or not it communicates with the hollow section 31A, and one of the other refrigerant flow paths is designated as the second refrigerant flow path.

[0131] In this embodiment, one or two of the expansion valve 17, strainer 72, and check valve 71 may be omitted.

[0132] [Other Embodiments] In the above embodiment, among the plurality of refrigerant passages formed in the flow path section 32, the refrigerant passages 57 and 58 that do not communicate with the hollow section 31A housing the valve body 60 passed through the flow path section 32 in a straight line, but they may also pass through the flow path section 32 in a bent or curved state.

[0133] In the above embodiment, the sealing portions 34a to 34d were formed on the inner surface of the hollow portion 31A in the flow path portion 32, but they may also be integrally formed around the openings 61a and 61b of the through hole (passage) 61 in the valve body 60. In this case, the tips of the sealing portions 34a to 34d come into contact with the inner surface of the hollow portion 31A, thereby suppressing leakage of refrigerant into the gap between them. It is preferable that the valve body 60 on which the sealing portions are formed is made of a material with a lower tensile modulus than the material of the flow path portion 32. This suppresses wear of the flow path portion 32 due to contact with the sealing portion of the valve body 60.

[0134] In the refrigerant flow path module 40 of the above embodiment, the high-pressure refrigerant flowing through the recess 62 of the valve body 60 and the refrigerant flow paths 51b, 53b, and 56b is configured to leak into the gap between the inner surface of the hollow portion 31A and the outer surface 60a of the valve body 60, or to the outside of the flow path portion 32. However, the refrigerant flow path module 40 may be configured to prevent such leakage.

[0135] In the above embodiment, the valve body 60 has a through hole 61 that constitutes a passage for low-pressure refrigerant and a recess 62 that constitutes a passage for high-pressure refrigerant. However, it is not limited to this. For example, the valve body 60 may have a recess formed as a passage for low-pressure refrigerant, or a through hole formed as a passage for high-pressure refrigerant. The valve body 60 is not limited to the spherical or cylindrical shape described above, but may have other shapes as well.

[0136] The rotation axis C2 of the valve body 60 may be oriented horizontally or vertically. The rotation axis C2 of the valve body 60 may be oriented in a direction inclined with respect to the vertical and horizontal directions.

[0137] In the above embodiment, the refrigerant flow path module 40 was used as a four-way switching valve, but it may also be used as a three-way switching valve.

[0138] In the above embodiment, the valve body 60 of the four-way switching valve 18 was housed in the hollow portion 31A formed in the flow path body 31 (flow path portion 32), but the valve body of another valve, for example, the valve body of an electrically operated expansion valve 17 or the valve body of an electrically operated solenoid valve may be housed there.

[0139] [Effects of the Embodiment] (1) The refrigerant flow path module 40 of the above embodiment comprises a flow path section 32 in which a first refrigerant flow path R1 (for example, refrigerant flow paths 51b, 52b, 53b, 56b) and a second refrigerant flow path R2 (for example, refrigerant flow paths 57, 58, 59) are formed, and a casing 33 that houses the flow path section 32. The flow path section 32 is made of synthetic resin or a material mainly composed of aluminum, and the casing 33 is made of steel.

[0140] With this configuration, the flow path section 32 having first and second refrigerant flow paths R1 and R2 is formed from a material mainly composed of synthetic resin or aluminum, so the flow path section 32 can be formed by mold molding such as injection molding or die casting, thereby improving the manufacturability and processability of the flow path section 32. Since the flow path section 32 is housed in a casing 33 made of steel material which has higher rigidity than the flow path section 32, even if high-pressure refrigerant flows through the first refrigerant flow path R1 and the second refrigerant flow path R2 and high pressure is applied to the flow path section 32, the pressure resistance of the flow path section 32 can be increased by the casing 33. Furthermore, since the flow path section 32 in this embodiment is formed from a material mainly composed of synthetic resin or aluminum, even if it has a structure having a pipe section 81, a housing section 82, and ribs 83, and a gap S between the ribs 83, it can be easily molded by mold molding. In addition, since the flow path section 32 is composed of a plurality of divided parts 32A, 32B, it can be easily molded by mold molding.

[0141] (2) In the refrigerant flow path module 40 of (1) above, in the above embodiment, an opening K is formed in the casing 33 that communicates with the first refrigerant flow path R1 and the second refrigerant flow path R2. The refrigerant flow path module 40 further includes a pipe (joint pipe) T that is joined to the casing 33 at the periphery of the opening K. With this configuration, since the pipe T is joined at the periphery of the opening K formed in the casing 33, leakage of refrigerant from the gap between the opening K and the pipe T can be suppressed.

[0142] (3) In the refrigerant flow path module 40 of (1) or (2) above, the casing 33 is made of stainless steel in the above embodiment. This configuration makes it possible to improve the corrosion resistance of the casing 33.

[0143] (4) In any one of the refrigerant flow path modules 40 described in (1) to (3) above, in the above embodiment, the flow path portion 32 has a hollow portion 31A that communicates with the first refrigerant flow path R1. The refrigerant flow path module 40 further comprises a valve body 60 housed in the hollow portion 31A. With this configuration, since the flow path portion 32 is formed from a material mainly composed of synthetic resin or aluminum, the flow path portion 32 having the hollow portion 31A can be easily formed by molding. Furthermore, the refrigerant flow path module 40 can be used as a valve that controls the flow of refrigerant, such as a flow path switching valve.

[0144] (5) In the refrigerant flow path module 40 described in (4), the valve body 60 has passages 61 and 62 that can communicate with the first refrigerant flow path R1. With this configuration, the refrigerant flow path can be switched using the passages of the valve body 60.

[0145] (6) In the refrigerant flow path module 40 of (4) or (5) above, in the above embodiment, the valve body 60 is made of synthetic resin or a material mainly composed of aluminum. With this configuration, the valve body 60 can be easily formed by mold molding, and the manufacturability and processability of the valve body 60 can be improved. If the valve body 60 has passages 61 and 62, the manufacturability and processability of the valve body 60 can be improved even further.

[0146] (7) In any one of the refrigerant flow path modules 40 described in (4) to (6), the second refrigerant flow path R2 does not communicate with the hollow portion 31A but penetrates the flow path portion 32. With this configuration, the second refrigerant flow path R2 can form a refrigerant flow that is not directly affected by the flow path switching valve 18.

[0147] (8) A method for manufacturing any one of the refrigerant flow path modules 40 described in (1) to (7) above includes, in this order, a first step of molding the flow path section 32 and a second step of housing the flow path section 32 in a casing 33. With this configuration, the first refrigerant flow path R1 and the second refrigerant flow path R2 can be easily formed in the flow path section 32 in the first step.

[0148] (9) The method for manufacturing the refrigerant flow path module 40 described in (2) above includes, in this order, a first step of inserting the pipe T into the opening K and welding it to the casing 33, and a second step of housing the flow path section 32 in the casing 33 and connecting the pipe T to the first refrigerant flow path R1 and the second refrigerant flow path R2. With this configuration, the heat generated when welding the pipe T to the casing 33 is prevented from being transmitted to the flow path section 32.

[0149] (10) A method for manufacturing any one of the refrigerant flow path modules 40 described in (1) to (7) above is a method in which the casing 33 of the refrigerant flow path module 40 is composed of a plurality of components 33D, 33E, 33F, 33G, 33H, 33I, and 33J, and the method includes in this order a first step of housing a flow path portion 32 in the casing 33 and a second step of joining the plurality of components 33D, 33E, 33F, 33G, 33H, 33I, and 33J by welding, wherein in the second step a gap t is formed between the flow path portion 32 housed in the casing 33 and the joint portion of the plurality of components 33D, 33E, 33F, 33G, 33H, 33I, and 33J. With this configuration, it is possible to suppress the transfer of heat to the flow path portion 32 when welding the plurality of components 33D, 33E, 33F, 33G, 33H, 33I, and 33J that constitute the casing 33.

[0150] Although embodiments have been described above, it should be understood that various modifications to the form and details are possible without departing from the spirit and scope of the claims.

[0151] 31A: Hollow section 32: Flow path section 33: Casing 33D: Component 33E: Component 33F: Component 33G: Component 33H: Component 33I: Component 33J: Component 40: Refrigerant flow path module 60: Valve body 61: Through hole (passage) 62: Recess (passage) K: Opening R1: Refrigerant flow path (first refrigerant flow path) R2: Refrigerant flow path (second refrigerant flow path) T: Joint pipe

Claims

1. A refrigerant flow path module comprising: a flow path section (32) having a first refrigerant flow path (R1) and a second refrigerant flow path (R2) through which a refrigerant flows; and a casing (33) housing the flow path section (32), wherein the flow path section (32) is formed of a synthetic resin or a material mainly composed of aluminum, and the casing (33) is formed of a steel material.

2. The refrigerant flow module according to claim 1, wherein the casing (33) has an opening (K) that communicates with the first refrigerant flow path (R1) and the second refrigerant flow path (R2), and the refrigerant flow module further comprises a pipe (T) that is joined to the casing (33) at the periphery of the opening (K).

3. The refrigerant flow path module according to claim 1 or 2, wherein the casing (33) is made of stainless steel.

4. The refrigerant flow path module according to any one of claims 1 to 3, wherein the flow path portion (32) has a hollow portion (31A) that communicates with the first refrigerant flow path (R1), and the refrigerant flow path module further comprises a valve body (60) housed in the hollow portion (31A).

5. The refrigerant flow path module according to claim 4, wherein the valve body (60) has passages (61, 62) that can communicate with the first refrigerant flow path (R1).

6. The refrigerant flow path module according to claim 4 or 5, wherein the valve body (60) is formed of a synthetic resin or a material mainly composed of aluminum.

7. The refrigerant flow path module according to any one of claims 4 to 7, wherein the second refrigerant flow path (R2) does not communicate with the hollow portion (31A) but penetrates the flow path portion (32).

8. A method for manufacturing a refrigerant flow path module according to any one of claims 1 to 7, comprising, in this order, a first step of molding the flow path portion (32) and a second step of housing the flow path portion (32) in the casing (33).

9. A method for manufacturing a refrigerant flow path module according to claim 2, comprising, in this order: a first step of inserting the pipe (T) into the opening (K) and welding it to the casing (33); and a second step of housing the flow path section (32) in the casing (33) and connecting the pipe (T) to the first refrigerant flow path (R1) and the second refrigerant flow path (R2).

10. A method for manufacturing a refrigerant flow path module according to any one of claims 1 to 7, wherein the casing (33) of the refrigerant flow path module is composed of a plurality of components (33D, 33E, 33F, 33G, 33H, 33I, 33J), and the method includes, in this order, a first step of housing the flow path portion (32) in the casing (33), and a second step of joining the plurality of components (33D, 33E, 33F, 33G, 33H, 33I, 33J) by welding, wherein in the second step, a gap (t) is formed between the flow path portion (32) housed in the casing (33) and the joint portion of the plurality of components (33D, 33E, 33F, 33G, 33H, 33I, 33J).

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