OUTDOOR UNIT OF AIR-CONDITIONING APPARATUS

[Technical Field]

[0001] The present invention relates to an outdoor unit of an air-conditioning apparatus that includes a parallel-pipe heat exchanger made of, for example, ; aluminum or an aluminum alloy.

[Background Art]

[0002] There is a known outdoor unit of an air-conditioning apparatus in which a spacer is provided between a heat exchanger and a bottom plate. Fins and tubes included in the heat exchanger are made of aluminum or aluminum alloys. The bottom plate is made of steel. The spacer is made of base metal that is less noble than aluminum or nonmetal such as synthetic resin. With the presence of the spacer, corrosion of the fins of the heat exchanger is suppressed (see Patent Literature 1, for example).

[Citation List] [Patent Literature]

[0003] [Patent Literature 1] Japanese Unexamined Patent Application Publication No. 2005-114273

[Summary of Invention] [Technical Problem]

[0004] In such an outdoor unit of an air-conditioning apparatus, metal substances such as iron powder or copper powder may adhere to the heat exchanger. Rainwater or drain water may enter the outdoor unit. The iron powder or copper powder adhered to the heat exchanger may stay with such water at the bottom of the heat exchanger that is in contact with the spacer, instead of flowing with the water. If such a state continues for a long time, electrolytic corrosion may occur on the heat exchanger included in the above known outdoor unit of an air-conditioning apparatus.

[0005] The present invention is to solve the above problem and to provide an outdoor unit of an air-conditioning apparatus in which the occurrence of electrolytic corrosion on a heat exchanger is suppressed.

[Solution to Problem]

[0006] An outdoor unit of an air-conditioning apparatus according to the present; invention includes a bottom plate made of metal; a heat exchanger made of metal that is different from the metal used for the bottom plate, the heat exchanger being i provided on the bottom plate with a front face thereof from which air flows there into facing toward an outside; and a lower supporting member made of synthetic resin and provided at a lower end of the heat exchanger. The lower supporting member: includes a pair of side plates extending in a lateral direction of the heat exchanger and facing each other, the side plates being configured to support the lower end of the heat exchanger; a sloping plate provided between the pair of side plates and sloping downward from one end to the other end thereof; and drain holes provided at two respective ends of the sloping plate.

[Advantageous Effects of Invention]

[0007] According to the present invention, the lower supporting member made of synthetic resin and provided at the lower end of the heat exchanger includes the sloping plate and the drain holes provided at both ends of the sloping plate. Therefore, even if any rainwater or drain water may adhere to the heat exchanger, such water flows downward along the sloping plate and is discharged onto the bottom plate through the drain holes. Hence, rainwater or drain water does not accumulate at the bottom of the heat exchanger. Accordingly, the occurrence of electrolytic; corrosion of the heat exchanger is prevented.

[Brief Description of Drawings]

[0008] [Fig. 1] Fig. 1 is an exploded perspective view of an outdoor unit of an air-conditioning apparatus according to Embodiment.
[Fig. 2] Fig. 2 is a perspective view illustrating an upper end of a parallel-pipe iheat exchanger included in the outdoor unit illustrated in Fig. 1.
[Fig. 3] Fig. 3 is a perspective view illustrating a lower end of the parallel-pipe; heat exchanger included in the outdoor unit illustrated in Fig. 1.
[Fig. 4] Fig. 4 is a perspective view illustrating one of lateral ends of the paralfel-pipe heat exchanger included in the outdoor unit illustrated in Fig. 1.
[Fig. 5] Fig. 5 is a perspective view illustrating one of first and second supporting members provided to the parallel-pipe heat exchanger according to Embodiment.
[Fig. 6] Fig. 6 includes a plan view of one of the first and second supporting members, a sectional view of one of the first and second supporting members taken along line X-X, and an enlarged sectional view of encircled part a.
[Fig. 7] Fig. 7 is a plan view of a top panel with a portion thereof cut out.
[Fig. 8] Fig. 8 is a sectional view taken along line Y-Y illustrated in Fig. 7.
[Fig. 9] Fig. 9 is a side view of the second supporting member attached to an upper end of a front flat portion of the parallel-pipe heat exchanger.
[Fig. 10] Fig. 10 includes perspective views each illustrating an upper end of a fan-motor-supporting member seen from obliquely above.

[Description of Embodiments]

[0009] An embodiment of the outdoor unit of an air-conditioning apparatus according to the present invention will now be described in detail with reference to the accompanying drawings.

Fig. 1 is an exploded perspective view of an outdoor unit of an air-conditioning apparatus according to Embodiment. Fig. 2 is a perspective view illustrating ani upper end of a parallel-pipe heat exchanger 1 included in the outdoor unit illustrated iri Fig. 1. Fig. 3 is a perspective view illustrating a lower end of the parallel-pipe heat ; exchanger 1 included in the outdoor unit illustrated in Fig. 1. Fig. 4 is a perspective view illustrating one of lateral ends of the parallel-pipe heat exchanger 1 included in the outdoor unit illustrated in Fig. 1.

[0010] The outdoor unit of an air-conditioning apparatus according to Embodiment includes a bottom plate 12 having leg portions 11, the parallel-pipe heat exchanger 1, for example, provided on the bottom plate 12 with the back surface thereof facing toward the outside, a front panel 13 facing the front surface of the parallel-pipe heat exchanger 1, a side panel 14, and a top panel 19, whereby the outdoor unit has a box-like appearance. The back surface of the parallel-pipe heat exchanger 1 corresponds to an air inlet side, and the front surface of the parallel-pipe heat exchanger 1 corresponds to an air outlet side.

[0011] The internal space of the outdoor unit is separated into an air-sending-device chamber 5 and a machine chamber 9 by a separator 10 extending between the; front surface of the parallel-pipe heat exchanger 1 and the front panel 13. In the air-: sending-device chamber 5, a fan motor 3 is provided on the front surface of the; parallel-pipe heat exchanger 1. The fan motor 3 is provided with a propeller fan 2. A compressor 6 provided on the bottom plate 12, a refrigerant pipe 7, an electric \ component 8, and so forth are provided in the machine chamber 9. The bottom plate 12 is, for example, a thin steel plate that is electrically conductive.

[0012] The parallel-pipe heat exchanger 1 includes, for example, a front flat portion 1a, a corner portion 1 b continuous with a left end of the front flat portion 1 a and bent toward the front side, and a side flat portion 1c continuous with the corner portion 1b and extending further toward the front side. That is, the parallel-pipe heat exchanger 1 has an L shape in plan view. The parallel-pipe heat exchanger 1 includes header pipes provided at both ends, respectively, of the L shape, a plurality of flat tubes provided in parallel with one another between the header pipes, and corrugated fins provided between adjacent ones of the flat tubes. The header pipes, the flat tubes, and the corrugated fins are made of aluminum (or aluminum alloys). The header pipes and the flat tubes are brazed or welded to each other. The flat tubes and the corrugated fins are brazed or welded to each other.

[0013] One of the two header pipes at both ends of the parallel-pipe heat exchanger 1 that is closer to the machine chamber 9 is connected to the compressor 6 through the refrigerant pipe 7 and via a heat exchanger and so forth included in an indoor unit (not illustrated). The parallel-pipe heat exchanger 1 of the outdoor unit functions as an evaporator in a heating operation and as a condenser in a cooling operation;

[0014] A first supporting member 15A as a lower supporting member is provided at the lower end of the front flat portion 1 a of the parallel-pipe heat exchanger 1. A second supporting member 15B as an upper supporting member is provided at the upper end of the front flat portion 1a of the parallel-pipe heat exchanger 1 (see Figs. 1 to 3). As illustrated in Fig. 4, the first and second supporting members 15A and 15B are fitted into a connecting member 20 and are fastened thereto with screws 21, respectively. The first and second supporting members 15A and 15B have the same shape as to be described below.

[0015] A third supporting member 16A as another lower supporting member is j provided at the lower end of the side flat portion 1 c of the parallel-pipe heat exchanger 1. A fourth supporting member 16B as another upper supporting member is provided at the upper end of the side flat portion 1 c of the parallel-pipe heat! Exchanger 1. The third and fourth supporting members 16A and 16B have the same shape as to be described below.

[0016] The fan motor 3 is secured to a fan-motor-supporting member 4 that is locked to the second supporting member 15B of the parallel-pipe heat exchanger 1. The fan-motor-supporting member 4 will be described separately below.

[0017] The electric component 8 includes a circuit board that supplies power to the fan motor 3, the compressor 6, and other elements. When the fan motor 3 is activated with the power supplied from the electric component 8, the propeller fan 2 rotates. In response to this, air is taken from the back sides of the front flat portion 1a, the corner portion 1b, and the side flat portion 1c of the parallel-pipe heat exchanger 1, is made to flow through the parallel-pipe heat exchanger 1 into the air-sending-device : chamber 5 provided on the front side of the parallel-pipe heat exchanger 1, and is then discharged toward the front side of the outdoor unit through a bellmouth 13a provided in the front panel 13. For example, in the cooling operation, refrigerant in the parallel-pipe heat exchanger 1 is cooled by the air, and the air that has flowed through the parallel-pipe heat exchanger 1 exchanges heat with the refrigerant and is thus heated.

[0018] The above elements are assembled together in the following order. First; the first supporting member 15A and the second supporting member 15B are attached to the lower end and the upper end, respectively, of the front flat portion 1a of the parallel-pipe heat exchanger 1. Subsequently, the first and second supporting ; members 15A and 15B now residing on the lower side and the upper side, respectively, are fitted into the connecting member 20 and are fastened thereto iwith the screws 21. Furthermore, the third supporting member 16A and the fourth I supporting member 16B are attached to the lower end and the upper end, respectively, of the side flat portion 1 c of the parallel-pipe heat exchanger 1.

[0019] Subsequently, the parallel-pipe heat exchanger 1 is placed on the bottom plate 12 and is secured thereto. Furthermore, the compressor 6 is placed on the bottom plate 12 and is secured thereto. Then, the refrigerant pipe 7 that is connected to the compressor 6 is connected to the parallel-pipe heat exchanger 1. Subsequently, the fan-motor-supporting member 4 is locked to the second supporting member 15B having been attached to the front flat portion 1 a, and the fan motor 3 is secured to the fan-motor-supporting member 4. Furthermore, the propeller fan 2 is attached to the fan motor 3, the separator 10 is attached to the connecting member 20, and the electric component 8 is secured to the separator 10. Lastly, the front panel 13 and the side panel 14 are attached to the bottom plate 12, and the top panel 19 is ; attached to the front panel 13 and the side panel 14, whereby the top of the assembly is covered.

[0020] Configurations of the first and second supporting members 15Aand 15B will now be described with reference to Figs, 5 to 8.

Fig. 5 is a perspective view illustrating one of the first and second supporting members 15A and 15B provided to the parallel-pipe heat exchanger 1 according to Embodiment. Fig. 6 includes a plan view of one of the first and second supporting members 15A and 15B, a sectional view of one of the first and second supporting members 15A and 15B taken along line X-X, and an enlarged sectional view of; encircled part a. Fig. 7 is a plan view of the top panel 19 with a portion thereof cut out. Fig. 8 is a sectional view taken along line Y-Y illustrated in Fig. 7.

[0021] The first and second supporting members 15A and 15B are made of synthetic resin. As illustrated in Figs. 5 and 6, the first and second supporting members 15A and 15B each include a pair of side plates 15a and 15b extending in the lateral; direction of the parallel-pipe heat exchanger 1 and facing each other, a plurality! of sloping plates 15d obtained by making cuts in a flat plate 15c, which connects the pair of side plates 15a and 15b to each other, in the longitudinal direction and each \ sloping downward in one direction from the flat plate 15c, drain holes 15e and 15f provided at two respective ends of each of the sloping plates 15d, supporting plates 15g provided on the inner surfaces of the pair of side plates 15a and 15b and at respective positions that are above the sloping plates 15d and are staggered with one another with respect to a virtual line extending in the longitudinal direction of the side plates 15a and 15b, a positioning projection 15h that positions the fan-motor- ; supporting member 4 and is provided on the outer surface of the side plate 15a provided on one side, and fitted portions 15i projecting from the outer surface of the side plate 15b provided on the other side and to be fitted into the fan-motor-supporting member 4. The supporting plates 15g function as hooks having convexities that are to be fitted into the lower end or the upper end of the front flat portion 1 a of the parallel-pipe heat exchanger 1.

[0022] As illustrated in Figs. 5 and 6, the first and second supporting members 15A and 15B each have a header receiving portion 15j at one lateral end thereof. Ah end of a corresponding one of the header pipes is to be inserted into the header receiving portion 15j. The header receiving portion 15j has a screw hole 15k into which a corresponding one of the screws 21 is to be screwed. Furthermore, the other lateral end of each of the first and second supporting members 15A and 15B is open, that is, the other lateral end forms an opening. Hence, when seen from the other lateral end, each of the first and second supporting members 15Aand 15B has a substantially H-shaped cross section. One of the sloping plates 15d that is nearest to the other lateral end of each of the first and second supporting members 15Aand 15B extends horizontally from a predetermined position thereof and is connected to the opening. That is, the opening functions as a drain hole.

[0023] The third and fourth supporting members 16Aand 16B, although not specifically illustrated, are made of synthetic resin, as with the first and second \ supporting members 15A and 15B, and are shorter than the first and second supporting members 15A and 15B. For example, one sloping plate is provided; between a pair of side plates. A drain hole is provided at an upper position of the sloping plate. A lower portion of the sloping plate extends horizontally from a \ predetermined position and is connected to an opening functioning as a drain hole. As with the first and second supporting members 15Aand 15B, the third and fourth supporting members 16Aand 16B each have a header receiving portion at one; lateral end thereof. Embodiment concerns a case where the third and fourth supporting members 16A and 16B each have one sloping plate. This case is only exemplary. The third and fourth supporting members 16A and 16B may each have two or more sloping plates.

[0024] To attach the first supporting member 15Ato the lower end of the parallel-pipe heat exchanger 1, the first supporting member 15A is oriented such that the supporting plates 15g face upward, and the lower end of the front flat portion 1a of the parallel-pipe heat exchanger 1 is inserted into a groove provided between the side plates 15a and 15b until coming into contact with the supporting plates 15g. Meanwhile, the lower end of a corresponding one of the header pipes is inserted into the header receiving portion 15j. Subsequently, the second supporting member 15B is attached to the parallel-pipe heat exchanger 1. The second supporting member 15B is obtained by inverting the first supporting member 15A illustrated in Fig. 5 such that the supporting plates 15g face downward. The upper end of the front flat portion 1a of the parallel-pipe heat exchanger1 is inserted into a groove provided between the side plates 15a and 15b until coming into contact with the supporting plates! 15g. Meanwhile, the upper end of the header pipe is inserted into the header receiving portion 15j. Subsequently, as described above, the first and second supporting: members 15A and 15B on the lower side and the upper side, respectively, are fitted into the connecting member 20 and are fastened thereto with the screws 21.

[0025] As illustrated in Fig. 1, the third supporting member 16Ais attached to the lower end of the side flat portion 1c of the parallel-pipe heat exchanger 1. The fourth; supporting member 16B, which is obtained by vertically inverting the third supporting member 16A, is attached to the upper end of the side flat portion 1c. The third and fourth supporting members 16Aand 16B are attached to the parallel-pipe heat ; exchanger 1 in the same manner as for the first and second supporting members 15A and 15B.

[0026] Subsequently, the parallel-pipe heat exchanger 1 to which the first and second supporting members 15A and 15B and the third and fourth supporting members 16A and 16B have been attached is placed on the bottom plate 12 and is secured thereto. In this case, the lower end of the parallel-pipe heat exchanger 1 is placed on the bottom plate 12 with the first supporting member 15A and the third supporting member 16A interposed there between. Therefore, the bottom plate 12, which is a thin steel plate, and the parallel-pipe heat exchanger 1, which is made of aluminum (or an aluminum alloy), are prevented from coming into direct contact with each other. Moreover, even if any rainwater or drain water may adhere to the inner side of the front flat portion 1a of the parallel-pipe heat exchanger 1, such water flows into the first supporting member 15Aand further flows downward along the sloping plates 15d onto the bottom plate 12 through the drain hole 15f and the opening at the other lateral end of the first supporting member 15A. On the other hand, even if any \ rainwater or drain water may adhere to the inner side of the side flat portion 1 c of the parallel-pipe heat exchanger 1, such water flows into the third supporting member 16A and further flows downward along the sloping plate onto the bottom plate 12 through the opening at the other lateral end of the third supporting member 16A.

[0027] Even if the top panel 19 is placed over the parallel-pipe heat exchanger 1, the gap between the top panel 19 and the parallel-pipe heat exchanger 1 is maintained to be of a predetermined size because the second supporting member 15B and the fourth supporting member 16B are interposed between the top panel 19 and the upper end of the parallel-pipe heat exchanger 1, as illustrated in Fig. 8. That is; the top panel 19, which is a thin steel plate, and the parallel-pipe heat exchanger 1,; which is made of aluminum (or an aluminum alloy), are prevented from coming into direct contact with each other. Moreover, even if any rainwater adhered to the underside of the top panel 19 may fall because of wind blowing upward toward the top panel|19, such water flows downward along the sloping plates 15d into the drain holes 15e.

[0028] Now, a configuration of the fan-motor-supporting member 4 will be described with reference to Figs. 9 and 10.

Fig. 9 is a side view of the second supporting member 15B attached to the upper end of the front flat portion 1 a of the parallel-pipe heat exchanger 1. Fig.; 10 includes perspective views each illustrating the upper end of the fan-motor-supporting member 4 seen from obliquely above. The entirety and the lower end of the farii-motor-supporting member 4 will be described with reference to Figs. 1 and 3.

[0029] The fan-motor-supporting member 4 is a steel plate, for example. As illustrated in Fig. 1, the fan-motor-supporting member 4 has a rectangular shape extending in the vertical direction of the parallel-pipe heat exchanger 1, with the fan motor 3 j secured to a central portion thereof. As illustrated in Fig. 10, the upper end of the fan-motor-supporting member 4 has a locking portion 4a having a groove that is open on the lower side thereof. The second supporting member 15B is locked by the locking portion 4a. The locking portion 4a has cuts 4b in a central portion of one of waljs of the groove thereof that is closer to the side plate 15a of the second supporting j member 15B. The positioning projections 15h are fitted into the cuts 4b.

[0030] As illustrated in Fig. 3, elastic members 4c are provided on two respective sides at the lower end of the fan-motor-supporting member 4. The fitted portions 15i provided on the side plate 15b of the first supporting member 15A are held between the elastic members 4c. Furthermore, the fan-motor-supporting member 4 hasja spacer 4d in a central portion at the lower end thereof. The spacer 4d extends toward the parallel-pipe heat exchanger 1 and is perpendicularly bent upward. The spacer 4d is provided for maintaining the gap between the fan-motor-supporting member 4 and the parallel-pipe heat exchanger 1 to be of a predetermined size by being ip contact with the front surface of the parallel-pipe heat exchanger 1.

[0031] With the presence of the positioning projection 15h, the axial center of the fan motor 3 secured to the fan-motor-supporting member 4 and the center of the bellmouth 13a provided in the front panel 13 substantially coincide with each other. Thus, the occurrence of axial displacement between the two is prevented.

[0032] According to Embodiment described above, the first supporting member 15A made of synthetic resin and provided at the lower end of the parallel-pipe heat exchanger 1 has the plurality of sloping plates 15d and the drain holes 15e and 15f provided at both ends of each of the sloping plates 15d. Therefore, even if any; rainwater or drain water may adhere to the parallel-pipe heat exchanger 1, such water flows downward along the sloping plates 15d and is discharged onto the bottom plate 12 through the drain holes 15f. Hence, rainwater or drain water does not accumulate at the bottom of the parallel-pipe heat exchanger 1. Accordingly, the occurrence of electrolytic corrosion of the parallel-pipe heat exchanger 1 is prevented.

[0033] Furthermore, the second supporting member 15B and the fourth supporting member 16B are interposed between the top panel 19 and the upper end of the parallel-pipe heat exchanger 1. Therefore, the gap between the top panel 19 and the parallel-pipe heat exchanger 1 is maintained to be of a predetermined size. Hence, the top panel 19, which is a thin steel plate, and the parallel-pipe heat exchanger 1, which is made of aluminum (or an aluminum alloy), are prevented from coming pnto direct contact with each other. Consequently, the occurrence of electrolytic corrosion due to adhesion of rainwater is prevented.

[0034] Furthermore, the fan-motor-supporting member 4 is locked to the second supporting member 15B at the locking portion 4a provided at the upper end thereof. Furthermore, the fan-motor-supporting member 4 is secured to the parallel-pipe heat exchanger 1 with the fitted portions 15i provided on the side plate 15b of the first supporting member 15A being held between the elastic members 4c provided on both sides at the lower end of the fan-motor-supporting member 4. Therefore, the fan motor 3 is easily attachable to the parallel-pipe heat exchanger 1. Moreover, the cuts 4b into which the positioning projections 15h are fitted are provided in a central; portion of one of the walls of the groove of the locking portion 4a that is closer to the side plate 15a of the second supporting member 15B. Therefore, the occurrence of lateral displacement of the fan motor 3 is prevented.

[0035] Furthermore, since the first and second supporting members 15A and 15B have the same configuration and the third and fourth supporting members 16A and 16B have the same configuration, the number of components is reduced. Accordingly, the manufacturing cost of the outdoor unit is reduced.

[Reference Signs List]

[0036] 1: parallel-pipe heat exchanger, 1a: front flat portion, 1b: corner portion, 1c: side flat portion, 2: propeller fan, 3: fan motor, 4: fan-motor-supporting member,: 4a: locking portion, 4b: cut, 4c: elastic member, 4d: spacer, 5 air-sending-device chamber, 6: compressor, 7: refrigerant pipe, 8: electric component, 9: machine chamber, 10: separator, 11: leg portion, 12: bottom plate, 13: front panel, 13a: bellmouth, 14: side panel, 15A: first supporting member, 15B: second supporting member, 15a: skte plate on one side, 15b: side plate on the other side, 15c: flat plate, 15d: sloping plate; 15e and 15f: drain hole, 15g: supporting plate, 15h: positioning projection, 15i: fitted; portion, 15j: header receiving portion, 15k: screw hole, 16A: third supporting member, 16B: fourth supporting member, 19: top panel, 20: connecting member, 21: screw

[Name of Document]

CLAIMS

[Claim 1] An outdoor unit of an air-conditioning apparatus comprising:
a bottom plate made of metal;
a heat exchanger made of metal that is different from the metal used for the bottom plate, the heat exchanger being provided on the bottom plate and a front face of the heat exchanger from which air flows there into facing toward an outside; and
a lower supporting member made of synthetic resin and provided at a lower end of the heat exchanger,
wherein the lower supporting member includes
a pair of side plates extending in a lateral direction of the heat exchanger and facing each other, the side plates being configured to support the lower end of the heat exchanger;
a sloping plate provided between the pair of side plates and sloping downward from one end to the other end thereof; and
drain holes provided at two respective ends of the sloping plate.

[Claim 2] The outdoor unit of an air-conditioning apparatus of claim 1, wherein the \ sloping plate is one of a plurality of sloping plates arranged in a longitudinal direction of the side plates.

[Claim 3] The outdoor unit of an air-conditioning apparatus of claim 1 or 2, further I comprising an upper supporting member made of synthetic resin and provided at an upper end of the heat exchanger, the upper supporting member having a shape that is the same as but is vertically inverse to the lower supporting member.

[Claim 4] The outdoor unit of an air-conditioning apparatus of claim 3, further comprising:
a positioning projection configured to position a fan-motor-supporting meinber that projects from an outer surface of one of the side plates of the upper supporting member,

wherein the positioning projection resides at a position on a back side of the heat exchanger.