DUST COLLECTION BOX AND AIR CONDITIONER WITH THE SAME

Abstract

 A structure for storing dust removed from an air filter in an indoor unit is devised in order to possibly save time and manpower.
As viewed from an indoor side (as viewed in plan), a dust collection box (90) is provided such that at least a part of the dust collection box (90) is arranged so as to outwardly protrude from an opening (1a) of a ceiling board (1). The dust collection box (90) is connected to a discharge duct (74). Dust removed from an air filter (40) in a casing body (26) is transferred to the dust collection box (90) through the discharge duct (74) by blow-off air from an indoor fan (39).

Description

TECHNICAL FIELD

[0001] The present invention relates to a dust collection box for storing dust removed from an air filter in an indoor unit of an air conditioner.

BACKGROUND ART

[0002] Conventionally, as an indoor unit of an air conditioner including an air filter at an air suction port, the indoor unit provided with a dust removing means for removing dust trapped by the air filter has been known. The air conditioner of this type includes an indoor unit with a dust container in which dust removed from the air filter is stored. Hence, when disposing of the dust in the dust container, a user needs to detach the dust container after removing a cover (e.g., grille) of the indoor unit.

[0003] On the other hand, as described in, e.g., Patent Document 1, a structure has been proposed, in which a dust container is arranged outside a casing of an indoor unit so that only the dust container can be removed, and in which dust removed from an air filter by a dust removing means is transferred into the dust container by airflow. This allows the dust trapped by the air filter to be discharged to outside the casing to store the dust in the dust container, thereby easily removing the dust from the dust container without requiring user intervention.

CITATION LIST

PATENT DOCUMENT

[0004] PATENT DOCUMENT 1: Japanese Patent Application No. 2005-83721

SUMMARY OF THE INVENTION

TECHNICAL PROBLEM

[0005] However, in the air conditioner in Patent Document 1 described above, the dust container is arranged in an empty space on an indoor-side panel which is a part of the casing of the indoor unit, and the volume of the dust container cannot be increased due to the size of the empty space.

[0006] Even if the dust removed from the air filter in the indoor unit is stored in the dust container, it is necessary to frequently remove the dust stored in the dust container. Hence, even if the dust removed from the air filter is discharged to outside the casing of the indoor unit as described above, it needs process to get the dust out from the dust container, thereby making such a process burdensome for a user.

[0007] The present invention has been made in view of the foregoing, and it is an object of the present invention to devise the structure for storing the dust removed from the air filter in the indoor unit, thereby possibly saving time and manpower.

SOLUTION TO THE PROBLEM

[0008] In order to accomplish such an object, at least a part of a dust collection box (90) of the present invention is provided so as to outwardly protrude from an opening (1a) of a ceiling board (1) as viewed from an indoor side. This makes the volume of the dust collection box (90) larger than that of a conventional dust collection box, thereby possibly reducing a frequency of dust collection.

[0009] Specifically, a first aspect of the invention is intended for an dust collection box which is connected to a casing (26) of an indoor unit (13) of an air conditioner (10) installed in the opening (1a) formed in the ceiling board (1) through a transfer passage (76), and which stores dust removed from an air filter (40) positioned on a suction side of an indoor fan (39) of the casing (26), and discharged to outside the casing (26) through the transfer passage (76). The dust collection box is provided in a space above a ceiling such that at least a part of the dust collection box is positioned so as to outwardly protrude from the opening (1a) of the ceiling board (1) as viewed from the indoor side

[0010] In such a structure, the dust collection box (90) for storing the dust removed from the air filter (40) in the indoor unit (13) is not limited due to the size of or the empty space on the casing (26) of the indoor unit (13). Hence, the volume of the dust collection box (90) can be substantially increased, thereby possibly reducing the frequency of the dust collection from the dust collection box (90).

[0011] The dust collection box (90) is attached to a side of the casing (26) of the indoor unit (13) with a stopping means (96) (Second Aspect of the Invention). This allows the dust collection box (90) to be attached and fixed to the casing (26). Hence, a working process is not required to attach the dust collection box (90) to a wall surface in the space above the ceiling, thereby facilitating the installation in an indoor space.

[0012] In particular, it is preferred that the stopping means is magnets (96); and the magnets (96) are arranged on a surface which will contact the casing (26) made of metal (Third Aspect of the Invention). Hence, the dust collection box (90) can be easily attached to the side of the casing (26), and can be reliably attached even if there are some asperities on an attachment surface of the casing (26).

[0013] In the structure described above, it is preferred that the dust collection box (90) is arranged so as not to overlap with an entire hole (27a) for maintenance and inspection, which is formed in an indoor-side panel (27) of the indoor unit (13), as viewed from the indoor side (Fourth Aspect of the Invention).

[0014] As described above, by arranging the dust collection box (90) so as not to overlap with the entire hole (27a) for maintenance and inspection in the indoor-side panel (27) as viewed from the indoor side, the dust collection box (90) can be arranged at a position much closer to the hole (27a) without losing a function of the hole (27a) as the maintenance and inspection hole (e.g., adjustment of a suspension height of the casing (26)). This ensures both of workability during the maintenance and inspection of the indoor unit (13), and workability during the maintenance (e.g., dust collection) of the dust collection box (90).

[0015] It is preferred that a hole (91) for dust collection is formed in at least one of lower and side surfaces of the dust collection box (90) corresponding to the hole (27a) for maintenance and inspection, which is formed in the indoor-side panel (27) of the indoor unit (13) (Fifth Aspect of the Invention). This allows the dust to be collected by a vacuum, etc. from the indoor side without removing the dust collection box (90) from the space above the ceiling. That is, the dust can be collected from the dust collection box (90) through the hole (27a) for maintenance and inspection, which is formed in the indoor-side panel (27) of the indoor unit (13), and through the hole (91) for dust collection, which is formed in the upper or side surface of the dust collection box (90) corresponding to the hole (27a), thereby improving the workability during the dust collection.

[0016] The dust collection box (100) may be supported by supporting members (101) so as to be suspended from a top wall surface in the space above the ceiling (Sixth Aspect of the Invention). In this way, the dust collection box (100) can be reliably attached and fixed to the casing (26) in the space above the ceiling.

[0017] In particular, it is preferred that the dust collection box (100) is suspended and supported by casing supporting members (111) for supporting the casing (26) so as to be suspended from the top wall surface in the space above the ceiling (Seventh Aspect of the Invention). Consequently, the supporting members (111) for suspending and supporting the casing (26) of the indoor unit (13) can be shared without providing supporting members only for the dust collection box (100) in order to suspend and support the dust collection box (100) in the space above the ceiling, thereby further reducing cost and workload during the installation of the dust collection box.

[0018] A removal port (100c) for removing dust inside the dust collection box (100) may be formed in a lower portion of the side surface of the dust collection box (100) (Eighth Aspect of the Invention). By proving the removal port (100c) in the lower portion of the side surface, the dust stored in the dust collection box (100) can be collected through the removal port (100c), thereby improving the workability during the dust collection.

[0019] In the structure described above, it is preferred that the dust collection box (90, 100) is connected to the casing (26) through a flexible duct (74) defining the transfer passage (76) (Ninth Aspect of the Invention).

[0020] This allows the casing (26) of the indoor unit (13) to be reliably connected to the dust collection box (90, 100) through the duct (74). The dust removed from the air filter (40) of the indoor unit (13) is transferred through the duct (74) by blow-off air from the indoor fan (39), and then is reliably stored in the dust collection box (90, 100). That is, even if the casing (26) of the indoor unit (13) and the dust collection box (90, 100) are in any physical relationship, or vibration is applied thereto, a connection state between the casing (26) of the indoor unit (13) and the dust collection box (90, 100) can be maintained by the flexible tube (74), thereby reliably transferring the dust from the casing (26) of the indoor unit (13) to the dust collection box (90, 100).

[0021] The dust collection box (90, 100) includes a dust intake port (90a, 100a) connected to the transfer passage (76), and a discharge port (90b, 100b) for discharging the blow-off air from the indoor fan (39) used for transferring the dust, to outside; and the discharge port (90b, 100b) is positioned higher than the intake port (90a, 100a) (Tenth Aspect of the Invention).

[0022] In this way, the blow-off air from the indoor fan (39) for transferring the dust from the indoor unit (13) to the dust collection box (90, 100) flows into the box (90, 100) through the intake port (90a, 100a) of the dust collection box (90, 100) together with the dust, and then is discharged to outside through the discharge port (90b, 100b). At this point, by providing the discharge port (90b, 100b) higher than the intake port (90a, 100a) as described above, only the dust, which is heavier than the air, of the air and dust flowing into the dust collection box (90, 100) through the intake port (90a, 100a) is remained in the dust collection box (90, 100), and the air is discharged to outside through the discharge port (90b, 100b) positioned higher than the intake port (90a, 100a). Consequently, the structure described above allows the dust to be reliably stored in the dust collection box (90, 100), and prevents the dust from flowing to outside through the discharge port (90b, 100b) formed in the dust collection box (90, 100) together with the air.

[0023] In particular, it is preferred that the discharge port (90b, 100b) is formed in an upper surface of the dust collection box (90, 100) (Eleventh Aspect of the Invention). The formation of the discharge port (90b, 100b) in the upper surface of the dust collection box (90, 100) as described above reliably prevents the dust from being discharged to outside through discharge port (90b, 100b) together with the airflow, thereby more reliably storing the dust in the dust collection box (90, 100).

[0024] The intake port (100a) and the discharge port (100b) may be formed at positions opposing each other as viewed in plan (Twelfth Aspect of the Invention). The blow-off air from the indoor fan (39), which enters the dust collection box (90, 100) through the intake port (90a, 100a), passes through the dust collection box (90, 100), and then is discharged to outside through the discharge port (90b, 100b) formed in the position opposing the intake port (90a, 100a) as viewed in plan. The structure described above allows the air to smoothly flowing through the dust collection box (90, 100), thereby preventing occurrence of the airflow making the dust floating in the dust collection box (90, 100). Consequently, the dust can be efficiently stored in the dust collection box (90, 100).

[0025] It is preferred that an opening area of the discharge port (90b, 100b) is larger than that of the intake port (90a, 100a) (Thirteenth Aspect of the Invention). This allows the air to be easily discharged to outside through the discharge port (90b, 100b) which is an outlet of the air. Hence, after transferring the dust to the dust collection box (90, 100) without the occurrence of the airflow by which the air flowing into the dust collection box (90, 100) through the intake port (90a, 100a) makes the dust floating in the box (90, 100), the air is promptly discharged to outside. Consequently, the dust can be more efficiently stored in the dust collection box (90, 100).

[0026] It is preferred that a net (92) is provided in the discharge port (90b, 100b) so as to cover an opening (Fourteenth Aspect of the Invention). This prevents bugs and dirt from entering the dust collection box (90, 100) through the discharge port (90b, 100b), thereby storing only the dust removed from the air filter (40) of the indoor unit (13) in the dust collection box (90, 100). Consequently, the dust can be more efficiently stored in the dust collection box (90, 100).

[0027] In the structure described above, at least a part of the dust collection box (90, 100) is made of a transparent member (93, 103) in order to observe a dust storage amount (Fifteenth Aspect of the Invention). This allows the dust storage amount in the dust collection box (90, 100) to be easily checked, thereby collecting the dust from the dust collection box (90, 100) at a proper time interval. Consequently, a working efficiency during the dust collection can be improved.

[0028] The sixteenth aspect of the invention relates to an air conditioner (10) including the dust collection box (90, 100) of any one of the first to fifteenth aspects of the invention.

[0029] Specifically, the sixteenth aspect of the invention is intended for an air conditioner provided with an indoor unit (13) in which a casing (26) includes an indoor heat exchanger (37), an indoor fan (39) for sucking air from an indoor space and blowing the air to the indoor heat exchanger (37), and an air filter (40) provided on an suction side of the indoor fan (39).

[0030] In addition, the air conditioner includes a dust removing means (50) for removing dust trapped by the air filter (40); a dust transfer means (70) for transferring the dust removed by the dust removing means (50), to outside the casing (26); and the dust collection box of the first to fifteenth aspects of the invention, which is positioned outside the casing (26), and stores the dust transferred by the dust transfer means (70).

[0031] In such a structure, after removing the dust trapped by the air filter (40) in the indoor unit (13) by the dust removing means (50), the dust is transferred to outside the casing (26) by the dust transfer means (70), and then is stored in the dust collection box (90, 100) of any one of the first to fifteenth aspects of the invention. This achieves the air conditioner (10) which can provide the advantages as described in the first and fifteenth aspects of the invention.

[0032] It is preferred that the dust collection box (90, 100) is connected to the casing (26) through a flexible duct (74) defining the transfer passage (76), and that the flexible duct (74) is detachably connected to at least one of the dust collection box (90) and the casing (26) (Seventeenth Aspect of the Invention).

[0033] This allows the flexible duct (74) to be easily attached/detached to/from the dust collection box (90, 100) or the casing (26) upon the installation or maintenance of the dust collection box (90, 100), thereby improving the workability.

[0034] In particular, it is preferred that a hook (123b) is provided an end portion of the flexible duct (74), and that the hook (123b) is engageable with a protrusion (122a) which is provided in a corresponding member connected to the flexible duct (74) (Eighteenth Aspect of the Invention). Hence, when attaching/detaching the flexible duct (74) to/from the dust collection box (90) or the casing (26), the hook (123b) in the end portion of the flexible duct (74) may be engaged with or released from the protrusion (122a) provided in the corresponding member, thereby facilitating the attachment/detachment of the flexible duct (74).

ADVANTAGES OF THE INVENTION

[0035] As described above, according to the present invention, the dust collection box (90) which is connected to the casing (26) of the indoor unit (13) of the air conditioner (10) installed in the opening (1a) of the ceiling board (1) through the transfer passage (76) is provided in the space above the ceiling such that at least a part of the dust collection box (90) outwardly protrude from the opening (1a) as viewed from the indoor side, thereby substantially increasing the volume of the dust collection box (90) without limitation due to the structure of the casing (26) as in the conventional dust collection box. An amount of dust which will be stored in the dust collection box (90) can be possibly increased, thereby reducing the frequency of the dust collection. Consequently, ease of maintenance for a user is improved.

[0036] According to the second aspect of the invention, the dust collection box (90) is attached to the side of the casing (26) of the indoor unit (13) with the stopping means (96). Hence, the dust collection box (90) can be easily installed in the space above the ceiling, thereby improving the workability during the installation. In particular, as in the third aspect of the invention, the magnets (96) arranged on the contact surface of the dust collection box (90) are used as the stopping means, thereby reliably attaching the dust collection box (90) to the side of the casing (26) even if there are some asperities on the surface of the casing (26).

[0037] According to the fourth aspect of the invention, the dust collection box (90) is arranged so as not to overlap with the entire hole (27a) for maintenance and inspection, which is formed in the indoor-side panel (27) of the indoor unit (13), as viewed from the indoor side. Hence, the function of the hole (27a) as the maintenance and inspection hole for the indoor unit (13) can be ensured, and the dust collection box (90) can be arranged at the position which is more accessible through the hole (27a).

[0038] According to the fifth aspect of the invention, the hole (91) for dust collection is formed in the lower or side surface of the dust collection box (90) corresponding to the hole (27a) for maintenance and inspection, which is formed in the indoor-side panel (27) of the indoor unit (13). Hence, the dust in the dust collection box (90) can be collected from the indoor side, thereby improving the workability during the dust collection.

[0039] According to the sixth aspect of the invention, the dust collection box (100) is supported by supporting members (101) so as to be suspended from the top wall surface in the space above the ceiling, thereby reliably installing the dust collection box (100) in the space above the ceiling.

[0040] According to the seventh aspect of the invention, the dust collection box (100) is suspended and supported by the same supporting members (111) as those for the casing (26) of the indoor unit (13), which is supported so as to be suspended from the top wall surface in the space above the ceiling. Hence, it is not necessary to separately provide the supporting members only for the dust collection box, thereby further reducing cost and workload during the installation thereof.

[0041] According to the eighth aspect of the invention, the removal port (100c) for removing the dust is formed in the lower portion of the side surface of the dust collection box (100). Hence, the dust can be efficiently removed from the dust collection box (100), thereby improving the workability during the dust collection.

[0042] According to the ninth aspect of the invention, the dust collection box (90, 100) is connected to the casing (26) of the indoor unit (13) through the flexible duct (74), and is configured to transfer the dust through the duct (74). Hence, the dust collection box (90, 100) and the indoor unit (13) can be reliably connected to each other, thereby reliably transferring the dust from the indoor unit (13) to the dust collection box (90, 100). In addition, by using the flexible duct (74) as described above, the connection between the dust collection box (90, 100) and the casing (26) of the indoor unit (13) can be ensured even if the vibration is applied.

[0043] According to the tenth aspect of the invention, the dust collection box (90, 100) includes the dust intake port (90a, 100a), and the discharge port (90b, 100b) through which the air is discharged, and the discharge port (90b, 100b) is positioned higher than the intake port (90a, 100a). Hence, only the dust can be stored in the dust collection box (90, 100), thereby reliably preventing the dust from being discharged to outside through the discharge port (90b, 100b) together with the air.

[0044] In particular, as in the eleventh aspect of the invention, the discharge port (90b, 100b) is formed in the upper surface of the dust collection box (90, 100), thereby reliably preventing the dust from flowing to outside through the discharge port (90b, 100b) together with the air. On the other hand, as in the twelfth aspect of the invention, the intake port (90a, 100a) and the discharge port (90b, 100b) are formed at the positions opposing each other as viewed in plan. Hence, the air can smoothly flow in the dust collection box (90, 100), thereby efficiently storing the dust in the dust collection box (90, 100).

[0045] According to the thirteenth aspect of the invention, since the opening area of the discharge port (90b, 100b) is larger than that of the intake port (90a, 100a), the air smoothly flows in the dust collection box (90, 100) to be discharged to outside through the discharge port (90b, 100b). Hence, the occurrence of the airflow making the air floating in the dust collection box (90, 100) can be prevented, thereby more efficiently storing the dust in the dust collection box (90, 100).

[0046] According to the fourteenth aspect of the invention, the net (92) is provided so as to cover the discharge port (90b, 100b). Hence, the entering of bugs and dirt into the dust collection box (90, 100) through the discharge port (90b, 100b) can be prevented, thereby more efficiently storing the dust in the dust collection box (90, 100).

[0047] According to the fifteenth aspect of the invention, at least a part of the dust collection box (90, 100) is made of the transparent member (93, 103). Hence, the amount of the dust stored in the dust collection box (90, 100) can be easily checked, thereby collecting the dust from the dust collection box (90, 100) at the proper time interval. Consequently, the working efficiency during the dust collection can be improved.

[0048] The air conditioner (10) of the sixteenth aspect of the invention includes the dust collection box (90, 100) of any one of the first to fifteenth aspects of the invention, thereby providing the advantages similar to those of the first and fifteenth aspects of the invention.

[0049] According to the seventeenth aspect of the invention, the flexible duct (74) defining the transfer passage (76) is detachably connected to at least one of the dust collection box (90) and the casing (26). Hence, the attachment/detachment of the flexible duct (74) is facilitated, thereby improving the workability during the installation or maintenance of the dust collection box (90). In particular, as in the eighteenth aspect of the invention, the hook (123b) is provided in the end portion of the flexible duct (74), and the hook (123b) is engageable with the protrusion (122a) provided in the corresponding member. Hence, the structure of the seventeenth aspect of the invention can be achieved, thereby providing the advantages similar to those of the seventeenth aspect of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] 

[FIG. 1] FIG. 1 is a circuit diagram illustrating a structure of an air conditioner including a dust collection box of an embodiment of the present invention.

[FIG. 2] FIGS. 2(a) and 2(b) are views illustrating an indoor unit. FIG. 2(a) is a plan view from a space above a ceiling. FIG. 2(b) is a side view.

[FIG. 3] FIG. 3 is a vertical cross-sectional view illustrating a structure inside a casing.

[FIG. 4] FIG. 4 is an IV-IV cross-sectional view of FIG. 3.

[FIG. 5] FIG. 5 is a V-V cross-sectional view of FIG. 4.

[FIG. 6] FIG. 6 is a perspective view of a decorative panel as viewed from below.

[FIG. 7] FIG. 7 is a plan view illustrating an air filter.

[FIG. 8] FIG. 8 is a perspective view of a dust container as viewed from behind.

[FIG. 9] FIGS. 9(a) and 9(b) are views illustrating a rotation mechanism of the dust container. FIG. 9(a) illustrates the non-rotated dust container. FIG. 9(b) illustrates the rotated dust container.

[FIG. 10] FIGS. 10(a) and 10(b) are views illustrating an opening/closing mechanism of a damper of a supply duct. FIG. 10(a) illustrates the closed damper. FIG. 10(b) illustrates the opened damper.

[FIG. 11] FIGS. 11(a), 11(b), 11(c), and 11(d) are views illustrating processes in a filter cleaning operation of the embodiment of the present invention. FIGS. 11 (a) illustrates a state upon normal operation. FIG. 11(b) illustrates a state upon winding a filter. FIG. 11(c) illustrates a state upon rewinding the filter. FIG. 11(d) illustrates a state upon discharging dust.

[FIG. 12] FIG. 12 is a perspective view schematically illustrating an attachment structure of the dust collection box.

[FIG. 13] FIG. 13 is a view illustrating a state in which a dust collection box of Embodiment 2 is installed in a space above a ceiling.

[FIG. 14] FIG. 14 is a view corresponding to FIG. 12, which illustrates a dust collection box of Modified Example 1 of Embodiment 2.

[FIG. 15] FIG. 15 is a view corresponding to FIG. 12, which illustrates a dust collection box of Modified Example 2 of Embodiment 2.

[FIG. 16] FIG. 16 is a view corresponding to FIG. 2(a), which illustrates an air conditioner of the other embodiment.

[FIG. 17] FIG. 17 is a cross-sectional view schematically illustrating a structure of a connection portion between a dust collection box and a discharge duct.

DESCRIPTION OF EMBODIMENTS

[0051] Embodiments of the present invention will be described hereinafter with reference to the drawings. The following description of the preferable embodiments are essentially provided as mere examples, and is not intended to limit the present invention, objects to which the present invention is applied, or use thereof.

«Embodiment 1»

[0052] The present embodiment relates to an air conditioner (10) including a dust collection box (90) of the present invention. In the air conditioner (10), an indoor unit (13) is installed above a ceiling of an indoor space. A structure of the air conditioner (10) of the present embodiment will be described first, followed by description of structures of the indoor unit (13) and dust collection box (90).

<Entire Structure>

[0053] As illustrated in FIG. 1, the air conditioner (10) includes an outdoor unit (11) and the indoor unit (13). The outdoor unit (11) is provided with a compressor (30), an outdoor heat exchanger (35), an expansion valve (36), a four-way switching valve (33), and an outdoor fan (12). The indoor unit (13) is provided with an indoor heat exchanger (37) and an indoor fan (39).

[0054] In the outdoor unit (11), a discharge side of the compressor (30) is connected to a first port (P1) of the four-way switching valve (33). A suction side of the compressor (30) is connected to a third port (P3) of the four-way switching valve (33).

[0055] The outdoor heat exchanger (35) is configured as a cross-fin-type fin-and-tube heat exchanger. One end of the outdoor heat exchanger (35) is connected to a fourth port (P4) of the four-way switching valve (33). The other end of the outdoor heat exchanger (35) is connected to a liquid stop valve (15).

[0056] The outdoor fan (12) is provided near the outdoor heat exchanger (35). In the outdoor heat exchanger (35), heat is exchanged between outdoor air sent by the outdoor fan (12) and refrigerant circulating in the outdoor heat exchanger (35). The expansion valve (36) whose degree of opening is variable is provided between the outdoor heat exchanger (35) and the liquid stop valve (15). The second port (P2) of the four-way switching valve (33) is connected to a gas stop valve (16).

[0057] The four-way switching valve (33) switches between a first state (state indicated by a solid line in FIG. 1) in which the first port (P1) and the second port (P2) are communicated with each other with the third port (P3) communicating with the fourth port (P4), and a second state (state indicated by a dashed line in FIG. 1) in which the first port (P1) and the fourth port (P4) are communicated with each other with the second port (P2) communicating with the third port (P3).

[0058] In the air conditioner (10), a heating operation is performed when the four-way switching valve (33) is in the first state, and a cooling operation is performed when the four-way switching valve (33) is in the second state. In the heating operation, a vapor compression refrigeration cycle is performed, in which the outdoor heat exchanger (35) and the indoor heat exchanger (37) in a refrigerant circuit (18) function as an evaporator and an condenser, respectively. On the other hand, in the cooling operation, a vapor compression refrigeration cycle is performed, in which the outdoor heat exchanger (35) and the indoor heat exchanger (37) in the refrigerant circuit (18) function as the condenser and the evaporator, respectively.

<Structure of the Indoor Unit>

[0059] As illustrated in FIG. 2, the indoor unit (13) includes an indoor casing (34) provided with a casing body (casing) (26) and a decorative panel (27). As described later, a dust collection box (90) for collecting dust removed from an air filter (40) in the casing body (26) is provided outside the casing body (26). As illustrated in FIGS. 3-5, the casing body (26) includes the indoor heat exchanger (37), a drain pan (38), the indoor fan (39), the air filter (40), a dust removing means (50), a dust container (60), and a dust transfer means (70).

[0060] The casing body (26) is formed in an approximately rectangular parallelepiped box-like shape with an open bottom. An heat insulator (17) is laminated on an inner surface of the casing body (26). The casing body (26) is installed with its lower portion being inserted into an opening (1a) of a ceiling board (1), and is supported so as to be suspended from a top wall surface in a space above a ceiling.

[0061] The decorative panel (27) is formed in a rectangular plate-like shape (see FIG. 6). As viewed in plan, the shape of the decorative panel (27) is slightly larger than that of the casing body (26). The decorative panel (27) is attached to the casing body (26) so as to cover a lower side of the casing body (26) with a sealing material (19) being interposed therebetween. Hence, the decorative panel (27) is exposed on the indoor side with the decorative panel (27) being attached to the casing body (26).

[0062] As illustrated in FIG. 6, the decorative panel (27) is formed with one suction port (22), and four blow-off ports (23). The suction port (22) is formed in a rectangular shape at the center of the decorative panel (27), and a suction grille (29) with slits is fitted into the suction port (22). Each of the blow-off ports (23) is formed in an elongated rectangular shape along each side of the decorative panel (27). In addition, each of blow-off ports (23) is provided with an air-direction adjuster plate (23a) (see FIG. 3). The air-direction adjuster plate (23a) rotates to adjust an air direction (blow-off direction).

[0063] As illustrated in FIG. 2, triangular opening portions (27a) are formed at four corners of the decorative panel (27). The opening portions (27a) are holes for maintenance and inspection, which are used by a maintenance person to access the space above the ceiling during the maintenance and inspection of the indoor unit (13). For example, the opening portions (27a) are used by a maintenance person to access the space above the ceiling when adjusting the suspension height of the casing body (26) supported so as to be suspended from the top wall surface in the space above the ceiling. The opening portions (27a) are usually covered with detachable covers (27b).

[0064] The indoor fan (39) is a so-called "turbo-fan." As illustrated in FIGS. 3 and 5, the indoor fan (39) is arranged near the center of the casing body (26), and is positioned above the suction port (22). The indoor fan (39) includes a fan motor (39a), and an impeller (39b). The fan motor (39a) is fixed to a top plate of the casing body (26). The impeller (39b) is connected to a rotating shaft of the fan motor (39a). A bell mouth (25) communicating with the suction port (22) is provided below the indoor fan (39). In the casing body (26), the bell mouth (25) divides a space upstream of the indoor heat exchanger (37) into sections on the indoor fan (39) side and the suction grille (29) side. The indoor fan (39) is configured to blow air sucked from below in a circumferential direction through the bell mouth (25).

[0065] The indoor heat exchanger (37) is configured as a cross-fin-type fin-and-tube heat exchanger. The indoor heat exchanger (37) is formed in a rectangular frame-like shape as viewed in plan, and is arranged so as to surround the indoor fan (39). In the indoor heat exchanger (37), heat is exchanged between indoor air (blow-off air) sent by the indoor fan (39) and refrigerant circulating in the indoor heat exchanger (37).

[0066] The drain pan (38) is arranged below the indoor heat exchanger (37). The drain pan (38) is for receiving drainage generated as a result of condensing moisture in air in the indoor heat exchanger (37). The drain pan (38) is provided with a drain pump (not illustrated in the figure) for discharging the drainage. The drain pan (38) is provided with a slope such that the drainage is concentrated at a portion where the drain pump is arranged.

[0067] The air filter (40) is formed in an elongated sheet-like shape, and is arranged below the bell mouth (25) (on an inlet side of the bell mouth (25)). As illustrated in FIG. 7, the air filter (40) includes a filter body (41) having a rectangular shape as viewed in plan, and wound-up portions (42). The filter body (41) has a size sufficient to cover the inlet of the bell mouth (25), and is configured to trap dust in indoor air sucked into the indoor fan (39). The wound-up portions (42) are continuously connected to each of a pair of opposing sides of the filter body (41), and are wound up by first winding drum (53) and second winding drum (54) of the dust removing means (50) as described later. Each of another pair of sides of the filter body (41) to which the wound-up portions (42) are not connected (hereinafter referred to as a "lateral side"), is formed with a damper tab (43) and a container tab (44). The damper tab (43) is formed at an end portion of the filter body (41), and the container tab (44) is formed across the approximately entire lateral side.

[0068] The dust removing means (50) is for removing dust trapped by the air filter (40). As illustrated in FIGS. 3 and 4, the dust removing means (50) includes a rotating brush (51) as a brush member, and a filter moving means (52).

[0069] The filter moving means (52) is for holding the air filter (40) at a predetermined position, and for reciprocating the air filter (40) with respect to the rotating brush (51). The filter moving means (52) includes the first winding drum (53), the second winding drum (54), and a guide roller (55).

[0070] The first winding drum (53) and the second winding drum (54) are arranged below the bell mouth (25), and on an outer side with respect to the inlet of the bell mouth (25). The first winding drum (53) is positioned on the right side as viewed in FIG. 3 (hereinafter referred to as a "rear side"), and the second winding drum (54) is positioned on the left side as viewed in FIG. 3 (hereinafter referred to as a "front side"). The first and second winding drums (53, 54) are rotatably driven by drive motors (56) illustrated in FIG. 4, and are configured to wind or rewind the wound-up portion (42) of the air filter (40). This moves the filter body (41) of the air filter (40) toward the front or rear side. The guide roller (55) is arranged slightly on the front side with respect to the first winding drum (53). The guide roller (55) is configured to support the wound-up portion (42) of the air filter (40) from below, and to rotate in response to the movement of the air filter (40).

[0071] A frame-like guide member (57) formed so as to surround the inlet of the bell mouth (25) is attached to a lower surface of the bell mouth (25) (see FIGS. 3 and 5). The guide member (57) is for guiding the movement of the air filter (40) from above.

[0072] The rotating brush (51) includes a rod-like shaft and a brush portion which is configured with a plurality of bristles provided around the shaft. The rotating brush (51) is arranged in a brush receiving opening (62) of the dust container (60) described later such that the rotating brush (51) is positioned below and on the front side of the air filter (40). The rotating brush (51) is configured such that the filter body (41) moves to contact the brush portion, thereby removing dust. The rotating brush (51) is arranged so as to interpose the air filter (40) between the rotating brush (51) and the guide member (57). Hence, The filter body (41) is reliably pushed against the rotating brush (51), thereby improving an efficiency of dust removal.

[0073] In the dust container (60), dust removed by the rotating brush (51) is temporarily stored. As illustrated in FIG. 8, the dust container (60) is a slightly-elongated rectangular-parallelepiped-shaped container. The dust container (60) is arranged below and on the front side of the air filter (40) so as to laterally extend across the air filter (40) (see FIGS. 3 and 4). As described above, the rotating brush (51) is provided in the brush receiving opening (62) formed in an upper surface of the dust container (60).

[0074] The dust container (60) is formed with an arc portion (61) in which a central portion of a front-side surface of the dust container (60) in the vertical direction protrudes in a convex shape. The air filter (40) is folded along the arc portion (61), and is wound by the second winding drum (54). Duct openings (63) connected to flexible tubes (73, 75) of the dust transfer means (70) described later are formed in an end surface (hereinafter referred to as a "lateral surface") and a rear-side surface (hereinafter referred to as a "rear surface") of the dust container (60) in the width direction.

[0075] The dust container (60) is configured to rotate in response to the movement of the air filter (40). Specifically, as illustrated in FIG. 9, the dust container (60) includes a rotating shaft (65) penetrating the dust container (60) in the longitudinal direction, and a filter contact portion (64) protruding from an end portion of the upper surface of the dust container (60).

[0076] The dust container (60) is configured such that the rear side of the dust container (60) is upwardly pulled due to a bias force of a spring (66) upon normal operation (see FIG. 9(a)). A sealing portion (not illustrated in the figure) is provided between the rear side of the dust container (60) and the guide member (57), thereby partitioning between an inside of the dust container (60) and the suction side of the indoor fan (39) with the rear side of the dust container (60) being upwardly pulled as described above.

[0077] In addition, the dust container (60) is configured such that, upon cleaning the filter, the container tab (44) of the air filter (40) contact the filter contact portion (64) by moving the air filter (40), thereby pushing down and downwardly rotating the dust container (60) (see FIG. 9(b)). In such a state, the above-described sealing portion opens so that the filter body (41) can easily pass between the dust container (60) and the guide member (57). As described above, the rotating shaft (65), the filter contact portion (64), and the spring (66) configure a rotation mechanism for rotating the dust container (60) by moving the air filter (40).

[0078] The dust transfer means (70) is for transferring (discharging) dust from the dust container (60) to outside the casing body (26) together with air by injecting blow-off air from the indoor fan (39) into the dust container (60), and includes a supply duct (71) and a discharge duct (74) as illustrated in FIGS. 3-5. That is, the dust transfer means (70) is configured to transfer the dust in the dust container (60) to outside the casing by using the blow-off air from the indoor fan (39).

[0079] The supply duct (71) and the discharge duct (74) are arranged in a space below the bell mouth (25). An outlet end of the supply duct (71) is connected to the duct opening (63) in the rear surface of the dust container (60) through the flexible tube (73). The discharge duct (74) is a flexible duct which can be easily deformed, and an inlet end of the discharge duct (74) is connected to the duct opening (63) in the lateral surface of the dust container (60).

[0080] The supply duct (71) is configured such that an inlet-side opening communicates with a space where the indoor fan (39) is arranged, and an openable damper (72) is provided on such an opening portion. That is, the inlet-side opening of the supply duct (71) is positioned between a blow-off side of the indoor fan (39) and the indoor heat exchanger (37). As illustrated in FIGS. 4 and 10, the damper (72) is configured to be opened/closed in response to the movement of the air filter (40). Specifically, an opening/closing lever (81), one end of which is attached to an openable lid (72a) of the damper (72), is provided in the supply duct (71). The opening/closing lever (81) includes a rotating shaft (82) in the middle of the opening/closing lever (81), and is configured to rotate about the rotating shaft (82). The other end of the opening/closing lever (81) functions as a filter contact portion (81a) coming out from an opening hole in an upper surface of the supply duct (71).

[0081] That is, the inlet-side opening of the supply duct (71) is configured as an injection port through which the blow-off air from the indoor fan (39) is injected before passing through the indoor heat exchanger (37). The damper (72) is configured as an opening/closing means for opening/closing the injection port of the dust transfer means (70).

[0082] Upon normal operation, in the damper (72), one end side (damper (72) side) of the opening/closing lever (81) is downwardly pulled by a spring (83), thereby closing the openable lid (72a) (see FIG. 10(a)). This stops the blow-off air from the indoor fan (39) from flowing into the supply duct (71). In such a state, the filter contact portion (81a) of the opening/closing lever (81) protrudes from the opening hole in the upper surface of the supply duct (71).

[0083] Upon cleaning the filter, in the damper (72), the damper tab (43) of the air filter (40) contact the filter contact portion (81a) in response to the movement of the air filter (40), thereby retracting the filter contact portion (81a) into the supply duct (71) (see FIG. 10(b)). In such a state, the one end side of the opening/closing lever (81) upwardly rotates to open the openable lid (72a) of the damper (72). This allows the blow-off air from the indoor fan (39) to flow from the damper (72) to the supply duct (71), thereby supplying such blow-off air to the dust container (60).

[0084] An outlet end of the discharge duct (74) penetrates through a side wall of the casing body (26), and the discharge duct (74) extends to the dust collection box (90) attached to a side surface of the casing body (26) as illustrated in FIG. 2. That is, the discharge duct (74) is configured to transfer (discharge) the dust stored in the dust container (60) to outside the casing together with air from the supply duct (71). An inside of the discharge duct (74) defines a transfer passage (76) of the present invention.

<Structure of the Dust Collection Box>

[0085] The dust collection box (90) is an approximately-rectangular-parallelepiped-shaped member made of metal, and, as illustrated in FIG. 2, a part of the dust collection box (90) is arranged so as to protrude outwardly from the opening (1a) of the ceiling board (1) as viewed in plan (viewed from the indoor side). In addition, the dust collection box (90) is arranged near the opening portion (27a) so as not to overlap with the opening portion (27a) which is positioned at the corner of the decorative panel (27) as viewed in plan. This prevents the dust collection box (90) from blocking the opening portion (27a) when accessing the space above the ceiling, e.g., in order to adjust the suspension height of the casing body (26); and facilitates accessing the dust collection box (90) through the opening portion (27a).

[0086] A duct opening (90a) (intake port) connected to the other end of the discharge duct (74) is formed in a posterior surface of the dust collection box (90) (on the right side as viewed in the figure). An discharge port (90b) for discharging the blow-off air from the indoor fan (39), which is injected into the dust collection box (90) through the supply duct (71) and the discharge duct (74), to the space inside the ceiling is formed in an upper surface of the dust collection box (90). In the present embodiment, the duct opening (90a) and the discharge port (90b) are provided in the posterior surface and upper surface of the dust collection box (90), respectively. However, the present invention is not limited to such a structure, and the duct opening (90a) and the discharge port (90b) may be provided, e.g., in surfaces other than the rear and upper surfaces.

[0087] The discharge port (90b) has a larger opening area than that of the duct opening (90a), and is provided with a net (92) for preventing bugs and dirt from entering the dust collection box (90). A transparent window (93) made of a transparent member (e.g., a glass or acrylic plate) is provided in a lower portion of a side surface of the dust collection box (90), and antibacterial agent or bug repellent is contained in the dust collection box (90). The entire dust collection box (90) or at least one surface thereof may be configured with the transparent member, and a door may be provided instead of the transparent window (93) to check an amount of the dust stored in the box by opening such a door.

[0088] A collection port (91) (hole for dust collection) is formed in a lower portion of a side surface of the dust collection box (90) corresponding to the opening portion (27a) (hole for maintenance and inspection) of the decorative panel (27). When collecting the dust from the dust collection box (90), a vacuum (95) is inserted into the collection port (91) with the vacuum (95) penetrating through the opening portion (27a) of the decorative panel (27), thereby collecting the dust from the dust collection box (90) by the vacuum (95) (see FIG. 2(b)). That is, the collection port (91) is formed at a position (e.g., in the lower portion of the side surface of the dust collection box (90) as viewed in the figure) where the dust in the dust collection box (90) can be easily collected through the opening portion (27a) of the decorative panel (27).

[0089] The present invention is not limited to the collection port (91) provided in the side surface of the dust collection box (90), and the collection port (91) may be provided, e.g., in a bottom surface as long as the dust can be easily collected from the dust collection box (90). It is preferable that the collection port (91) has a sealing structure in which the dust does not flow out from the collection port (91) except upon the dust collection, and only an end of a vacuum can be inserted into the collection port (91).

[0090] As illustrated in FIG. 12, the dust collection box (90) is attached to the side surface of the casing body (26) with magnets (96) (stopping means). That is, the casing body (26) is formed by assembling metal members, and is configured such that a plurality of magnets (96) provided on the side surface of the dust collection box (90) can be attached thereto. The magnets (96) allow the dust collection box (90) to be easily fixed to the side surface of the casing body (26). By using the magnets (96) in such a manner, the dust collection box (90) can be reliably attached to the side surface of the casing body (26) even if there are some asperities on the side surface of the casing body (26).

[0091] In the present embodiment, the dust collection box (90) is attached to the side surface of the casing body (26) by using the magnets (96), but the present invention is not limited to such a structure. The dust collection box (90) may be fixed to the side surface of the casing body (26), e.g., with adhesive, or by using other engaging means such as a projection provided in at least one of the dust collection box (90) and the casing body (26) to be engaged with a member of the other one of the dust collection box (90) and the casing body (26).

[0092] As described above, the dust collection box (90) is arranged so as to outwardly protrude from the opening (1a) of the ceiling board (1) as viewed in plan, thereby increasing the volume of the dust collection box (90) without limitation due to the size of the opening (1a) of the ceiling board (1), or the size of the casing body (26). This allows a large amount of dust to be trapped, thereby reducing a frequency of the dust collection from the dust collection box (90). Consequently, a working efficiency of the dust collection can be improved.

[0093] Since the dust collection box (90) is attached to the side surface of the casing body (26), a working process is not required to support the dust collection box (90) in the space above the ceiling. Consequently, workload is reduced during installation of the dust collection box (90).

[0094] In addition, since the dust in the dust collection box (90) is collected through the opening portion (27a) of the decorative panel (27), and the collection port (91) of the dust collection box (90) by the vacuum (95), the dust can be collected from the indoor side without working in the space above the ceiling. Consequently, workability is improved.

[0095] As described above, by arranging the discharge port (90b) higher than the duct opening (90a), the dust discharged to the dust collection box (90) together with the blow-off air from the indoor fan (39) drops by its own weight to be accumulated, and the blow-off air is discharged to the space above the ceiling through the discharge port (90b). Hence, this prevents the dust from being discharged to the space above the ceiling together with the air through the discharge port (90b), thereby efficiently storing the dust in the dust collection box (90). In particular, as described above, the discharge port (90b) is formed in the upper surface of the dust collection box (90), thereby more reliably preventing the dust from being discharged through the discharge port (90b).

[0096] Since the discharge port (90b) has the larger opening area than that of the duct opening (90a), airflow resistance of the discharge port (90b) decreases to easily discharge the air from the dust collection box (90). This prevents the dust from floating in the dust collection box (90) due to disturbed airflow, thereby reliably store the dust in the dust collection box (90).

[0097] In addition, as described above, the net (92) is provided in the discharge port (90b), thereby preventing bugs and dirt from entering the dust collection box (90) through the discharge port (90b). Consequently, the dust can be more efficiently stored in the dust collection box (90).

[0098] The transparent window (93) is provided in the lower portion of the side surface of the dust collection box (90), thereby easily checking the amount of the dust accumulated in the dust collection box (90) from outside. Consequently, the dust in the dust collection box (90) can be collected at a proper time interval.

<Filter Cleaning Process>

[0099] The air conditioner (10) of the present embodiment can switch between a normal operation for cooling/heating a room, and a filter cleaning operation for cleaning the air filter (40).

[0100] First, in the normal operation, the compressor (30), the outdoor fan (12), and the indoor fan (39) are driven. In the indoor unit (13), the indoor air is sucked into the indoor unit (13) through the suction port (22) to pass through the bell mouth (25), and then blows from the indoor fan (39). The blow-off air is cooled or heated by exchanging heat between the blow-off air and the refrigerant in the indoor heat exchanger (37), and then is supplied to an indoor space through the blow-off ports (23).

[0101] As illustrated in FIG. 11(a), upon the above-described normal operation, the air filter (40) is arranged at a predetermined position so as to cover the bell mouth (25). Hence, the indoor air sucked through the suction port (22) passes through the air filter (40) before flowing into the bell mouth (25). At this point, the dust is trapped by the air filter (40). The damper (72) of the supply duct (71) is closed, and therefore the blow-off air from the indoor fan (39) does not flow into the supply duct (71). Consequently, the blow-off air from the indoor fan (39) is all supplied to the indoor heat exchanger (37), thereby reducing degradation in operation efficiency of the indoor fan (39).

[0102] Next, the filter cleaning operation (filter cleaning process) will be described with reference to FIGS. 11(b)-11(d). The filter cleaning operation includes a dust removing process for removing the dust trapped by the air filter (40); and a dust transfer process for transferring the removed dust to outside the casing body (26).

[0103] First, in the filter cleaning operation, when stopping the indoor fan (39), the two drive motors (56) of the dust removing means (50) are driven to remove the dust. In such a state, as illustrated in FIG. 11(b), the second winding drum (54) winds up the air filter (40), thereby moving the air filter (40). The container tab (44) of the air filter (40) contacts the filter contact portion (64) of the dust container (60), thereby downwardly rotating the dust container (60). This forms a gap between the rear side of the dust container (60) and the guide member (57). Consequently, the filter body (41) passes between the rotating brush (51) and the guide member (57) without being stopped by the dust container (60). Since the dust container (60) is connected to the supply duct (71) and to the discharge duct (74) through the flexible tubes (73, 75), they are not disconnected by the rotation of the dust container (60).

[0104] When the filter body (41) passes between the dust container (60) and the guide member (57), the dust is removed by the rotating brush (51). The removed dust is stored in the dust container (60). In such a state, the damper (72) is closed. After the entire filter body (41) passes through the rotating brush (51), the drive motors (56) automatically and reversely rotate to rewind the air filter (40) (see FIG. 11(c)). Hence, the air filter (40) is wound by the first winding drum (53). The container tab (44) of the air filter (40) remains in contact with the filter contact portion (64) until a rotational direction of the drive motors (56) is switched as described above. Consequently, the dust container (60) remains rotated downwardly.

[0105] When the air filter (40) is rewound and returns to a predetermined position, the container tab (44) of the air filter (40) is separated from the filter contact portion (64), and then the dust container (60) upwardly rotates to return to the original state. That is, the gap between the rear side of the dust container (60) and the guide member (57) is sealed. When the air filter (40) returns to the predetermined position, the indoor fan (39) is driven again to perform the dust transfer process.

[0106] When the indoor fan (39) is driven again, the air filter (40) is further wound by the first winding drum (53). That is, in FIGS. 11, the air filter (40) moves from the predetermined positioned to the right side. When the air filter (40) moves, the damper tab (43) of the air filter (40) contacts the filter contact portion (81a) of the supply duct (71). Subsequently, as illustrated in FIG. 11(d), the opening/closing lever (81) of the supply duct (71) rotates to open the openable lid (72a) of the damper (72). At this point, the drive motors (56) are stopped.

[0107] When opening the damper (72), a part of the blow-off air from the indoor fan (39) flows into the supply duct (71), and then is supplied to the dust container (60). The air flowing into the dust container (60) flows into the discharge duct (74) together with the dust, and then is discharged into the dust collection box (90) arranged outside the casing body (26). At this point, only the dust is stored in the dust collection box (90), and the blow-off air from the indoor fan (39) is discharged to the space above the ceiling through the discharge port (90b) formed in the dust collection box (90). Since the gap between the dust container (60) and the guide member (57) is sealed, the air supplied to the dust container (60) does not flow out through the brush receiving opening (62). After such a discharge process is performed for a predetermined period of time, the drive motors (56) are driven again to return the air filter (40) to the predetermined position. This makes the damper tab (43) of the air filter (40) separate from the filter contact portion (81 a) of the opening/closing lever (81), thereby closing the damper (72). Then, the filter cleaning operation is completed.

[0108] In the above-described filter cleaning operation, timing of the reverse rotation drive of the drive motors (56), or timing of starting/stopping the drive motors (56) may be determined depending on a rotational speed of the drive motors (56). In order to determine the timing of starting/stopping the drive motors (56), a limit switch may be arranged in a predetermined portion, and a striker corresponding thereto may be provided in the air filter (40).

[0109] In addition, in the filter cleaning operation, it is not necessary to perform the dust transfer process every time. For example, a storage amount detecting means for detecting when a dust storage amount of the dust container (60) exceeds a predetermined amount upon the filter cleaning operation may be provided, and the dust transfer process may be performed only when the storage amount detecting means detects such a state.

Advantages of Embodiment 1

[0110] As described above, in the present embodiment, the dust collection box (90) for storing the dust which is removed from the air filter (40), and then is discharged to outside the casing body (26) is provided so as to outwardly protrude from the opening (1a) of the ceiling board (1) as viewed in plan. Hence, the volume of the dust collection box (90) can be increased without the limitation due to the size of the opening (1a) of the ceiling board (1), or the size of the casing (34). This allows a large amount of dust to be stored in the dust collection box (90), thereby reducing a frequency of the dust collection from the dust collection box (90). Consequently, the working efficiency of the dust collection can be improved.

[0111] In addition, by attaching the dust collection box (90) to the side surface of the casing body (26), parts such as supporting members, and an attachment work of the dust collection box (90) to a lateral or top wall surface in the space above the ceiling are not required as compared to arranging only the dust collection box (90) in the ceiling, thereby facilitating an installation process. In particular, the dust collection box (90) is attached to the side surface of the casing body (26) with the magnets (96), thereby easily and reliably fixing the dust collection box (90) to the side surface of the casing body (26) even if there are some asperities on the side surface of the casing body (26).

[0112] The dust collection box (90) is arranged so as not to overlap with the entire opening portion (27a) of the decorative panel (27) as viewed from the indoor side, thereby preventing the dust collection box (90) from blocking the opening portion (27a) used for the maintenance of the casing body (26), and accessing the dust collection box (90) through the opening portion (27a) to collect the dust. Consequently, workability during the maintenance of the casing body (26) can be ensured, and workability during the dust collection from the dust collection box (90) can be improved.

[0113] The duct opening (90a) to which the discharge duct (74) is connected is provided in the posterior surface of the dust collection box (90), and the discharge port (90b) is provided in the upper surface of the dust collection box (90). Hence, the dust discharged into the dust collection box (90) is accumulated in the dust collection box (90) by its own weight, and only the air is discharged to the space above the ceiling through the discharge port (90b). That is, since the discharge port (90b) is positioned higher than the duct opening (90a), the dust discharged into the dust collection box (90) through the duct opening (90a) is stored in the dust collection box (90) without being discharged to the space above the ceiling through the discharge port (90b). This results in efficiently storing the dust in the dust collection box (90).

[0114] In addition, since the discharge port (90b) has the larger opening area than that of the duct opening (90a), the airflow resistance of the discharge port (90b) decreases to make the air smoothly pass through the dust collection box (90). This prevents occurrence of an airflow making the dust floating in the dust collection box (90), thereby more efficiently storing the dust in the dust collection box (90).

[0115] The discharge duct (74) connected to the duct opening (90a) is the flexible duct. Hence, even if relative displacement is caused between the casing body (26) and the dust collection box (90) due to vibration, etc., a connection state between the casing body (26) and the dust collection box (90) can be maintained, thereby reliably transferring the dust from the casing body (26) to the dust collection box (90).

[0116] The net (92) is provided in the discharge port (90b). Hence, this reliably prevents bugs and dirt from entering the dust collection box (90) through the discharge port (90b), thereby efficiently storing only the dust in the dust collection box (90).

[0117] In addition, the collection port (91) is formed in the lower portion of the side surface of the dust collection box (90). Hence, the vacuum is inserted into the dust collection box (90) from the indoor side with the vacuum penetrating through the opening portion (27a) and collection port (91), thereby collecting the dust from the dust collection box (90). Consequently, even when collecting the dust from the dust collection box (90), the dust can be collected from the indoor side without working in the space above the ceiling, thereby improving the working efficiency.

«Embodiment 2»

[0118] Next, Embodiment 2 of the present invention will be described with reference to FIG. 13. As illustrated in FIG. 13, the present embodiment differs from Embodiment 1 in that a dust collection box is not attached to the side surface of the casing body (26) of the indoor unit (13), but is supported by the top wall surface in the space above the ceiling. Hence, the same reference numbers as those in Embodiment 1 represent the same or like elements, and different portions will be described below.

[0119] That is, a dust collection box (100) of the present embodiment is connected and fixed to one ends of a plurality of supporting members (101), the other ends of which are fixed to the top wall surface in the space above the ceiling; and is supported by the supporting members (101) so as to be suspended from the top wall surface in the space above the ceiling. The dust collection box (100) is formed with a duct opening (100a) and a discharge port (100b) at positions opposing each other as viewed in plan. The discharge port (100b) is provided higher than the duct opening (100a). As similar to Embodiment 1, the other end of the discharge duct (74) extending from the casing body (26) of the indoor unit (13) is connected to the duct opening (100a). The discharge duct (74) is the flexible duct, and the discharge port (100b) is provided with the net as similar to Embodiment 1.

[0120] A collection port (100c) for collecting dust is provided in a lower portion of a side surface of the dust collection box (100). The collection port (100c) is provided with, e.g., a door (102), thereby accessing a space in the dust collection box (100) only when collecting the dust. A reference number "103" in FIG. 13 represents a transparent window for easily observing an amount of the dust in the dust collection box (100), which is made of a glass or acrylic plate, as similar to Embodiment 1.

[0121] In the present embodiment, the discharge port (100b) is formed in the side surface of the dust collection box (100). However, the present invention is not limited to such a structure, and the discharge port (100b) may be formed in an upper surface of the dust collection box (100). As similar to Embodiment 1, the formation of the discharge port (100b) in the upper surface can more reliably prevents the dust from being discharged to the space above the ceiling through the discharge port by airflow.

Advantages of Embodiment 2

[0122] As described above, according to the present embodiment, the dust collection box (100) for storing the dust removed from the air filter (40) is supported by the plurality of supporting members (101) so as to be suspended from the top wall surface in the space above the ceiling, thereby further increasing the size of the dust collection box (100). Consequently, the frequency of the dust collection can be possibly reduced. In addition, the dust collection box (100) is suspended and supported separately from the casing body (26), thereby not requiring strength improvement of the indoor casing (34), which is required upon attaching the dust collection box to the casing body (26).

[0123] As described above, the discharge duct (74) which is the flexible duct connects between the dust collection box (100) and the casing body (26), thereby preventing breakage of the duct or disconnection of the connection portion even if causing vibration or relative displacement between the dust collection box (100) and the casing body (26). Consequently, the dust can be reliably discharged from the casing body (26) to the dust collection box (100).

[0124] In addition, the duct opening (100a) and the discharge port (100b) are provided at the positions in the dust collection box (100), which oppose each other as viewed in plan, thereby smoothly circulating the air flowing into the dust collection box (100) through the duct opening (100a), in the dust collection box (100) without blocking the airflow. This more reliably prevents the occurrence of the airflow making the dust float in the dust collection box (100).

Modified Example 1 of Embodiment 2

[0125] As illustrated in FIG. 14, Modified Example 1 is that the dust collection box (100) is also suspended and supported by supporting members (111) (casing supporting members) for suspending and supporting the casing body (26) in the present embodiment.

[0126] Specifically, the dust collection box (100) is arranged on a side of the casing body (26) supported so as to be suspended from the top wall surface in the space above the ceiling, and is connected and fixed to the supporting members (111) for supporting the casing body (26). For example, in an example illustrated in FIG. 14, the dust collection box (100) is connected and fixed to one supporting member (111) at two points positioned one above the other.

[0127] Such a structure makes a single supporting member function as the supporting member of the dust collection box (100) and of the casing body (26), thereby reducing the number of parts, and reducing workload upon attachment of the supporting members in the space above the ceiling.

Modified Example 2 of Embodiment 2

[0128] As illustrated in FIG. 15, Modified Example 2 is that a plurality of casing bodies (26) (in FIG. 15, two casing bodies (26)) are connected to one dust collection box (100) in the present embodiment.

[0129] Specifically, duct openings (100a) are formed in opposing surfaces of the dust collection box (100), and are connected to one ends of the discharge ducts (74), the other ends of which are connected to the casing bodies (26). The discharge port (100b) is formed in the upper surface of the dust collection box (100).

[0130] As described above, one dust collection box (100) is connected to the discharge ducts (74) extending from the plurality of casing bodies (26), thereby not requiring the dust collection box (100) per indoor unit (13). Consequently, cost reduction and downsizing of the entire system can be realized.

[0131] In FIG. 15, one dust collection box (100) is connected to the discharge ducts (74) extending from two casing bodies (26). However, the present invention is not limited to such a structure, and one dust collection box (100) may be connected to, e.g., three or more casings.

«Other Embodiment»

[0132] The above-described embodiments may be configured as described below.

[0133] For example, in each of the above-described embodiments, the dust collection box (90, 100) is fixed to the casing body (26) of the indoor unit (13) or to the top wall surface in the space above the ceiling. However, the present invention is not limited to such a structure, and the dust collection box (90, 100) may be installed on a floor surface in the space above the ceiling.

[0134] In each of the above-described embodiments, the dust collection box (90, 100) is made of metal members. However, the present invention is not limited to such a structure, and the dust collection box (90, 100) may be made of resin material, paper, or wood for the purpose of weight reduction. In addition, the dust collection box (90, 100) has the rectangular parallelepiped shape. However, the present invention is not limited to such a structure, and the dust collection box (90, 100) may have, e.g., a cylindrical shape.

[0135] In each of the above-described embodiments, the dust container (60) and the damper (72) are driven in response to the movement of the air filter (40), and the dust removed from the air filter (40) by the rotating brush (51) is discharged to outside the casing body (26) with the blow-off air from the indoor fan (39). However, the present invention is not limited to such a structure, any structure may be applied as long as the dust trapped by the air filter (40) is removed, and the removed dust is discharged to outside the casing body (26).

[0136] In each of the above-described embodiments, the dust removed by the rotating brush (51) is temporarily stored in the dust container (60), and then is transferred. However, the dust removed by the rotating brush (51) may be directly transferred by the blow-off air from the indoor fan (39) without the dust container (60) and the supply duct (71).

[0137] In addition, in each of the above-described embodiments, the end portions of the discharge duct (74) are simply connected to the dust collection box (90, 100) and the casing body (26). However, the present invention is not limited to such a structure, and the end portions may be detachable. The detachable end portions of the duct (74) will be described hereinafter in detail by using the structure of Embodiment 1 as an example.

[0138] Specifically, as illustrated in FIGS. 16 and 17, in a connection portion (121) of the dust collection box (90) and the discharge duct (74), a first connection portion (122) is provided in the duct opening (90a) of the dust collection box (90), and a second connection portion (123) is provided in the corresponding end portion of the discharge duct (74). The first connection portion (122) and the second connection portion (123) are engaged with each other.

[0139] The first connection portion (122) is an approximately cylindrical member where a protrusion (122a) (projection) is formed on the outer circumferential surface so as to extend around the entire circumference. An engagement portion (123c) of the second connection portion (123) described later is engaged with the protrusion (122a). One end portion of the first connection portion (122) is fitted with the duct opening (90a) of the dust collection box (90).

[0140] The second connection portion (123) includes a body (123a) which is an approximately cylindrical member having the diameter larger than that of the first connection portion (122), and a hook (123b) is integrally formed on an outer circumferential surface of the body (123a). The hook (123b) includes the cylindrical engagement portion (123c) for engaging with the protrusion (122a) of the first connection portion (122), which outwardly extends in the axial direction of the discharge duct (74); a tab-like lever (123d) extending in a direction opposite to the engagement portion (123c); and an elastically-deformable portion (123e) which elastically connects the engagement portion (123c) and the lever (123d) to the body (123a) at an intermediate portion of the engagement portion (123c) and the lever (123d). The lever (123d) is formed so as to extend outwardly toward a leading end thereof. In such a structure, the elastically-deformable portion (123e) is deformed by inwardly displacing the lever (123d) in the radial direction, thereby outwardly displacing the engagement portion (123c) extending in the direction opposite to the lever (123d), in the radial direction. On the other hand, when the lever (123d) returns to the original position, the engagement portion (123c) returns to the original position due to an elastic restoring force of the elastically-deformable portion (123e).

[0141] Hence, when engaging the engagement portion (123c) of the second connection portion (123) with the protrusion (122a) of the first connection portion (122), the engagement portion (123c) contacts the protrusion (122a). Subsequently, the elastically-deformable portion (123e) elastically supporting the engagement portion (123c) is elastically deformed to outwardly displace the engagement portion (123c) in the radial direction, thereby allowing the engagement of the engagement portion (123c) and the protrusion (122a) (see FIG. 17(b)). On the other hand, when detaching the second connection portion (123) from the first connection portion (122), the lever (123d) is inwardly deformed in the radial direction to outwardly displace the engagement portion (123c) in the radial direction, thereby separating the engagement portion (123c) from the protrusion (122a) of the first connection portion (122). Consequently, the engagement of the engagement portion (123c) and the protrusion (122a) can be released.

[0142] In such a structure, the discharge duct (74) can be easily attached/detached to/from the dust collection box (90), thereby improving the workability during the installation and maintenance of the indoor unit (13) and the dust collection box (90).

[0143] The above-described connection structure may be applicable to a connection portion (125) of the discharge duct (74) and the casing body (26).

INDUSTRIAL APPLICABILITY

[0144] As described above, the present invention is useful as a dust collection box for storing dust discharged from an indoor unit of an air conditioner including a dust removing function of an air filter.

DESCRIPTION OF REFERENCE CHARACTERS

[0145] 

1

Ceiling Board

1a

Opening

10

Air Conditioner

13

Indoor Unit

26

Casing Body (Casing)

27

Decorative Panel (Indoor-Side Panel)

27a

Opening Portion (Hole for Maintenance and Inspection)

27b

Cover

34

Casing

39

Indoor Fan

40

Air Filter

50

Dust Removing Means

51

Rotating Brush

60

Dust Container

70

Dust Transfer Means

71

Supply Duct

72

Damper

74

Discharge Duct (Flexible Duct)

76

Transfer Passage

90, 100

Dust Collection Box

90a, 100a

Duct Opening (Intake Port)

90b, 100b

Discharge Port

91

Collection Port (Hole for Dust Collection)

92

Net

93, 103

Transparent Window (Transparent Member)

96

Magnet

100c

Collection Port (Removal Port)

101

Supporting Member

102

Door

111

Supporting Member (Casing Supporting Member)

121

Connection Portion

122a

Protrusion (Projection)

123b

Hook

Claims

1. A dust collection box which is connected to a casing (26) of an indoor unit (13) of an air conditioner (10) installed in an opening (1a) formed in a ceiling board (1) through a transfer passage (76), and which stores dust removed from an air filter (40) positioned on a suction side of an indoor fan (39) of the casing (26), and discharged to outside the casing (26) through the transfer passage (76), wherein
the dust collection box is provided in a space above a ceiling such that at least a part of the dust collection box is positioned so as to outwardly protrude from the opening (1a) of the ceiling board (1) as viewed from an indoor side.

2. The dust collection box of claim 1, being attached to a side of the casing (26) of the indoor unit (13) with a stopping means (96).

3. The dust collection box of claim 2, wherein
the stopping means is magnets (96); and
the magnets (96) are arranged on a surface which will contact the casing (26) made of metal.

4. The dust collection box of claim 2, being arranged so as not to overlap with an entire hole (27a) for maintenance and inspection, which is formed in an indoor-side panel (27) of the indoor unit (13), as viewed from the indoor side.

5. The dust collection box of claim 2, wherein
a hole (91) for dust collection is formed in at least one of lower and side surfaces of the dust collection box corresponding to the hole (27a) for maintenance and inspection, which is formed in the indoor-side panel (27) of the indoor unit (13).

6. The dust collection box of claim 1, being supported by supporting members (101) so as to be suspended from a top wall surface in the space above the ceiling.

7. The dust collection box of claim 6, being suspended and supported by casing supporting members (111) for supporting the casing (26) so as to be suspended from the top wall surface in the space above the ceiling.

8. The dust collection box of claim 1, wherein
a removal port (100c) for removing dust inside the dust collection box is formed in a lower portion of the side surface of the dust collection box.

9. The dust collection box of claim 1, being connected to the casing (26) through a flexible duct (74) defining the transfer passage (76).

10. The dust collection box of claim 1, comprising:

a dust intake port (90a, 100a) connected to the transfer passage (76); and

a discharge port (90b, 100b) for discharging blow-off air from the indoor fan (39) used for transferring the dust, to outside,

wherein the discharge port (90b, 100b) is positioned higher than the intake port (90a, 100a).

11. The dust collection box of claim 10, wherein
the discharge port (90b, 100b) is formed in an upper surface of the dust collection box.

12. The dust collection box of claim 10, wherein
the intake port (100a) and the discharge port (100b) are formed at positions opposing each other as viewed in plan.

13. The dust collection box of claim 10, wherein
an opening area of the discharge port (90b, 100b) is larger than that of the intake port (90a, 100a).

14. The dust collection box of claim 10, wherein
a net (92) is provided in the discharge port (90b, 100b) so as to cover an opening.

15. The dust collection box of claim 1, wherein
at least a part of the dust collection box is made of a transparent member (93, 103) in order to observe a dust storage amount.

16. An air conditioner provided with an indoor unit (13) in which a casing (26) includes an indoor heat exchanger (37), an indoor fan (39) for sucking air from an indoor space and blowing the air to the indoor heat exchanger (37), and an air filter (40) provided on an suction side of the indoor fan (39), comprising:

a dust removing means (50) for removing dust trapped by the air filter (40);

a dust transfer means (70) for transferring the dust removed by the dust removing means (50), to outside the casing (26); and

the dust collection box of any one of claims 1-15, which is positioned outside the casing (26), and stores the dust transferred by the dust transfer means (70).

17. The air conditioner of claim 16, wherein
the dust collection box (90) is connected to the casing (26) through a flexible duct (74) defining the transfer passage (76); and
the flexible duct (74) is detachably connected to at least one of the dust collection box (90) and the casing (26).

18. The air conditioner of claim 17, wherein
a hook (123b) is provided in an end portion of the flexible duct (74); and
the hook (123b) is engageable with a protrusion (122a) which is provided in a corresponding member connected to the flexible duct (74).

Drawing