TECHNICAL FIELD
[0001] The present invention relates to an electromagnetic induction heating unit and an
air conditioner.
BACKGROUND WART
[0002] A refrigeration cycle is provided with a radiator, which releases the heat from a
refrigerant, a heater, which imparts heat to the refrigerant, and the like. The refrigerant
that circulates through the refrigeration cycle obtains heat by, for example, exchanging
heat with indoor air during a cooling operation cycle, exchanging heat with outdoor
air during a heating operation cycle, and the like.
[0003] According to the refrigeration cycle of an air conditioner recited in Patent Document
1 (i.e., Japanese Unexamined Patent Application Publication No.
H08-210720) indicated below, a system has been proposed wherein the refrigerant obtains heat
not only from indoor air and outdoor air as discussed above but also by means of a
refrigerant heating apparatus separately provided. In this refrigerant heating apparatus,
heat is imparted to the refrigerant, which flows through the interior of a heat exchanger,
by heating the heat exchanger with a burner. Thus, because this air conditioner adopts
a refrigerant heating apparatus, it is possible to heat the refrigerant when the refrigerant
requires heat without being constrained by, for example, the indoor or outdoor air
temperature.
SUMMARY OF THE INVENTION
<Technical Problem>
[0004] Instead of heating with a system that uses the fire of a burner and the like, it
is also possible to adopt an electrical electromagnetic induction heating system as
the refrigerant heating apparatus discussed above. For example, an electromagnetic
induction coil can be wound around a refrigerant piping, which contains a magnetic
material, and thereby, owing to the magnetic flux induced by the flow of electric
current to the electromagnetic induction heating coil, the refrigerant piping can
generate heat. Furthermore, the refrigerant can be heated using the heat generated
in that refrigerant piping.
[0005] However, if the heating of the refrigerant piping by electromagnetic induction generates
a magnetic field, then that magnetic field will arise not only inside the refrigerant
piping but also in portions outside of that piping.
[0006] In response, it is conceivable to dispose, around the refrigerant piping, a member
that has a material that tends to capture magnetic flux; however, even in such a case,
it is sometimes difficult to sufficiently hinder the leakage of the magnetic field.
[0007] The present invention considers the points discussed above, and it is an object of
the present invention to provide an electromagnetic induction heating unit and an
air conditioner that, even if a magnetic field is generated by an electromagnetic
induction heating unit when performing electromagnetic induction heating, the amount
of the magnetic field that leaks to the portions outside of the refrigerant piping
can be kept small.
<Solution to Problem>
[0008] An electromagnetic induction heating unit according to a first aspect of the invention
is an electromagnetic induction heating unit that heats a refrigerant piping or a
material that thermally contacts a refrigerant that flows through the refrigerant
piping, or both, and comprises: a coil, an external member, and a magnetic part. The
coil is disposed in the vicinity of the refrigerant piping. The external member is
disposed around the refrigerant piping and includes a magnetic body. The magnetic
part is disposed on the outer side of the coil, which is the opposite side of the
inner side, namely, the refrigerant piping side, of the coil, and on the inner side
of the external member and contains a magnetic material whose magnetic permeability
is higher than that of the external member. Both end parts of the external member
in the directions in which the refrigerant piping extends are positioned on the inner
side of both end parts of the magnetic part. Furthermore, heating performed using
the electromagnetic induction heating unit herein includes at least: the case wherein
a heat generating member that thermally contacts the refrigerant piping is heated
through electromagnetic induction; the case wherein a heat generating member that
thermally contacts the refrigerant flowing through the refrigerant piping is heated
through electromagnetic induction; and the case wherein a heat generating member that
constitutes at least part of the refrigerant piping is heated through electromagnetic
induction.
[0009] There are cases wherein, when electromagnetic induction heating is performed, not
only does a magnetic field arise in the target magnetic body, which is meant to generate
heat, but also in the periphery thereof.
[0010] In contrast, in the present electromagnetic induction heating unit, the magnetic
part, which contains a magnetic material of a higher magnetic permeability than that
of the external member, is disposed on the outer side of the coil; consequently, the
magnetic field that arises in portions outside of the refrigerant piping tends to
pass through the magnetic part more than through the external member. Furthermore,
because both end parts of the external member in the directions in which the refrigerant
piping extends are positioned on the inner side of both end parts of the magnetic
body, the magnetic flux that would leak out to portions outside of the refrigerant
piping can be much more effectively captured than the external member can. Thereby,
when electromagnetic induction heating is performed, the magnetic field that arises
in portions outside of the refrigerant piping can be made to efficiently pass through
the magnetic body; consequently, the strength of the magnetic field in outside of
the magnetic part caused by the leakage can be kept lower than the strength of the
magnetic field in the magnetic part.
[0011] An electromagnetic induction heating unit according to a second aspect of the invention
is the electromagnetic induction heating unit according to the first aspect of the
invention, wherein the coil is wound around at least part of the refrigerant piping.
[0012] In the present electromagnetic induction heating unit, part of the magnetic flux
that arises owing to the flow of electric current to the coil can be aligned with
the directions in which the refrigerant piping extends. Consequently, if the longitudinal
directions of the magnetic body included in the refrigerant piping and the axial directions
of the refrigerant piping are substantially the same, then the heating efficiency
of the electromagnetic induction can be improved.
[0013] An electromagnetic induction heating unit according to a third aspect of the invention
is the electromagnetic induction heating unit according to the first or second aspects
of the invention, wherein at least part of the magnetic part extends to at least one
side selected from the group consisting of: one side of the coil in directions in
which the refrigerant piping extends; and another side, which is the opposite side
of the one side with respect to the coil.
[0014] In the present electromagnetic induction heating unit, the magnetic flux that arises
owing to the supply of electric power to the coil and that would leak out to the opposite
side of the refrigerant piping can be captured by the magnetic part prior to being
conducted to the external member. Consequently, the magnetic part can hinder a greater
amount of the magnetic field leakage than the external member can. Thereby, not only
the leakage of the magnetic field to the outer side of the magnetic part but also
the leakage of the magnetic field to the outer side of the external member can be
much more effectively reduced by virtue of the external member capturing the magnetic
field that leaks to the outer side of the magnetic part.
[0015] An electromagnetic induction heating unit according to a fourth aspect of the invention
is the electromagnetic induction heating unit according to any one aspect of the first
through third aspects of the invention, wherein at least part of the magnetic part
extends to the inner side of the coil, which is the outer side of the refrigerant
piping when viewed from the axial directions of the refrigerant piping.
[0016] In the present electromagnetic induction heating unit, the strength of the magnetic
field generated by the coil can be kept lower than a strength that would leak to the
portions outside of the magnetic part and thereby the magnetic field can be made to
pass through the magnetic part more efficiently.
[0017] An electromagnetic induction heating unit according to a fifth aspect of the invention
is the electromagnetic induction heating unit according to any one aspect of the first
through fourth aspects of the invention, wherein the magnetic part comprises a plurality
of magnetic components disposed such that the magnetic components contact one another.
[0018] In the present electromagnetic induction heating unit, the magnetic part is not made
as an integral member that conforms to a target shape; rather, the magnetic part can
be made as a combination of multiple components that conform to the target shape.
Furthermore, because these magnetic components are disposed in a state wherein they
contact one another, any decline in the magnetic permeability at the portions at which
the magnetic components contact one another can be reduced.
[0019] An electromagnetic induction heating unit according to a sixth aspect of the invention
is the electromagnetic induction heating unit according to any one aspect of the first
through fifth aspects of the invention, wherein the magnetic part contains a material
that is a good conductor.
[0020] In the present electromagnetic induction heating unit, even if the magnetic flux
is made to pass through the magnetic part for the purpose of reducing the number of
lines of magnetic force on the outer side of the magnetic part, the Joule heat generated
by the electrical resistance can be reduced because the magnetic part contains a material
that is a good conductor.
[0021] An electromagnetic induction heating unit according to a seventh aspect of the invention
is the electromagnetic induction heating unit according to any one aspect of the first
through sixth aspects of the invention, wherein the magnetic part contains ferrite.
[0022] In the present electromagnetic induction heating unit, the magnetic flux can be made
to actively pass through the magnetic part, which contains ferrite, and thereby the
magnetic field that leaks to the outer side of the magnetic part can be reduced.
[0023] An air conditioner according to all eighth aspect of the invention is an air conditioner
that comprises: an electromagnetic induction heating unit according to any one aspect
of the first through seventh aspects; and a refrigeration cycle that includes a portion
wherethrough a refrigerant flows to the refrigerant piping.
[0024] In the present air conditioner, even if electromagnetic induction heating is performed,
the impact on the surroundings of the electromagnetic induction heating unit can be
reduced.
<Advantageous Effects of Invention>
[0025] In the electromagnetic induction heating unit according to the first aspect of the
invention, the strength of the magnetic field in outside of the magnetic part caused
by the leakage can be kept lower than the strength of the magnetic field in the magnetic
part.
[0026] Tin the electromagnetic induction heating unit according to the second aspect of
the invention, the heating efficiency of the electromagnetic induction can be improved.
[0027] In the electromagnetic induction heating unit according to the third aspect of the
invention, not only the leakage of the magnetic field to the outer side of the magnetic
part but also the leakage of the magnetic field to the outer side of the external
member can be much more effectively reduced by virtue of the external member capturing
the magnetic field that leaks to the outer side of the magnetic part.
[0028] In the electromagnetic induction heating unit according to the fourth aspect of the
invention, the magnetic field can be made to pass through the magnetic part more efficiently.
[0029] In the electromagnetic induction heating unit according to the fifth aspect of the
invention, any decline in the magnetic permeability at the portions at which the magnetic
components contact one another can be reduced.
[0030] In the electromagnetic induction heating unit according to the sixth aspect of the
invention, the Joule heat generated by the electrical resistance can be reduced.
[0031] In the electromagnetic induction heating unit according to the seventh aspect of
the invention, the magnetic field that leaks to the outer side of the magnetic part
can be reduced.
[0032] In the air conditioner according to the eighth aspect of the invention, even if electromagnetic
induction heating is performed, the impact on the surroundings of the electromagnetic
induction heating unit can be reduced.
BRIEF DESCRIPTION OF THE DRAWING
[0033]
FIG. 1 is a refrigerant circuit diagram of an air conditioner according to one embodiment
of the present invention.
FIG. 2 is an external oblique view that includes a front surface side of an outdoor unit.
FIG. 3 is an oblique view of the internal layout and configuration of the outdoor unit.
FIG. 4 is an external oblique view that includes a rear surface side of the internal layout
and configuration of the outdoor unit.
FIG. 5 is a general, front, oblique view that shows the internal structure of a machine
chamber of the outdoor unit.
FIG. 6 is an oblique view that shows the internal structure of the machine chamber of the
outdoor unit.
FIG. 7 is an oblique view of a bottom plate and an outdoor heat exchanger of the outdoor
unit.
FIG. 8 is a top plan view of the layout of an electromagnetic induction heating unit.
FIG. 9 is a schematic oblique view of the electromagnetic induction heating unit mounted
to an accumulator pipe.
FIG. 10 is an external oblique view of the state wherein a shielding cover has been removed
from the electromagnetic induction heating unit.
FIG. 11 is a cross sectional view of the electromagnetic induction heating unit mounted to
the accumulator pipe.
FIG. 12 is a view that shows the state wherein a thermistor and a fuse are mounted.
FIG. 13 is an explanatory diagram of the state wherein magnetic flux arises around the electromagnetic
induction heating unit.
FIG. 14 is a schematic oblique view of a first ferrite case.
FIG. 15 is a view of the vicinity of a screw part on the upper side of the first ferrite
case.
FIG. 16 is a view of the vicinity of a screw part on the lower side of the first ferrite
case.
FIG. 17 is a top plan view of the shielding cover.
FIG. 18 is a front view of the shielding cover.
FIG. 19 is a view that shows an aspect wherein ferrite parts tend to conduct magnetic flux
more than the shielding cover does.
FIG. 20 is an explanatory diagram of a refrigerant piping according to another embodiment
(C).
FIG. 21 is an explanatory diagram of the refrigerant piping according to another embodiment
(D).
FIG. 22 is a view that shows an example of the layout of a coil and the refrigerant piping
according to another embodiment (E).
FIG. 23 is a view that shows an example of the layout of bobbin covers according to another
embodiment (E).
FIG. 24 is a view that shows an example of the layout of ferrite cases according to another
embodiment (E).
DESCRIPTION OF EMBODIMENTS
[0034] An exemplary case of an air conditioner
1, which comprises an electromagnetic induction heating unit
6 according to one embodiment of the present invention, will now be explained, referencing
the drawings.
<1-1> Air Conditioner 1
[0035] FIG. 1. is a refrigerant circuit diagram that shows a refrigerant circuit
10 of the air conditioner
1.
[0036] The air conditioner
1 is an apparatus wherein an outdoor unit
2, which serves as a heat source side apparatus, and an indoor unit
4, which serves as a utilization side apparatus, are connected by a refrigerant piping,
and the space wherein the utilization side apparatus is disposed is air conditioned;
furthermore, the air conditioner
1 comprises a compressor
21, a four-way switching valve
22, an outdoor heat exchanger
23, an outdoor motor operated expansion valve
24, an accumulator
25, outdoor fans
26, an indoor heat exchanger
41, an indoor fan
42, a hot gas bypass valve
27, a capillary tube
28, the electromagnetic induction heating unit
6, and the like.
[0037] The compressor
21, the four-way switching valve
22, the outdoor heat exchanger
23, the outdoor motor operated expansion valve
24, the accumulator
25, the outdoor fans
26, the hot gas bypass valve
27, the capillary tube
28, and the electromagnetic induction heating unit
6 are housed inside the outdoor unit
2. The indoor heat exchanger
41 and the indoor fan
42 are housed inside the indoor unit
4.
[0038] The refrigerant circuit
10 comprises a discharge pipe
A, an indoor side gas pipe
B, an indoor side liquid pipe
C, an outdoor side liquid pipe
D, an outdoor side gas pipe
E, an accumulator pipe
F, a suction pipe
G, a hot gas bypass circuit
H, branched piping
K, and union piping
J. The refrigerant that passes through the indoor side gas pipe
B and the outdoor side gas pipe
E is mostly in the gas state, but the refrigerant passing through is not limited to
the gas state. The refrigerant that passes through the indoor side liquid pipe
C and the outdoor side liquid pipe
D is mostly in the liquid state, but the refrigerant passing through is not limited
to the liquid state.
[0039] The discharge pipe
A connects the compressor
21 and the four-way switching valve 22. A discharge temperature sensor
29d, which detects the temperature of the refrigerant passing through, is provided to
the discharge pipe
A. Furthermore, an electric power supply part
21e supplies electric power to the compressor
21. The amount of electric power the electric power supply part
21e supplies is detected by a compressor electric power detection unit
29f.
[0040] The indoor side gas pipe
B connects the four-way switching valve
22 and the indoor heat exchanger
41. A pressure sensor
29a, which detects the pressure of the refrigerant passing through, is provided along
the indoor side gas pipe
B.
[0041] The indoor side liquid pipe
C connects the indoor heat exchanger
41 and the outdoor motor operated expansion valve
24.
[0042] The outdoor side liquid pipe
D connects the outdoor motor operated expansion valve
24 and the outdoor heat exchanger
23.
[0043] The outdoor side gas pipe
E connects the outdoor heat exchanger
23 and the four-way switching valve
22.
[0044] The accumulator pipe
F connects the four-way switching valve
22 and the accumulator
25 and, in the state wherein it is installed in the outdoor unit
2, extends in the vertical directions. The electromagnetic induction heating unit
6 is mounted to part of the accumulator pipe
F. At least a heat generating portion of the accumulator pipe
F, which is enveloped by a coil
68 (discussed below), comprises a magnetic pipe
F2 provided such that it envelops a copper pipe
F1, wherein the refrigerant flows (refer to
FIG. 11). The magnetic pipe
F2 is made of steel use stainless (SUS) 430. SUS 430 is a ferromagnetic material; when
placed in a magnetic field, eddy currents arise, which generate heat by the action
of Joule heat induced by the material's own electrical resistance. The portion of
the piping that constitutes the refrigerant circuit
10 and that is outside of the magnetic pipe
F2 comprises copper pipes. Furthermore, the material property of the pipe that envelops
the copper pipe is not limited to SUS 430, and can be, for example: one type of conductor
selected from the group consisting of iron, copper, aluminum, chrome, and nickel;
an alloy containing at least two or more types of metal selected from the same group;
and the like. In addition, examples of SUS include ferritic steel, martensitic steel,
or a combination thereof. Furthermore, it is preferable to use a material that is
a ferromagnetic, has a comparatively high electrical resistance, and has a higher
Curie temperature than that of the working temperature range. Furthermore, the accumulator
pipe
F herein requires a larger amount of electric power; however, instead of a magnetic
body and a material that contains a magnetic body, it may contain a material that
can be induction heated. Furthermore, for example, the magnetic material may constitute
all of the accumulator pipe
F, only an inner side surface of the accumulator pipe
F, or be simply included in the material that constitutes the accumulator pipe
F. By performing electromagnetic induction heating in this manner, the accumulator pipe
F can generate heat by electromagnetic induction, and thereby the refrigerant that
is suctioned into the compressor
21 via the accumulator
25 can be heated. Thereby, the heating capacity of the air conditioner
1 can be improved. In addition, for example, even if the compressor
21 is not sufficiently heated when heating operation is started up, the electromagnetic
induction heating unit
6 can perform quick heating, thereby supplementing the capacity shortfall during startup.
Furthermore, if the four-way switching valve
22 switches to the cooling operation state and the defrosting operation, which eliminates
frost that adheres to the outdoor heat exchanger
23 and the like, is performed, then the compressor
21 can compress the quickly heated refrigerant by virtue of the electromagnetic induction
heating unit 6 quickly heating the accumulator pipe
F. Consequently, the temperature of the hot gas discharged from the compressor
21 can be quickly raised. Thereby, the time needed for the defrosting operation to perform
defrosting can be shortened. Thereby, even if it is necessary to perform the defrosting
operation when appropriate during heating operation, it is possible to return to the
heating operation as quickly as possible and thereby to improve user comfort.
[0045] The suction pipe
G connects the accumulator
25 and the inlet side of the compressor 21.
[0046] The hot gas bypass circuit
H connects a branching point
A1, which is provided along the discharge pipe
A, and a branching point
D1, which is provided along the outdoor side liquid pipe
D. The hot gas bypass valve
27, which is capable of switching between the state in which the refrigerant is permitted
to pass through and the state in which it isn't, is disposed along the hot gas bypass
circuit
H. Furthermore, the capillary tube
28, which lowers the pressure of the refrigerant passing through, is provided along the
hot gas bypass circuit
H between the hot gas bypass valve
27 and the branching point
D1. Because the pressure of the refrigerant can approach that of the refrigerant after
the pressure has been decreased by the outdoor motor operated expansion valve
24 during heating operation, the capillary tube
28 can hinder a rise in the pressure of the refrigerant in the outdoor side liquid pipe
D by supplying hot gas, which has passed through the hot gas bypass circuit
H, to the outdoor side liquid pipe
D.
[0047] The branched piping
K constitutes part of the outdoor heat exchanger
23 and is the refrigerant piping that, to increase the effective surface area for exchanging
heat, extends from a gas side inlet/outlet
23e of the outdoor heat exchanger
23 and branches into multiple pipes at a branching and merging point
23k (discussed below). The branched piping
K comprises a first branch pipe
K1, a second branch pipe
K2, and a third branch pipe
K3, each of which independently extend from the branching and merging point
23k to a merging and branching point
23j; furthermore, the branched pipes
K1, K2, K3 merge at the merging and branching point
23j. Furthermore, viewed from the union piping
J side, the branched piping
K branches at the merging and branching point
23j and extends therefrom.
[0048] The union piping
J constitutes part of the outdoor heat exchanger
23 and is a piping that extends from the merging and branching point
23j to a liquid side inlet/outlet
23d of the outdoor heat exchanger
23. The union piping
J can, during cooling operation, make uniform the degree of supercooling of the refrigerant
flowing out of the outdoor heat exchanger
23 and, during heating operation, defrost any ice that adheres to the vicinity of the
lower end of the outdoor heat exchanger
23. The union piping
J has a cross sectional area that is substantially three times that of each of the
branched pipes
K1, K2, K3, and therefore the amount of refrigerant passing through is substantially three times
that of each of the branched pipes
K1, K2, K3.
[0049] The four-way switching valve
22 is capable of switching between a cooling operation cycle and a heating operation
cycle. In
FIG. 1, solid lines indicate the connection state wherein heating operation is performed,
and dotted lines indicate the connection state wherein cooling operation is performed.
During heating operation, the indoor heat exchanger
41 functions as a cooler of the refrigerant, and the outdoor heat exchanger
23 functions as a heater of the refrigerant. During cooling operation, the outdoor heat
exchanger
23 functions as a cooler of the refrigerant, and the indoor heat exchanger
41 functions as a heater of the refrigerant.
[0050] The outdoor heat exchanger
23 comprises the gas side inlet/outlet
23e, the liquid side inlet/outlet
23d, the branching and merging point
23k, the merging and branching point
23j, the branched piping
K, the union piping
J, and heat exchanging fins
23z. The gas side inlet/outlet
23e is positioned at an end part on the outdoor side gas pipe
E side of the outdoor heat exchanger
23 and connects to the outdoor side gas pipe
E. The liquid side inlet/outlet
23d is positioned at an end part on the outdoor side liquid pipe
D side of the outdoor heat exchanger
23 and connects to the outdoor side liquid pipe
D. The branching and merging point
23k branches the piping that extends from the gas side inlet/outlet
23e and can branch or merge the refrigerant in accordance with the direction in which
the refrigerant is flowing. In the branched piping
K, multiple pipes extend from the branched portions at the branching and merging point
23k. The merging and branching point
23j merges the branched piping
K and can merge or branch the refrigerant in accordance with the direction in which
the refrigerant is flowing. The union piping
J extends from the merging and branching point
23j to the liquid side inlet/outlet
23d. The heat exchanging fins
23z are plate shaped aluminum fins arrayed in the plate thickness directions and disposed
at prescribed intervals. Both the branched piping
K and the union piping
J are to be inserted through the heat exchanging fins
23z, which they have in common. Specifically, the branched piping
K and the union piping
J are disposed such that they are inserted through, at different portions of, each
of the heat exchanging fins
23z, which they have in common, in the plate thickness directions. An outdoor air temperature
sensor
29b, which detects the outdoor air temperature, is provided to the outdoor heat exchanger
23 on the leeward side in the direction of the airflow of the outdoor fans
26. In addition, an outdoor heat exchanger temperature sensor
29c, which detects the temperature of the refrigerant flowing through the branched piping
K, is provided to the outdoor heat exchanger
23.
[0051] An indoor temperature sensor
43, which detects the indoor temperature, is provided inside the indoor unit
4. In addition, the indoor heat exchanger
41 is provided with an indoor heat exchanger temperature sensor
44, which detects the temperature of the refrigerant on the indoor side liquid pipe
C, along which the outdoor motor operated expansion valve
24 is connected, side of the indoor heat exchanger
41.
[0052] A control unit
11 is constituted by the connection of an outdoor control unit
12, which controls equipment disposed inside the outdoor unit
2, and an indoor control unit
13, which controls equipment disposed inside the indoor unit
4, via a communications wire
11a. The control unit
11 performs various control functions with respect to the air conditioner
1.
[0053] In addition, a timer
95, which counts in order to measure the time elapsed when various control functions
are performed, is provided to the outdoor control unit
12.
[0054] Furthermore, a controller
90, which accepts the input of settings from the user, is connected to the control unit
11.
<1-2> Outdoor Unit 2
[0055] FIG. 2 is an external oblique view of the front surface side of the outdoor unit
2. FIG. 3 is an oblique view that shows the positional relationship between the outdoor heat
exchanger
23 and the outdoor fans
26. FIG. 4 is an oblique view of the rear surface side of the outdoor heat exchanger
23.
[0056] The outer surface of the outdoor unit
2 is a substantially rectangular parallelepipedic outdoor unit casing that comprises
a top plate
2a, a bottom plate
2b, a front panel
2c, a left side surface panel
2d, a right side surface panel
2f, and a rear surface panel
2e.
[0057] The outdoor unit
2 is partitioned by a partition plate
2h into a fan chamber, which is on the left side surface panel
2d side and wherein the outdoor heat exchanger
23, the outdoor fans
26, and the like are disposed, and a machine chamber, which is on the right side surface
panel
2f side and wherein the compressor
21, the electromagnetic induction heating unit
6, and the like are disposed. In addition, the outdoor unit
2 comprises outdoor unit support platform
2g, which are fixed to the bottom plate
2b by screwing and constitute the lowest end parts of the outdoor unit
2 on the right and left sides. Furthermore, the electromagnetic induction heating unit
6 is disposed at an upper position of the machine chamber in the vicinity of the left
side surface panel
2d and the top plate
2a. Here, a plurality of the heat exchanging fins
23z of the outdoor heat exchanger
23 discussed above is arrayed in the plate thickness directions, which are substantially
oriented in the horizontal directions. The union piping
J is disposed by inserting it through the heat exchanging fins
23z of the outdoor heat exchanger
23 in the thickness directions at the lowermost portion of the heat exchanging fins
23z. The hot gas bypass circuit
H is disposed such that it runs along below the outdoor fans 26 and the outdoor heat
exchanger
23.
[0058] FIG. 5 is a general, front, oblique view that shows the internal structure of the machine
chamber of the outdoor unit
2. FIG. 6 is an oblique view that shows the internal structure of the machine chamber of the
outdoor unit
2. FIG. 7 is an oblique view that shows the layout of the outdoor heat exchanger
23 and the bottom plate
2b in relation to each other.
FIG. 8 is a top plan view that shows the layout of the electromagnetic induction heating
unit
6.
[0059] The partition plate
2h of the outdoor unit
2 partitions, from the front to the back and from the upper end to the lower end, the
fan chamber, wherein the outdoor heat exchanger
23, the outdoor fans
26, and the like are disposed, and the machine chamber, wherein the electromagnetic induction
heating unit
6, the compressor
21, the accumulator
25, and the like are disposed. The compressor
21 and the accumulator
25 are disposed in a lower space of the machine chamber of the outdoor unit
2. Furthermore, the electromagnetic induction heating unit
6, the four-way switching valve
22, and the outdoor control unit
12 are disposed in an upper space of the machine chamber of the outdoor unit
2, above the compressor
21, the accumulator
25, and the like. The compressor
21, the four-way switching valve
22, the outdoor heat exchanger
23, the outdoor motor operated expansion valve
24, the accumulator
25, the hot gas bypass valve
27, the capillary tube
28, and the electromagnetic induction heating unit
6, which are disposed in the machine chamber and are the functional elements that constitute
the outdoor unit
2, are corrected via the discharge pipe
A, the indoor side gas pipe
B, the outdoor side liquid pipe
D, the outdoor side gas pipe
E, the accumulator pipe
F, the hot gas bypass circuit
H, and the like such that the refrigerant circuit
10 shown in
FIG. 1 performs a refrigeration cycle. Here, as discussed below, the hot gas bypass circuit
H comprises nine linked portions, namely, a first bypass portion
H1 through a ninth bypass portion
H9; furthermore, when the refrigerant flows to the hot gas bypass circuit
H, it flows in order from the first bypass portion
H1 to the ninth bypass portion
H9.
<1-3> Electromagnetic Induction Heating Unit 6
[0060] FIG. 9 is a schematic oblique view of the electromagnetic induction heating unit
6 mounted to the accumulator pipe
F. FIG. 10 is an external oblique view that shows the state wherein a shielding cover
75 has been removed from the electromagnetic induction heating unit
6. FIG. 11 is a cross sectional view of the electromagnetic induction heating
unit 6 mounted to the accumulator pipe
F.
[0061] The electromagnetic induction heating unit 6 is disposed such that it covers the
magnetic pipe
F2, which is the heat generating portion of the accumulator pipe
F, from the outer side in the radial directions and causes the magnetic pipe
F2 to generate heat by electromagnetic induction heating. The heat generating portion
of the accumulator pipe
F has a double pipe structure that comprises the copper pipe
F1 on the inner side and the magnetic pipe
F2 on the outer side.
[0062] The electromagnetic induction heating unit
6 comprises a first hex nut
61, a second hex nut
66, a first bobbin cover
63, a second bobbin cover
64, a bobbin main body
65, a first ferrite case
71, a second ferrite case
72, a third ferrite case
73, a fourth ferrite case
74, first ferrite parts
98, second ferrite parts
99, the coil
68, the shielding cover
75, a thermistor
14, a fuse
15, and the like.
[0063] The first hex nut
61 and the second hex nut
66 are made of resin, and the electromagnetic induction heating unit
6 and the accumulator pipe
F are stably fixed using a
C ring (not shown). The first bobbin cover
63 and the second bobbin cover
64 are made of resin and cover the accumulator pipe
F from the outer side in the radial directions at the upper end position and the lower
end position, respectively. The first bobbin cover
63 and the second bobbin cover
64 each have four screw holes for screws
69, which are for screwing the first through fourth ferrite cases
71-74 (discussed below) to the first bobbin cover
63 and the second bobbin cover
64 using screws
69. Furthermore, the second bobbin cover
64 has an electromagnetic induction thermistor insertion opening
64f, which is for inserting the thermistor
14 into the second bobbin cover
64 in order to mount the thermistor
14 to the outer surface of the magnetic pipe
F2. In addition, the second bobbin cover
64 has a fuse insertion opening
64e, which is for inserting the fuse
15 shown in
FIG. 13 into the second bobbin cover
64 in order to mount the fuse
15 to the outer surface of the magnetic pipe
F2. The thermistor
14 converts the temperature detected to a signal and transmits such to the control unit
11. The fuse
15 converts the detection result to a signal and transmits such to the control unit
11. If the control unit
11 receives a notification from the fuse
15 that the temperature detected exceeds a prescribed limit, then the control unit
11 performs control such that the supply of electric power to the coil
68 is stopped, thereby avoiding thermal damage to the equipment. The bobbin main body
65 is made of resin, and the coil
68 is wound around the bobbin main body
65. The coil
68 is wound helically around the outer side of the bobbin main body
65, the directions in which the accumulator pipe
F extends being the axial directions. The coil
68 is connected to a control printed circuit board
18 (not shown), and receives the supply of a high frequency electric current. The output
of the control printed circuit board
18 is controlled by the control unit
11. As shown in
FIG. 12, the thermistor
14 and the fuse
15 are mounted in the state wherein the bobbin main body
65 and the second bobbin cover
64 are mated. Here, in the state wherein the thermistor
14 is mounted, satisfactory pressure contact between the thermistor
14 and the outer surface of the magnetic pipe
F2 is maintained by a leaf spring
16, which presses the thermistor
14 inward in the radial directions of the magnetic pipe
F2. In addition, in the state wherein the fuse
15 is mounted, too, satisfactory contact pressure between the fuse
15 and the outer surface of the magnetic pipe
F2 is likewise maintained by a leaf spring
17, which presses the fuse
15 inward in the radial directions of the magnetic pipe
F2. Thus, because tight contact is satisfactorily maintained between the thermistor
14 and the outer surface of the accumulator pipe
F as well as between the fuse
15 and the outer surface of the accumulator pipe
F, responsiveness is improved and sudden changes in temperature owing to electromagnetic
induction heating can be detected promptly. The first ferrite case
71 is inserted into the first bobbin cover
63 and the second bobbin cover
64 from the directions in which the accumulator pipe
F extends and is fixed by the screws
69. The first ferrite case
71 through the fourth ferrite case
74 each house first ferrite parts
98 and second ferrite parts
99, which are made of ferrite-a raw material that has high magnetic permeability. As
shown in the magnetic flux explanatory diagram of
FIG. 13, by capturing the magnetic field generated by the coil
68 and thereby forming a path for the magnetic flux, the first ferrite parts
98 and the second ferrite parts
99 tend not to externally leak the magnetic field. The shielding cover
75 is disposed at the outermost circumferential portion of the electromagnetic induction
heating unit
6 and collects the magnetic flux that cannot be completely gathered by the first ferrite
parts
98 and the second ferrite parts
99 alone. Thereby, virtually none of the magnetic flux leaks to the outer side of the
shielding cover
75: furthermore, the location at which the magnetic flux is generated can be determined
independently.
(Ferrite Cases and Ferrite Parts)
[0064] The details of the ferrite cases will now be explained.
[0065] FIG. 14 is a schematic oblique view of the first ferrite case
71, wherein the first ferrite parts
98 and the second ferrite parts
99 are housed and fixed.
FIG. 15 shows the structure of the vicinity of the screw part on the upper side of the first
ferrite case
71. FIG. 16 shows the structure of the vicinity of the screw part on the lower side of the first
ferrite case
71. Furthermore, the first through fourth ferrite cases
71-74 all have the same shape.
[0066] The first ferrite case
71 is made of resin and has a function wherein the first bobbin cover
63 and the second bobbin cover
64 are inserted from the directions in which the accumulator pipe
F extends and are thereby fixed and a function wherein the first ferrite parts
98 and the second ferrite parts
99 are housed and held.
[0067] The first ferrite case
71 comprises a bottom surface part
71j, side surface parts
71h, a first cover screw part
71a, a first cover screw hole
71b, a second cover screw part
71f, a second cover screw hole
71g, shielding cover screw parts
71c, and shielding cover screw holes
71d.
[0068] The bottom surface part
71j constitutes the bottom surface of the first ferrite case
71. As discussed below, the first ferrite parts
98 and the second ferrite parts
99 are bonded to the bottom surface part
71j. In the state wherein it is fixed to the electromagnetic induction heating unit
6, the bottom surface part
71j is provided at a position at which its surface is oriented in the radial directions,
its longitudinal directions being the directions in which the accumulator pipe
F extends. The bottom surface part
71j is mounted to one of four symmetrically provided substantially linear sides of the
outer edges of the first bobbin cover
63 and the second bobbin cover
64 in the radial directions. Thereby, the rear surface side of the bottom surface part
71j and the substantially linear sides of both the first bobbin cover
63 and the second bobbin cover
64 are fixed in the state wherein they have been brought into contact. Thereby, the
first ferrite case
71 has a structure that restrains movement in the circumferential directions.
[0069] The side surface parts
71h have surfaces that extend from both sides of the bottom surface part
71j in directions orthogonal to the longitudinal directions thereof and in the direction
leading away from the bottom surface part
71j.
[0070] The first cover screw part
71a is provided for screwing the first ferrite case
71 and the first bobbin cover
63 together and is provided at a position displaced from a virtual space that extends
in the radial directions and is interposed by the two side surface parts
71h. Thereby, the first ferrite parts
98 can be disposed as far as the vicinity of the magnetic pipe
F2, which makes it possible to reduce leakage of the magnetic force.
[0071] The second cover screw part
71f is provided for screwing the first ferrite case
71 and the second bobbin cover
64 together and is provided, on the opposite side of the first cover screw part
71a, at a position displaced from the virtual space that extends in the radial directions
and is interposed by the two side surface parts
71h. Thereby, the first ferrite parts
98 can be disposed as far as the vicinity of the magnetic pipe
F2, which makes it possible to reduce leakage of the magnetic force. Furthermore, because
the first cover screw part
71a and the second cover screw part
71f are disposed on opposite sides of the virtual space that extends in the radial directions
and is interposed by the two side surface parts
71h, the first cover screw part
71a and the second cover screw part
71f serve not only to reduce leakage of the magnetic force but also to more rigidly fix
the first ferrite case
71 to the first bobbin cover
63 and the second bobbin cover
64.
[0072] The second cover screw hole
71g is used for screwing the first ferrite case
71 and the second bobbin cover
64 to one another, thereby fixing them. Specifically, as in the first cover screw hole
71b discussed above, the second cover screw hole
71g of the first ferrite case
71 and a screw hole (not shown) for the screw
69 of the second bobbin cover
64 are screwed together by the metal screw
69 and are thereby fixed.
[0073] The shielding cover screw parts
71c are provided at two upper locations and two lower locations and are formed such that
they protrude toward the outer side, which is the opposite of the inner side wherein
the side surface parts
71h face one another.
[0074] The shielding cover screw holes
71d are openings that are provided to each of the shielding cover screw parts
71c and, in the state wherein the shielding cover
75 is mounted as shown in
FIG. 9, the shielding cover
75 is screwed by screws. Thereby, the first ferrite case
71 and the shielding cover
75 are fixed. Furthermore, the shielding cover screw parts
71c and the shielding cover screw holes
71d are also provided for each of the second through fourth ferrite cases
72-74; however, in actuality, the shielding cover
75 is fixed by just two opposing ferrite cases of the first through forth ferrite cases
71-74; in the present embodiment, the two opposing ferrite cases are the first ferrite case
71 and the third ferrite case
73.
[0075] Furthermore, the first ferrite parts
98 and the second ferrite parts
99 housed in each of the ferrite cases
71-74 are disposed such that their surface portions contact one another.
[0076] In addition, the two different shapes of the ferrite parts
98, 99, namely, the shape of the first ferrite parts
98 and the shape of the second ferrite parts
99, combine to conduct the magnetic field. A ferrite part that is integrally formed in
a
U shape is not used; rather, ferrite parts of the same shape are combined, which makes
it possible to lower cost. Furthermore, the first ferrite parts
98 and the second ferrite parts
99 housed in each of the ferrite cases
71-74 are disposed such that their surface portions contact one another.
(Shielding Cover)
[0077] The details of the shielding cover
75 will now be explained.
[0078] As shown in the top cross sectional view of
FIG. 17, the shielding cover
75 is a substantially octagonal piece of sheet metal that contains a magnetic material
and that in a plan view follows along the shape of the outer edge of the first through
fourth ferrite cases
71-74 when they are mounted to the first bobbin cover
63 and the second bobbin cover
64.
[0079] As shown in the top plan view of
FIG. 17, the shielding cover
75 comprises an overlapped portion
75d, wherein one end
75a and an other end
75b in the circumferential directions overlap in the plate thickness directions. In the
overlapped portion
75d, a surface in the vicinity of the one end
75a and a surface in the vicinity of the other end
75b are welded-from above to below in the directions in which the accumulator pipe
F extends-in the state wherein the two surfaces are in contact with one another. Thereby,
even if a magnetic field is generated by the electromagnetic induction heating unit
6 and the leakage magnetic flux is drawn in by the shielding cover
75, it is possible to prevent the local generation of eddy currents because at no place
do the parts of the shielding cover
75 contact one another locally. Thereby, it is possible to reduce the heat generated
by the shielding cover
75, which constitutes the outer side of the electromagnetic induction heating unit
6, and to maintain a low temperature as a provision against the risk of the user touching
the shielding cover
75. In addition, as can be understood by comparing
FIG. 10, which shows the state wherein the shielding cover
75 is not mounted, and
FIG. 9, which shows the state wherein the shielding cover
75 is mounted, the shielding cover
75 envelops the coil
68 such that a finger and the like of the user is denied access to the coil
68. Furthermore, here, the user can be effectively prevented from accessing the coil
68 because both ends of the coil
68 in the directions in which the accumulator pipe
F extends are disposed between both ends of the shielding cover
75.
[0080] In addition, as shown in
FIG. 18, the shielding cover
75 has screw holes
75x, 75y in the vicinity of the upper end in the longitudinal directions. As shown in
FIG. 9, when the shielding cover
75 is fixed to the first ferrite case
71, these screw holes
75x, 75y function as holes wherethrough screws
70a, 70b pass.
[0081] FIG. 19 is a cross sectional view that shows an aspect wherein the magnetic flux tends to
be conducted to the ferrite parts
98,
99 more than to the shielding cover
75.
[0082] The magnetic permeability of the ferrite parts
98, 99 is higher than that of the shielding cover
75, which comprises a piece of sheet metal; furthermore, the ferrite parts
98, 99 are disposed such that they extend in the radial directions at the upper end and
the lower end of the coil
68 and such that they straddle the coil
68 when viewed from the directions in which the accumulator pipe
F extends. Consequently, the magnetic flux that would leak out tends to be conducted
to the ferrite parts
98, 99 more than to the shielding cover
75, the magnetic flux generated by the coil
68 is collected by the ferrite parts
98, 99 before it is collected by the shielding cover
75, and therefore virtually all of that magnetic flux can be conducted to the ferrite
parts
98,
99. Furthermore, it is possible to lighten the burden of the shielding cover
75 to prevent magnetic flux leakage, and thereby the magnetic field that leaks out of
the electromagnetic induction heating unit
6 can be significantly more reduced.
[0083] In addition, because the first ferrite case
71 is formed from a resin, even if the shielding cover
75 is screwed to the first ferrite case
71 using the metal screws
70a, 70b, the first ferrite parts
98 and the second ferrite parts
99 do not directly contact the shielding cover
75. Thus, because a structure is adopted wherein the first ferrite parts
98 and the second ferrite parts
99 do not contact the shielding cover
75, there is naturally no local point of contact between the first ferrite parts
98 and the second ferrite parts
99 on one side and the shielding cover
75 on the other side. Consequently, even if an electric current flows to the coil
68 owing to electromagnetic induction, the concentration of magnetic flux that would
result from the presence of a point of contact between the first ferrite parts
98 and the second ferrite parts
99 on one side and the shielding cover
75 on the other side tends not to occur. Thereby, it is possible to hinder the occurrence
of a rise in the temperature in some portion owing to the concentration of magnetic
flux.
[0084] In addition, with regard to the ferrite parts
98, 99 of the second through fourth ferrite cases
72-74 that the shielding cover
75 covers from the outer side in the radial directions at a position other than a gap
portion of the shielding cover
75, the shielding cover
75, which contains the magnetic body, and the first ferrite parts
98 and the second ferrite parts
99, which are housed in the second through fourth ferrite cases
72-74, can have a double structure that hinders leakage of magnetic flux. Thereby, it is
possible to more effectively hinder the leakage of magnetic flux.
[0085] Furthermore, as shown in
FIG. 8, the portion of the shielding cover
75 positioned near the right side surface panel
2f of the outdoor unit
2 in a plan view is disposed such that it is secured against and plane parallel with
the right side surface panel
2f. Thereby, the magnetic flux conducted to the shielding cover
75 is prevented from, for example, being further conducted to the right side surface
panel
2f or causing the local generation of heat by the generation of eddy currents at local
points of contact between the right side surface panel
2f and the shielding cover
75.
<Features of the Air Conditioned 1 of the Present Embodiment>
[0086] There are cases wherein, when electromagnetic induction heating is performed, not
only does a magnetic field arise in the target magnetic body, which is meant to generate
heat, but also in the periphery thereof.
[0087] In contrast, in the electromagnetic induction heating unit
6 of the air conditioner
1, the ferrite parts
98, 99, which contain a magnetic material of a higher magnetic permeability than that of
the shielding cover
75, are disposed on the outer side of the coil
68 and such that they extend nearer to the coil
68 than the shielding cover
75 does. Consequently, the magnetic field that arises in portions outside of the accumulator
pipe
F tends to pass through the ferrite parts
98, 99 more than through the shielding cover
75. Consequently, the ferrite parts
98, 99 can efficiently capture the magnetic flux that would leak out to portions outside
of the accumulator pipe
F. Thereby, when electromagnetic induction heating is performed, the magnetic field
that arises in portions outside of the accumulator pipe
F can be made to efficiently pass through the ferrite parts
98, 99; furthermore, any magnetic flux not collected by the ferrite parts
98, 99 is collected by the shielding cover
75. Consequently, the magnetic flux that leaks out to portions outside of the electromagnetic
induction heating unit
6 can be reduced.
<Other Embodiment>
[0088] The above text explained an embodiment of the present invention based on the drawings,
but the specific constitution is not limited to these embodiments, and it is understood
that variations and modifications may be effected without departing from the spirit
and scope of the invention.
(A)
[0089] The above embodiment explained an exemplary case wherein the ferrite parts
98, 99 conduct the magnetic flux.
[0090] However, the present invention is not limited thereto.
[0091] For example, the material used to conduct the magnetic flux may be a good conductor
that is not as magnetic as ferrite. In such a case, it is possible to reduce the Joule
heat generated by electrical resistance when the magnetic field has been conducted.
(B)
[0092] The embodiment explained a case wherein the electromagnetic induction heating unit
6 is mounted to the accumulator pipe
F of the refrigerant circuit
10.
[0093] However, the present invention is not limited thereto.
[0094] For example, a refrigerant piping other than the accumulator pipe F may be provided.
In such a case, a magnetic body of, for example, the magnetic pipe
F2 is provided to a portion of the refrigerant piping whereto the electromagnetic induction
heating unit
6 is provided.
(C)
[0095] The embodiment explained an exemplary case wherein the accumulator pipe
F is configured as a double pipe, namely, as the copper pipe
F1 and the magnetic pipe
F2.
[0096] However, the present invention is not limited thereto.
[0097] As shown in
FIG. 20, for example, a member to be heated
F2a and two stoppers
F1a, F1b may be disposed inside the accumulator pipe
F, the refrigerant piping to be heated, or the like. Here, the member to be heated
F2a contains a magnetic material and generates heat by the electromagnetic induction
heating of the abovementioned embodiment. At two locations on the inner side of the
copper pipe
F1, the stoppers
F1a, F1b continuously permit the passage of the refrigerant but do not permit the passage
of the member to be heated
F2a. Thereby, the member to be heated
F2a does not move even when the refrigerant flows. Consequently, the target heating position
of the accumulator pipe
F and the like can be heated. Furthermore, the heat transfer efficiency can be improved
because the member to be heated
F2a and the refrigerant directly contact one another.
(D)
[0098] Instead of using the stoppers
F1a, the position of the member to be heated
F2a explained in the abovementioned other embodiment (C) may be prescribed with respect
to the piping.
[0099] As shown in
FIG. 21, for example, bent portions
FW may be provided to the copper pipe
F1 at two locations, and the member to be heated
F2a may be disposed on the inner side of the copper pipe
F1 between the two bent portions
FW. In so doing, too, the movement of the member to be heated
F2a can be hindered while the refrigerant is made to pass through.
(E)
[0100] The abovementioned embodiment explained a case wherein the coil
68 is helically wound around the accumulator pipe
F.
[0101] However, the present invention is not limited thereto.
[0102] For example, as shown in
FIG. 22, coils
168, which are wound around bobbin main bodies
165, are disposed at the circumference of-without being wound around-the accumulator
pipe
F. Here, each of the bobbin main bodies
165 is disposed such that its axial directions are substantially perpendicular to the
axial directions of the accumulator pipe
F. In addition, the two pairs of the bobbin main bodies
165 and coils
168 are disposed such that they sandwich the accumulator pipe
F.
[0103] In this case, for example, as shown in
FIG. 23, a first bobbin cover
163 and a second bobbin cover
164, wherethrough the accumulator pipe
F is inserted, may be disposed in a state wherein they are mated to the bobbin main
bodies
165.
[0104] Furthermore, as shown in
FIG. 24, the first bobbin cover
163 and the second bobbin cover
164 may be interposed by a first ferrite case
171 and a second ferrite case
172, and thereby fixed.
FIG. 24 presents an exemplary case wherein two ferrite cases are disposed such that they
sandwich the accumulator pipe
F; however, as in the abovementioned embodiment, ferrite cases may be disposed in four
directions. In addition, as in the abovementioned embodiment, the ferrite parts may
be housed therein.
[0105] Furthermore, the shielding cover 175 may be provided such that it covers the outermost
circumferential portion of the electromagnetic induction heating unit
6 fixed in this manner.
<Miscellaneous>
[0106] The above text explained embodiments of the present invention based on the drawings,
but the specific constitution is not limited to these embodiments. For example, the
present invention also includes combination embodiments obtained by, where appropriate,
combining the abovementioned embodiments with portions other than those included in
the embodiments discussed above within a range that a person skilled in the art could
effect based on the scope of the invention described above.
INDUSTRIAL APPLICABILITY
[0107] Using the present invention is particularly effective in an electromagnetic induction
heating unit and an air conditioner wherein, even if a refrigerant piping is heated
by electromagnetic induction, it is possible to hinder the leakage of the magnetic
field to the periphery while hindering the local generation of heat, and thereby the
refrigerant can be heated using electromagnetic induction.
REFERENCE SIGNS LIST
[0108]
- 1
- Air conditioner
- 6
- Electromagnetic induction heating unit
- 10
- Refrigerant circuit
- 14
- Thermistor
- 15
- Fuse
- 21
- Compressor
- 22
- Four-way switching valve
- 23
- Outdoor heat exchanger
- 24
- Motor operated expansion valve
- 25
- Accumulator
- 41
- Indoor heat exchanger
- 65
- Bobbin main body
- 68
- Coil
- 71-74
- First through fourth ferrite cases
- 75
- Shielding cover
- 98, 99
- First ferrite part, second ferrite part
- F
- Accumulator pipe, refrigerant piping
CITATION LIST
PATENT LITERATURE
Patent Document 1
[0109] Japanese Unexamined Patent Application Publication No.
H08-210720