INTEGRATED INDOOR-OUTDOOR UNIT TYPE AIR CONDITIONER

Abstract

 The inner frame (24) of the integrated indoor-outdoor unit type air conditioner includes: a back board member (25) formed of a sheet metal material to constitute a back face of the air conditioner, having an upper end provided with a hooking portion(25c); a drain pan (11) formed of a resin material to constitute a bottom of the air conditioner, connected to a lower end of the back board member (25) to support components of the outdoor unit; and an intermediate frame member (12) formed of a resin material, connected to an intermediate portion of the back board member (25) to support components of the indoor unit.

Description

{Technical Field}

[0001] The present invention relates to an integrated indoor-outdoor unit type air conditioner in which an indoor unit and an outdoor unit are vertically integrated to be attached to a wall.

{Background Art}

[0002] PTL 1 discloses a technique of an air conditioner of a type to be installed on a floor, the air conditioner being provided in its bottom with a drain pan formed of a steel plate and a foam heat insulating material. The drain pan also serves as a base of a casing constituting an outer shell of the air conditioner to support weight of a heat exchange coil and components such as for humidification, installed inside the casing.

{Citation List}

{Patent Literature}

[0003] 

{PTL 1}
The Publication of Japanese Patent No.3236516

{Summary of Invention}

{Technical Problem}

[0004] In an air conditioner of a type to be installed on a floor as described in PTL 1, although total weight of internal components of the air conditioner is applied to a drain pan (base), the drain pan is made of metal to increase strength of the drain pan. As a result, it is possible to support each component without problems.

[0005] Meanwhile, in recent years, a compact integrated indoor-outdoor unit type air conditioner in which an indoor unit and an outdoor unit are vertically integrated has been increasing in demand.

[0006] The integrated indoor-outdoor unit type air conditioner described above is configured to be attached to a wall of a house and the like, and is provided with a casing inside which an inner frame is provided so that components of each of the indoor unit and the outdoor unit are mounted on the inner frame.

[0007] The inner frame is provided in an upper portion of its back face with a hooking portion through which the inner frame is fixed to a surface of the wall.

[0008] In this way, since total weight of the integrated indoor-outdoor unit type air conditioner is applied to the hooking portion of the inner frame, it is necessary to reduce the weight of the integrated indoor-outdoor unit type air conditioner, particularly weight of the inner frame, in order to reduce a load to the surface of the wall. However, it is not preferable that weight-saving reduces strength and rigidity of the inner frame.

[0009] In addition, in the integrated indoor-outdoor unit type air conditioner described above, rainwater sometimes enters inside the casing through an inlet port and an outlet port through which outdoor air is blown to a heat exchanger built in the outdoor unit. However, in a structure in which a base of the outdoor unit is made of metal and a drain pan made of resin is provided only for a bottom of the heat exchanger, the drain pan cannot be finely formed. Thus, it is difficult to completely recover the rainwater. The same applies to condensed water that is condensed in a compressor and on an inner surface of the casing. In particular, during heating operation, since condensation easily occurs on an outer surface of the casing, there is a possibility that the condensed water as well as rainwater leaks to an indoor side.

[0010] Thus, it is preferable that a drain pan (base) as a whole is produced with resin molding with an excellent modeling property to enable rainwater and condensed water to be recovered in a wide range, however, there is a possibility that rigidity of the drain pan may be insufficient as a base.

[0011] The present invention is made in light of the above-mentioned circumstances, and an object of the present invention is to provide an integrated indoor-outdoor unit type air conditioner in which an outdoor unit and an indoor unit are vertically integrated, and which is capable of reducing weight thereof and improving recovery of rainwater and condensed water while securing strength and rigidity of an inner frame.

{Solution to Problem}

[0012] In order to solve the problem described above, the present invention applies the following solutions.

[0013] An integrated indoor-outdoor unit type air conditioner in accordance with the present invention has a structure in which components constituting an outdoor unit, and components constituting an indoor unit, are vertically integrated, and the integrated indoor-outdoor unit type air conditioner includes an inner frame that includes: a back board member that is formed of a sheet metal material so as to constitute a back face of the integrated indoor-outdoor unit type air conditioner, and whose upper end portion is provided with hooking portion; a first tray member that is formed of a resin material to constitute a bottom of the integrated indoor-outdoor unit type air conditioner, and that is connected to a lower end of the back board member to support components of one of the outdoor unit and the indoor unit; and a second tray member that is formed of a resin material, and that is connected to an intermediate portion of the back board member to support components of the other of the outdoor unit and the indoor unit.

[0014] According to the structure described above, the components of the outdoor unit and the indoor unit are supported on the first tray member connected to the lower end of the back board member of the inner frame and the second tray member connected to the intermediate portion of the back board member, respectively, to constitute the integrated indoor-outdoor unit type air conditioner.

[0015] Each of the first tray member and the second tray member is formed of a resin material to be very lightweight, so that it is possible to reduce weight of the inner frame. As a result, it is possible to reduce a load to the surface of the wall on which the integrated indoor-outdoor unit type air conditioner is hung.

[0016] Further, the first tray member and the second tray member are formed by resin molding, so that a modeling property can be noticeably improved as compared with those formed of metal. Thus, the first tray member and the second tray member serve as a drain pan so that it is possible to effectively recover rainwater entered from the outside and condensed water. As a result, it is possible to prevent the rainwater and the condensed water from leaking to the indoor side.

[0017] Furthermore, in the structure described above of the integrated indoor-outdoor unit type air conditioner in accordance with the present invention, at least one of the first tray member and the second tray member has a lateral width dimension that is greater than a depth dimension thereof, and a metal angle member is attached to at least a front end and a rear end along a lateral width direction of the at least one of the first tray member and the second tray member for reinforcement so that the angle member at the rear end is connected and fixed to the back board member.

[0018] In the structure described above, at least one of the first tray member and the second tray member is reinforced with the metal angle member. The angle member is only attached to the end of the tray member, so that weight of the inner frame does not greatly increase. Thus, it is possible to reduce weight of the inner frame while strength and rigidity thereof are increased.

[0019] Further, in the structure described above of the integrated indoor-outdoor unit type air conditioner in accordance with the present invention, exterior panel members are fixed around a periphery of each of the first tray member and the second tray member to constitute a casing serving as an outer shell of the integrated indoor-outdoor unit type air conditioner.

[0020] In accordance with the structure described above, the inner frame composed of the back board member, the first tray member, and the second tray member, and the exterior panel members, constitute a semi-monocoque structure, so that a lightweight and strong casing is formed. As a result, it is possible to achieve both increase in rigidity and reduction in weight of the integrated indoor-outdoor unit type air conditioner.

[0021] Further, in the structure described above of the integrated indoor-outdoor unit type air conditioner in accordance with the present invention, a plurality of partition members each of which has a different face direction in vertical view and plan view is fixed so as to connect between the first tray member and the second tray member.

[0022] In accordance with the structure described above, relative movement in a horizontal direction in a space between the first tray member and the second tray member is regulated by the plurality of partition members each of which has a different face direction. As a result, it is possible to increase strength of the inner frame.

{Advantageous Effects of Invention}

[0023] As described above, in accordance with the integrated indoor-outdoor unit type air conditioner in accordance with the present invention, in an air conditioner in which an outdoor unit and an indoor unit are vertically integrated, it is possible to reduce weight thereof and improve recovery of rainwater and condensed water while strength and rigidity of the inner frame are secured.

{Brief Description of the Drawings}

[0024] 

{Fig. 1}
Fig. 1 is a perspective view of an integrated indoor-outdoor unit type air conditioner in accordance with an embodiment of the present invention.

{FIG. 2}
Fig. 2 is an inner structure diagram of the integrated indoor-outdoor unit type air conditioner shown in Fig. 1 as viewed from a back face side thereof.

{Fig. 3}
Fig. 3 is a perspective view showing an inner frame of a first embodiment.

{Fig. 4}
Fig. 4 is a perspective view showing a state where partition members are fixed to the inner frame.

{Fig. 5}
Fig. 5 is a perspective view showing a state where exterior panel members are to be attached to the inner frame.

{Fig. 6}
Fig. 6 is a perspective view showing a state where the exterior panel members are fixed to the inner frame.

{Fig. 7}
Fig. 7 is a perspective view showing an inner frame of a second embodiment.

{Fig. 8}
Fig. 8 is a perspective view showing an inner frame of a third embodiment.

{Fig. 9}
Fig. 9 is a perspective view showing an inner frame of a fourth embodiment.

{Description of Embodiments}

[0025] Hereinafter, the embodiments of the present invention will be described with reference to the accompanying drawings.

[0026] Fig. 1 is a perspective view of an integrated indoor-outdoor unit type air conditioner in accordance with an embodiment of the present invention, and Fig. 2 is an inner structure diagram of the integrated indoor-outdoor unit type air conditioner shown in Fig. 1 as viewed from a back face side thereof.

[0027] An integrated indoor-outdoor unit type air conditioner 1 is to be installed by being hooked on a surface of an indoor wall of a house, a condominium, and the like. In the air conditioner 1, components constituting an outdoor unit 2 and components constituting an indoor unit 3 are vertically integrated, as shown in FIG. 2.

[0028] A casing 4 serving as an outer shell of the integrated indoor-outdoor unit type air conditioner 1 is composed of exterior panel members, such as a front panel 4a, side panels 4b, a top panel 4c, and a back panel (not shown). The casing 4 is provided in its top face (the top panel 4c) with an inlet port 6 through which indoor air is inhaled, and is provided in its front face (the front panel 4a) with an outlet port 7 through which air-conditioned air is blown into an interior of a room.

[0029] In the casing 4, there is provided an inner frame 24 (refer to Figs. 3 to 6) described later. As shown in Fig. 2, the casing 4 is provided in its lowermost portion with a flat and rectangular tray-like drain pan 11 (a first tray member) constituting a bottom of the integrated indoor-outdoor unit type air conditioner, and is provided in its intermediate portion with also a similar tray-like intermediate frame member 12 (a second tray member). Each of the drain pan 11 and the intermediate frame member 12 is formed of a resin material by injection molding.

[0030] The outdoor unit 2 is composed of components such as a condenser 14 and a cooling fan 15 that are supported on the drain pan 11, as well as is composed of others such as a compressor and a control device that are not shown.

[0031] Further, the indoor unit 3 is composed of a unit box 21 provided on the intermediate frame member 12. There are an evaporator, a blower (sirocco fan), and the like built in the unit box 21 and are not shown.

(First Embodiment)

[0032] Figs. 3 to 6 show the inner frame 24 of the first embodiment, provided in the casing 4.

[0033] The inner frame 24 is formed of a sheet metal material, and is composed of a left-and-right pair of back board members 25 constituting the back face of the integrated indoor-outdoor unit type air conditioner 1, the drain pan 11 above, and the intermediate frame member 12 described above.

[0034] Each of the back board members 25 is a steel angle member, for example, and includes a vertical back face board 25a and a side face board 25b. The back face board 25a is provided its upper end portion with a hole-like hooking portion 25c. When the integrated indoor-outdoor unit type air conditioner 1 is attached to a surface of a wall, the hooking portion 25c is hung by an attachment bracket or the like provided in the surface of the wall.

[0035] The drain pan 11 is connected to a lower end of each of the back board members 25, and the intermediate frame member 12 is connected to an intermediate portion of each of the back board members 25. Specifically, an angle shape formed by the back face board 25a and the side face board 25b of each of the right and left back board members 25 are brought into contact with right and left corner portions of each of the drain pan 11 and the intermediate frame member 12 on a rear end side thereof to be fastened and fixed with a bolt (not shown), for example. The side face board 25b of each of the back board members 25 is provided in a limited range from an upper end of the intermediate frame member 12 to a lower end of the drain pan 11, for example.

[0036] Each of the drain pan 11 and the intermediate frame member 12 has a lateral width dimension greater than a depth dimension thereof. The dimensions include a lateral width dimension of about 950 mm and a depth dimension of about 200 mm, for example. There is a metal angle member 28 that is attached to each of a front end and a rear end of the drain pan 11 along a direction of the lateral width for reinforcement. The angle member 28 is fixed to the drain pan 11 with a fixing means, such as bolting, bonding, fitting, integral molding.

[0037] The angle member 28 at the rear end is connected to a back board member 25 and is fixed thereto by bolting, welding, or the like. It is also conceived that the angle member 28 at the rear end is integrated with the back board member 25 by welding or the like in advance, and then is connected to the drain pan 11. If the drain pan 11 has a small aspect ratio, it is conceived that each of right and left ends of the drain pan 11 is reinforced with an angle member. Likewise, it is also conceived that each of a front end, a rear end, and side ends of the intermediate frame member 12 is reinforced with an angle member.

[0038] As shown in Figs. 3 to 6, there are a plurality of partition members 31, 32, and 33 each of which has a different face direction in vertical view and plan view, and which is fixed so as to connect the drain pan 11 and the intermediate frame member 12. For the partition members 31, 32, and 33, a member formed into an angle-shape, a channel-shape, or the like by bending a sheet metal material, a member formed of a resin material by molding, and the like, are available. For example, a face direction of the partition member 31 is along the long side of each of the drain pan 11 and the intermediate frame member 12, and a face direction of the partition member 32 is along the short side of each of the drain pan 11 and the intermediate frame member 12. Further, the partition member 33 has a face along the short side of each of the drain pan 11 and the intermediate frame member 12, as well as has a face along the long side thereof.

[0039] Further, as shown in Figs. 5 and 6, exterior panel members, such as the side panels 4b, the front panel 4a shown in Figs 1 and 2, and a back panel that is not shown, are fixed around a periphery of each of the drain pan 11 and the intermediate frame member 12 to constitute the casing 4. In an actual assembly, each of the exterior panel members 4a, 4b, and 4c is fixed after the outdoor unit and the indoor unit are assembled on the drain pan 11 and the intermediate frame member 12 of the inner frame 24, respectively.

[0040] The integrated indoor-outdoor unit type air conditioner is configured as above.

[0041] The integrated indoor-outdoor unit type air conditioner 1 includes the inner frame 24 that includes: the back board member 25 that is formed of a sheet metal material so as to constitute a back face of the air conditioner and that is provided in its upper end portion with the hooking portion 25c; a drain pan 11 that is formed of resin by molding to constitute a bottom of the air conditioner 1 and that is connected to a lower end of the back board member 25 to support components of the outdoor unit 2; and the intermediate frame member 12 that is also formed of resin by molding and that is connected to an intermediate portion of the back board member 25 to support components of the indoor unit 3.

[0042] In accordance with the structure described above, it is possible to produce each of the drain pan 11 and the intermediate frame member 12, formed of resin by molding, with a very light weight. As a result, weight of the inner frame 24 is reduced, so that it is possible to reduce a load to the surface of the wall on which the integrated indoor-outdoor unit type air conditioner is hung.

[0043] Further, the drain pan 11 and the intermediate frame member 12 are formed by resin molding, so that a modeling property can be noticeably improved as compared with those formed of metal. Thus, the drain pan 11 can recover rainwater entering inside the casing 4 from an inlet port and an outlet port (not shown) through which outdoor air is blown, the ports being provided in the back face of the integrated indoor-outdoor unit type air conditioner 1, and condensed water condensed in the casing 4 effectively. As a result, it is possible to prevent the water from leaking into the inside of a room. The same applies to the intermediate frame member 12 if it also serves as a drain pan.

[0044] In the integrated indoor-outdoor unit type air conditioner 1, the drain pan 11 has a lateral width dimension greater than a depth dimension thereof, and the metal angle member 28 is attached to each of front and rear ends along the lateral width direction of the drain pan 11 for reinforcement, and also the angle member 28 at the rear side is connected and fixed to the back board member 25.

[0045] Thus, the metal angle member 28 reinforces the drain pan 11, and applies rigidity capable of supporting weight of components of the outdoor unit 2 to the drain pan 11. As a result, it is possible to improve durability of a compressor (not shown) for vibration and the like. The same applies to the intermediate frame member 12 if it is also reinforced by the angle member 28.

[0046] The angle member 28 is only attached to each of ends of the drain pan 11 (or the intermediate frame member 12), so that weight of the inner frame 24 does not greatly increase. Thus, it is possible to reduce the weight while strength and rigidity of the inner frame 24 are increased.

[0047] Further, the exterior panel members, such as the front panel 4a, the side panels 4b, the top panel 4c, and the back panel (not shown), are fixed around the periphery of each of the drain pan 11 and the intermediate frame member 12 to constitute the casing 4.

[0048] Thus, the inner frame 24 composed of the back board member 25, the drain pan 11, and the intermediate frame member 12, and the exterior panel members 4a, 4b, and 4c, constitute a semi-monocoque structure, so that the lightweight and strong casing 4 is formed. As a result, it is possible to achieve both increase in rigidity and reduction in weight of the integrated indoor-outdoor unit type air conditioner 1.

[0049] Since the plurality of partition members 31, 32, and 33 each of which has a different face direction in vertical view and plan view is fixed so as to connect the drain pan 11 and the intermediate frame member 12, relative movement in a horizontal direction in a space between the drain pan 11 and the intermediate frame member 12 is regulated by the plurality of partition members 31, 32, and 33.

[0050] For example, relative movement of the intermediate frame member 12 in its longitudinal direction with respect to the drain pan 11 is regulated by the partition members 31 and 33, and relative movement of the intermediate frame member 12 in its lateral direction with respect to the drain pan 11 is regulated by the partition members 32 and 33. As a result, it is possible to further increase strength of the inner frame 24.

(Second Embodiment)

[0051] Fig. 7 shows an inner frame 24A of the second embodiment.

[0052] The inner frame 24A includes a left-and-right pair of angle members 25d each of which is formed by extending a lower end of each of the back board members 25 (back face boards 25a) in either right or left lateral direction of the drain pan 11. The inner frame 24A is formed so that the angle members 25d and the two angle members 28 provided in the longitudinal direction of the drain pan 11 enclose four peripheral sides of the drain pan 11. Structure of other portions is identical with those of the inner frame 24 of the first embodiment.

[0053] In accordance with the structure described above, the metal and frame-like angle members 25d and 28 enclose around the entire periphery of the drain pan 11 for reinforcement, so that it is possible to increase a reinforcement effect of the drain pan 11 as compared with that of the first embodiment.

(Third Embodiment)

[0054] Fig. 8 shows an inner frame 24B of the third embodiment.

[0055] The inner frame 24B includes a vertical left-and-right pair of angle members 25e each of which is formed by further bending and extending upward a front end of each of the left-and-right pair of angle members 25d each of which is formed by extending the lower end of each of the back board members 25, the angle members 25d being shown in the inner frame 24A of the second embodiment. The inner frame 24B is formed by connecting each of the angle members 25e to either right or left front end corner of each of the drain pan 11 and the intermediate frame member 12 for further reinforcement.

[0056] In accordance with the inner frame 24B, even if the indoor unit 3 to be mounted on the intermediate frame member 12 is a heavy weight, it is possible to support the weight with the two angle members 25e.

[0057] Further, if the two angle members 25e are increased in thickness, connection rigidity between the drain pan 11 and the intermediate frame member 12 is increased. As a result, it is possible to reliably prevent relative movement of the intermediate frame member 12 in its horizontal direction with respect to the drain pan 11.

(Fourth Embodiment)

[0058] Fig. 9 shows an inner frame 24C of the fourth embodiment.

[0059] The inner frame 24C is formed by attaching each of two thick angle members 35 extending vertically to either right or left front end corner of each of the drain pan 11 and the intermediate frame member 12 in the inner frame 24 of the first embodiment for reinforcement, as well as by providing the partition member 32 in the inner frame 24.

[0060] The inner frame 24C can also increase the connection rigidity between the drain pan 11 and the intermediate frame member 12. Since the angle members 28 reinforcing the drain pan 11 are only provided in the front and rear ends, the inner frame 24C can also contribute to reduction in weight.

[0061] As described above, in accordance with the integrated indoor-outdoor unit type air conditioner 1 in accordance with the present embodiments, in an air conditioner in which the outdoor unit 2 and the indoor unit 3 are vertically integrated, it is possible to reduce weight thereof and improve recovery of rainwater and condensed water while strength and rigidity of the inner frame 24 are secured.

[0062] The present invention is not limited to the structures of the embodiments described above, and changes and modifications may be optionally made without departing from the scope of the present invention. An embodiment in which the changes and the modifications above are added should be included in the scope of right of the present invention.

[0063] For example, the following is not limited the embodiments above: a shape and a position of the drain pan 11, the intermediate frame member 12, the back board member 25, the angle members 25d, 25e, 28, and 35, the partition members 31, 32, and 33, and the like; a vertical relationship between the outdoor unit 2 and the indoor unit 3; and an aspect ratio and the like of a shape of the integrated indoor-outdoor unit type air conditioner 1.

{Reference Signs List}

[0064] 

1

integrated indoor-outdoor unit type air conditioner

2

outdoor unit

3

indoor unit

4

casing

4a

front panel (exterior panel member)

4b

side panel (exterior panel member)

4c

top panel (exterior panel member)

6

inlet port

7

outlet port

11

drain pan (first tray member)

12

intermediate frame member (second tray member)

24, 24A, 24B, and 24C

inner frame

25

back board member

25c

hooking portion

25d

angle member (second angle member)

25e

angle member (third angle member)

28

angle member (first angle member)

31, 32, and 33

partition member

35

angle member (fourth angle member)

Claims

1. An integrated indoor-outdoor unit type air conditioner (1) in which components constituting an outdoor unit (2) and components constituting an indoor unit (3) are vertically integrated, the integrated indoor-outdoor unit type air conditioner (1) comprising an inner frame (24,24A,24B,24C), the integrated indoor-outdoor unit type air conditioner (1) being characterized in that the inner frame comprises:

a back board member (25) that is formed of a sheet metal material so as to constitute a back face of the integrated indoor-outdoor unit type air conditioner (1), and whose upper end portion is provided with a hooking portion (25c);

a first tray member (11) that is formed of a resin material to constitute a bottom of the integrated indoor-outdoor unit type air conditioner (1), and that is connected to a lower end of the back board member (25) to support components of one of the outdoor unit (2) and the indoor unit (3); and

a second tray member (12) that is formed of a resin material, and that is connected to an intermediate portion of the back board member (25) to support components of the other of the outdoor unit (2) and the indoor unit (3).

2. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 1, wherein at least one of the first tray member (11) and the second tray member (12) has a lateral width dimension that is greater than a depth dimension thereof, and a first angle member (28) made of a metal is attached to at least a front end and a rear end along a lateral width direction of the at least one of the first tray member (11) and the second tray member (12) for reinforcement so that the first angle member at the rear end is connected and fixed to the back board member (25).

3. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 1 or 2, further comprising exterior panel members (4a,4b,4c) that are fixed around a periphery of each of the first tray member (11) and the second tray member (12) to constitute a casing serving as an outer shell of the integrated indoor-outdoor unit type air conditioner (1).

4. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 3, further comprising a plurality of partition members (31,32,33) each of which has a different face direction in vertical view and plan view, the partition members being fixed so as to connect between the first tray member (11) and the second tray member (12).

5. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 2,
wherein the inner frame (24A) includes a left-and-right pair of second angle members (25d) each of which is formed by extending a lower end of each of the back board members (25) in either right or left lateral direction of the first tray member (11), and
wherein the inner frame (24A) is formed so that the second angle members (25d) and the two first angle members (28) provided in the longitudinal direction of the first tray member (11) enclose four peripheral sides of the first tray member (11).

6. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 2,
wherein the inner frame (24B) includes a vertical left-and-right pair of third angle members (25e) each of which is formed by further bending and extending upward a front end of each of a left-and-right pair of second angle members (25d) each of which is formed by extending the lower end of each of the back board members (25), and
wherein the inner frame (24B) is formed by connecting each of the third angle members (25e) to either right or left front end corner of each of the first tray member (11) and the second tray member (12).

7. The integrated indoor-outdoor unit type air conditioner (1) according to Claim 2,
wherein the inner frame (24C) is formed by attaching each of two fourth angle members (35) extending vertically to either right or left front end corner of each of the first tray member (11) and the second tray member (12) and providing a partition member (32) which is fixed so as to connect between the first tray member (11) and the second tray member (12) .

Drawing