HEAT PUMP DEVICE

Abstract

 The present disclosure provides a heat pump device that easily ensures airtightness of an electrical equipment box, and allows easy assembling of the electrical equipment box. The heat pump device of the present disclosure includes: a refrigerant circuit inside which a flammable refrigerant is sealed and circulated, and to which a compressor and a heat exchanger are connected; a sensor attached to each portion of the refrigerant circuit; a control board that is connected to the sensor, and controls driving of the compressor; and an electrical component box storing the control board, wherein the control board is disposed at a location for closing an opening portion provided on the electrical component box, and a connector for connecting the sensor and the control board is mounted on an exposed portion of the control board that is a portion exposed from the electrical component box through the opening portion.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

[0001] The present invention relates to a heat pump device.

Description of the Related Art

[0002] Japanese Patent Laid-Open No. 10-220824 discloses an air-conditioning device as a heat pump device that uses a flammable refrigerant as a working refrigerant, and ensures safety of operation of the device in case of leakage of the flammable refrigerant. In this air-conditioning device, electrical components are placed away from a heat exchanger, and then connection terminals are provided on a case for the electrical components, and wirings are connected to the electrical components through the connection terminals. Consequently, exposure of the electrical components to a high-density flammable refrigerant is reduced, and the refrigerant is prevented from being ignited.

SUMMARY OF THE INVENTION

[0003] The present disclosure provides a heat pump device that easily secures airtightness of an electrical component box, and allows easy assembling of the electrical component box.

[0004] A heat pump device of the present disclosure includes: a refrigerant circuit inside which a flammable refrigerant is sealed and circulated, and to which a compressor and a heat exchanger are connected; a sensor attached to each portion of the refrigerant circuit; a control board that is connected to the sensor, and controls driving of the compressor; and an electrical component box storing the control board, wherein the control board is disposed at a location for closing an opening portion provided on the electrical component box, and a connector for connecting the sensor and the control board is mounted on an exposed portion of the control board that is a portion exposed from the electrical component box through the opening portion.

[0005] The heat pump device of the present disclosure can expose, from the exposed portion that closes the opening portion, a connector of wiring through which a weak current flows, and which does not ignite even when exposed to the flammable refrigerant. Consequently, it is easy to ensure airtightness of the electrical component box, and it is easy to assemble the electrical component box.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] 

Figure 1 is a front view of a heat pump device according to Embodiment 1;

Figure 2 is a cross-sectional view of the heat pump device according to Embodiment 1;

Figure 3 is a cross-sectional view taken along the III-III line in Figure 2;

Figure 4 is a refrigeration cycle circuit diagram of the heat pump device according to Embodiment 1;

Figure 5 is an exploded perspective view of an electrical component box according to Embodiment 1;

Figure 6 is a cross-sectional view taken along the VI-VI line in Figure 3;

Figure 7 is an enlarged view of Figure 6;

Figure 8 is a perspective view of a resin case according to Embodiment 1; and

Figure 9 is a cross-sectional view of a control board according to another embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(Findings that Formed the Basis of the Present Disclosure)

[0007] When the present inventors reached the present disclosure, technologies of heat pump devices required the use of refrigerant with low global warming potential (GWP). Therefore, the concerning industry addressed the problem of refrigerant with low GWP which is generally highly reactive and flammable, and proposed a technology to separate electrical components and refrigerant from each other even if the refrigerant leaked from a refrigerant circuit. In such a circumstance, the present inventors have realized that, even if all the refrigerant in the refrigerant circuit leaks, having the concentration of the refrigerant in the electrical component box not exceeding an ignition limit is sufficient to prevent ignition within the electrical component box in case of leakage of the flammable refrigerant, and have used this fact as a clue and have come up with the idea of achieving both of sufficient airtightness necessary for the electrical component box, and easy assembling.

[0008] Further, the present inventors have discovered the problem that, if connection terminals are used to separate the refrigerant and the electrical components from each other, a lot of man-hours are required for assembly because many wires are connected through the connection terminals, and have come up with constructing the subject matter of the present disclosure.

[0009] Hence, the present disclosure discloses a heat pump device that easily secures airtightness of an electrical component box, and allows easy assembling of the electrical component box.

[0010]  Hereinafter, an embodiment will be described in detail with reference to the drawings. However, unnecessarily detailed descriptions may be omitted. For example, detailed descriptions of well-known matters, or redundant descriptions of substantially the same configurations may be omitted. This is to avoid the following descriptions from becoming unnecessarily redundant, and to facilitate understanding of those skilled in the art.

[0011] Note that the accompanying drawings and the following descriptions are provided to allow those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter described in the claims.

[0012] Figure 1 is a front view of a heat pump device 1, and shows the heat pump device 1 seen from the front side. Figure 2 is a cross-sectional view showing an internal structure of the heat pump device 1, and shows the internal structure seen from the front side. Figure 3 is a cross-sectional view taken along the III-III line in Figure 2. The heat pump device 1 shown from Figure 1 to Figure 3 is an outdoor unit applicable to a so-called heat pump hot water heater.

[0013] As shown in Figure 1, the heat pump device 1 has a substantially cuboid housing 10. In the present embodiment, each portion of the housing 10 is made of a steel plate.

[0014] The housing 10 has a bottom plate 14 forming a bottom surface of the housing 10, a pair of side panels 15 covering the left side of the housing 10 from the front and back thereof, a front panel 16 covering the left side of a front surface of the housing 10, and a top plate 17 covering an upper surface of the housing 10. The front panel 16 has two openings 16a arranged one over another, and a blower 21 is exposed from each opening 16a. Note that, although not shown in Figure 1, each of the openings 16a is externally covered with a grate that allows ventilation when the heat pump device 1 is in use.

[0015] As shown in Figure 2 and Figure 3, a partition plate 11 extending in an up-down direction is provided inside the housing 10. The inside space of the housing 10 is partitioned into left and right sides, namely a blower chamber 12 and a mechanical chamber 13, by the partition plate 11.

[0016] A heat exchanger 20, and the two blowers 21 which are disposed one over another, are installed in the blower chamber 12. In the housing 10, the front surface of the blower chamber 12 is covered with the front panel 16.

[0017] The heat exchanger 20 of the present embodiment almost fully extends along a height direction of the housing 10. Furthermore, the heat exchanger 20 is formed in a substantially L shape in plan view of the housing 10 so as to be exposed to a back surface 10A and a side surface 10B of the housing 10.

[0018] For the heat exchanger 20, for example, a fin-tube heat exchanger is used.

[0019] For the blower 21, for example, an axial fan with propeller-shaped impellers is used. The blower 21 is disposed such that an axial flow direction is directed to the opening 16a of the front panel 16.

[0020] Stored inside the mechanical chamber 13 are various types of equipment forming a refrigerant circuit, such as a compressor 22, a water heat exchanger 23, and an expansion device 24 shown in Figure 4 described later, and refrigerant piping 25 connecting these pieces of equipment to each other.

[0021] For the water heat exchanger 23, for example, a plate heat exchanger is used.

[0022] A cut-out portion 26 is formed in an upper portion of the partition plate 11, and an electrical component box 30 is installed in the cut-out portion 26. The electrical component box 30 is mounted spanning over the blower chamber 12 and the mechanical chamber 13 through the cut-out portion 26 and an electrical component box support plate 29a mounted on an upper end of a fan support frame 29 that supports the blower 21. Moreover, as shown in Figure 2, a space that allows ventilation is formed between the top plate 17 and an upper end of the electrical component box 30 disposed above the blower chamber 12 and the mechanical chamber 13.

[1-1-2. Configuration of Refrigerant Circuit]

[0023] Figure 4 is a circuit diagram showing a refrigerant circuit according to Embodiment 1.

[0024] As shown in Figure 4, the compressor 22, a four-way valve 27, the water heat exchanger 23, the expansion device 24, and the heat exchanger 20 are annularly connected through the predetermined refrigerant piping 25 to form the refrigerant circuit.

[0025] Predetermined water supply piping 28 is connected to the water heat exchanger 23, and, in the water heat exchanger 23, heat exchange is performed with a refrigerant circulating in the refrigerant circuit.

[0026] The refrigerant compressed to high temperature and high pressure by the compressor 22 flows as shown by the solid arrows in FIG. 4, and is sent to the water heat exchanger 23 so as to be heat-exchanged with water flowing through the water supply piping 28, cooled and condensed by the water heat exchanger 23. The water that receives the heat of the refrigerant becomes hot water, and is supplied to, for example, use-side equipment (not shown).

[0027] The refrigerant discharged from the water heat exchanger 23 is decompressed in the expansion device 24 to evaporate, is heat-exchanged in the heat exchanger 20 to be a gas refrigerant, and is returned again to the compressor 22.

[0028] Further, by switching the four-way valve 27, the refrigerant flows as shown by the broken-line arrows in Figure 4, is heat-exchanged with outside air in the heat exchanger 20, is decompressed in the expansion device 24, and is then sent to the water heat exchanger 23 so as to allow the water flowing through the water supply piping 28 to be cooled down. Cold water is supplied to the use-side equipment (not shown).

[0029] Here, a flammable refrigerant is used as the refrigerant in the present embodiment. The flammable refrigerant is R32 or a mixed refrigerant containing 70 weight percent or more of R32, or propane or a mixed refrigerant containing propane. R32 and propane are both refrigerants having low GWP, and small environmental loads.

[0030] Note that an inflammable refrigerant may be used as the refrigerant, instead of the flammable refrigerant.

[0031] The refrigerant circuit is provided with sensors for detecting various physical quantities. A temperature sensor (not shown) for measuring the temperature of a pipe surface is mounted in each portion of the refrigerant piping. Pressure sensors (sensor) PS1, PS2 for measuring the pressure of the refrigerant are mounted on an intake side and a discharge side, respectively, of the compressor 22. Moreover, for the water supply piping 28, temperature sensors (sensors) TS1, TS2 for detecting water temperature are mounted on an upstream side and a downstream side of the water heat exchanger 23. Further, a refrigerant sensor (sensor) RS1 for detecting leakage of the refrigerant from the heat exchanger 20 is mounted in the vicinity of the heat exchanger 20.

[0032] Furthermore, the expansion device 24 and the four-way valve 27 have actuators for driving the expansion device 24 and the four-way valve 27, respectively.

[1-1-3. Configuration of Electrical Component Box]

[0033] Figure 5 is an exploded perspective view showing the electrical component box 30 of Embodiment 1.

[0034] As shown in Figure 5, the electrical component box 30 has an electrical component box body 32 that is made of sheet metal in the shape of an open-top box with an opening 31, and a lid member 33 that is formed in a substantially rectangular flat plate shape and closes the opening 31. The electrical component box body 32 is made of a material with high thermal conductivity, for example, a metal material. The lid member 33 is attached to the electrical component box body 32 through an O-ring 38.

[0035] Note that, in the present embodiment, although the entire electrical component box body 32 is made of a metal material, only a portion located on the blower chamber 12 may be made of a metal material.

[0036] As shown in Figure 5, the electrical component box body 32 has a rectangular blower-side portion 32A located on the blower chamber 12 side, and a rectangular mechanical-side portion 32B located on the mechanical chamber 13 side. A bottom surface opening portion 35 as a rectangular opening is formed on a bottom surface of the blower-side portion 32A of the electrical component box body 32. The bottom surface opening portion 35 is formed at a portion of the blower-side portion 32A, near the mechanical-side portion 32B. Moreover, an opening portion 35a as a rectangular opening is formed on a bottom surface of the mechanical-side portion 32B. The lid member 33 has a rectangular blower-side portion 33A located on the blower chamber 12 side, and a rectangular mechanical-side portion 33B located on the mechanical chamber 13 side.

[0037] On the electrical component box body 32, a control board 60 is installed to span between the blower-side portion 32A and the mechanical-side portion 32B. The details of the control board 60 will be described later.

[0038] The electrical component box body 32 is formed by folding a sheet metal into a box shape, and welding joints at four corners to form an airtight box.

[0039] The lid member 33 is secured to the upper end of the electrical component box body 32 through the O-ring 38 with securing screws 37. Consequently, the opening 31 is sealed closed by the lid member 33 and the O-ring 38. More specifically, as shown in Figure 5, a flange 32F, which is formed by folding the sheet metal, is formed on a peripheral edge of the upper end of the electrical component box body 32. An O-ring groove in which the O-ring 38 is fitted is formed on a peripheral edge of the lower surface of the lid member 33, and the O-ring 38 is fitted in the O-ring groove, and then the lid member 33 is secured to the flange 32F with six securing screws 37. The O-ring 38 is foam rubber, or chloroprene rubber, EPDM, NBR, H-NBR or the like.

[0040] The lid member 33 is secured to the flange 32F of the mechanical-side portion 32B of the electric equipment component box body 32 with six securing screws 37, and is secured to the flange 32F of the blower-side portion 32A of the electric equipment component box body 32 with two securing screws 37.

[0041] The electrical component box body 32 is disposed at a location such that a ratio of the volume occupied by the mechanical-side portion 32B is smaller than that of the volume occupied by the blower-side portion 32A.

[0042] Consequently, a seal length (the length of the O-ring 38) between the electrical component box body 32 and the lid member 33 in the mechanical-side portion 32B of the electrical component box body 32 is set shorter.

[0043] As described above, the space allowing ventilation is formed between the lower surface of the top plate 17 of the housing 10 and the upper surface of the lid member 33. As shown in Figure 5, a partition member 39 provided on the upper surface of the lid member 33 is disposed at the boundary between the blower-side portion 33A and the mechanical-side portion 33B so as to close the space. The partition member 39 has a plurality of openings (not shown) formed at equal intervals to allow ventilation between the mechanical chamber 13 and the blower chamber 12 through the openings.

[0044] When the heat pump device 1 is in operation, since the blower 21 is operated, the inside of the blower chamber 12 has a negative pressure. Consequently, the air on the mechanical chamber 13 side flows to the blower chamber 12 side through the plurality of openings of the partition member 39. With the flow of the air, the entire area of the upper surface of the lid member 33 is cooled by the air.

[0045] Moreover, as shown in Figure 5, a cable gland (seal means) 49 is attached to the electrical component box body 32. The cable gland 49 allows wiring inside the electrical component box 30 to be drawn to the outside while keeping airtightness. A power supply line 48 (see Figure 6) for supplying electric supply to the control board 60, and the wiring, such as a compressor connection line connecting the control board 60 and the compressor 22, through which a large current can flow, are pulled out from the inside of the electrical component box 30 to the outside through the cable gland 49.

[0046] In the present embodiment, the current equal to or greater than a later-described reference current I at maximum flows through the power supply line 48 of the control board 60, and the compressor connection line.

[1-1-4. Configuration of Control Board]

[0047] The control board 60 is a board for controlling the respective portions of the heat pump device 1, such as the blower 21, the compressor 22 in Figure 4, the expansion device 24, and the four-way valve 27. Moreover, the control board 60 is connected to the sensors attached to the respective portions of the refrigerant circuit and the water supply piping 28, and receives output signals transmitted from the sensors. Specifically, the control board 60 receives the output signals from the pressure sensors PS1, PS2, the temperature sensors TS1, TS2, the refrigerant sensor RS1, etc.

[0048] Figure. 6 is a cross-sectional view of the electrical component box 30 taken along the VI-VI line in Figure 3. Figure 7 is an enlarged view of Figure 6. As shown in Figure 5 to Figure 7, a relay (electrical part) 63 and a capacitor (electrical part) 65 are mounted on an upper surface 60A of the control board 60. Moreover, an inverter element 64 and a plurality of connectors 69 are mounted on a lower surface 60B of the control board 60. The relay 63 and the capacitor 65 protrude upward from the upper surface 60A of the control board 60, and are used to control the blower 21, the compressor 22, the expansion device 24, the four-way valve 27, etc. The inverter element 64 has a flat shape along the lower surface 60B of the control board 60, and is smaller in height compared to the relay 63 and the capacitor 65. In short, the connectors 69 and the inverter element 64 having smaller dimensions in the height direction are disposed on the lower surface 60B of the control board 60, and the relay 63 and the capacitor 65 having larger dimensions in the height direction are disposed on the upper surface 60A of the control board 60. Therefore, it is easy to dispose the control board 60 on a lower side inside the electrical component box 30, and it is easy to place the control board 60 and the electrical component box body 32 close to each other.

[0049] Although the relay 63 has a possibility of occurrence of sparks at an internal contact during operation, the upper surface 60A of the control board 60 on which the relay 63 is disposed is located inside the electrical component box 30, the relay 63 is not easily exposed to high-density refrigerant in case of leakage of the refrigerant from the refrigerant circuit.

[0050] Further, the wiring such as the power supply line 48 of the control board 60 and a compressor connection line (not shown) through which the current equal to or greater than the reference current I can flow is pulled out from the upper surface 60A of the control board 60. Since the upper surface 60A is located inside the electrical component box 30, the connection portions of the power supply line 48 and the compressor connection line with the control board 60 are not easily exposed to high-density refrigerant in case of leakage of the refrigerant from the refrigerant circuit.

[0051] The control board 60 is attached to the electrical component box body 32 with a screw through a resin case 70 made of a resin. The resin case 70 is located between the control board 60 and the electrical component box body 32 made of metal, and secures the control board 60 in a position so as not to contact the electrical component box body 32. The control board 60, which is attached through the resin case 70 to the electrical component box body 32, is disposed at a location in the electrical component box body 32 so as to close both the bottom surface opening portion 35 and the opening portion 35a from the inside of the electrical component box 30.

[0052]  Figure 8 is a perspective view of the resin case 70, and shows the resin case 70 seen from below. As shown in Figure 5 to Figure 8, attached to a lower surface 70A of the resin case 70 is a heat sink 71 that dissipates heat of the inverter element 64 mounted on the lower surface 60B of the control board 60 by a plurality of fins. The heat sink 71 is disposed in a direction to protrude downward from the bottom opening portion 35. The heat sink 71 is disposed on the bottom surface of the blower-side portion 32A, near the mechanical-side portion 32B of the electrical component box body 32. In the present embodiment, one end of the heat sink 71 is located on the boundary between the mechanical-side portion 32B and the blower-side portion 32A. In other words, the one end of the heat sink 71 is located on the boundary partitioned by the partition plate 11.

[0053] In the resin case 70, a heat dissipation opening 73 as a substantially rectangular opening passing through the resin case 70 in the up-down direction is formed at a location where the heat sink 71 and the bottom surface opening portion 35 overlap one over another. The heat sink 71 and the inverter element 64 contact each other through the heat dissipation opening 73. A guide portion 73a surrounding the heat dissipation opening 73 and protruding downward is formed on the peripheral edge of the heat dissipation opening 73 on the lower surface 70A of the resin case 70. The guide portion 73a is formed in a shape along an inner peripheral edge of the bottom surface opening portion 35 of the electric component box body 32, and positioning of the resin case 70 relative to the electrical component box body 32 is performed by inserting the guide portion 73a into the bottom surface opening portion 35.

[0054] Moreover, on the lower surface 70A of the resin case 70, a seal groove 73b recessed upward is formed on the outer peripheral side of the guide portion 73a. The seal guide 73b is formed in a shape surrounding the entire periphery of the guide portion 73a. An annular seal member 42 made of an elastic material, such as chloroprene rubber of foam rubber, is fitted in the seal groove 73b. The seal member 42 is interposed between the seal groove 73b and a peripheral edge portion of the bottom surface opening portion 35 of the electrical component box body 32, and fills the gap between the lower surface 70A of the resin case 70 and the electrical component box body 32. Consequently, the bottom surface opening portion 35 is sealed closed by the control board 60, the resin case 70, and the seal member 42.

[0055] In the resin case 70, a second opening portion 75 passing through the resin case 70 in the up-down direction is formed at a location where the second opening portion 75 and the opening portion 35a overlap one over another. Further, an exposed portion 67 that is a portion of the lower surface 60B of the control board 60 is exposed to the outside of the electrical component box 30 through the second opening portion 75 and the opening portion 35a. A number of connectors 69 are mounted on the board, and disposed on the exposed portion 67. The connectors 69 are female connectors, and connected to wiring 80 and the like extending from the sensors such as the pressure sensors PS1, PS2, the temperature sensors TS1, TS2 and the refrigerant sensor RS1, the expansion device 24, the four-way valve 27, the blower 21, and the like. As described above, the opening portion 35a is located on the mechanical chamber 13 separated by the partition plate 11 from the blower chamber 12 in which the heat exchanger 20 is disposed. Therefore, rainwater and dust from the outside of the housing 10, and condensed water or the like on the heat exchanger 20 due to driving of the blower 21 do not easily adhere to the connectors 69.

[0056] Connected to the connectors 69 is only the wiring 80 through which a current that is small enough no to cause ignition of the flammable refrigerant when exposed to the flammable refrigerant used in the refrigerant circuit of the heat pump device 1 flows. More specifically, at a concentration of the flammable refrigerant in the exposed portion 67 when all the flammable refrigerant used in the refrigerant circuit of the heat pump device 1 leaks, the current lower than ignition energy of the flammable refrigerant flows through the wiring 80. In the present embodiment, the value of current flowing through the wiring 80 connected to the connectors 69 is set so that the reference current I is maximum. In the present embodiment, the reference current I is 15A.

[0057] A second guide portion 75a surrounding the second opening portion 75 and protruding downward is formed on the lower surface 70A of the resin case 70. The second guide portion 75a is formed in a shape along the inner peripheral edge of the opening portion 35a, and positioning of the resin case 70 relative to the electrical component box body 32 is performed by inserting the second guide portion 75a into the opening portion 35a.

[0058] On the lower surface 70A of the resin case 70, a gasket groove 75b recessed upward is formed on the outer peripheral side of the second guide portion 75a. The gasket groove 75b is formed in a shape surrounding the entire periphery of the second guide portion 75a. An annular gasket 42a made of an elastic material is fitted in the gasket groove 75b. The gasket 42a is formed by, for example, chloroprene rubber of foam rubber. The gasket 42a is disposed at a location surrounding the opening portion 35a and the second opening portion 75, and is interposed and held between the resin case 70 and the electrical component box body 32. Consequently, the gap between the resin case 70 and the electrical component box body 32 around the opening portion 35a and the second opening portion 75 is filled with the gasket 42a.

[0059]  Moreover, as shown in Figure 8, the resin case 70 has a protruding portion 75c that rises upward from the upper end of the second guide portion 75a, and surrounds the second opening portion 75. Furthermore, the protruding portion 75c is a portion contacting the peripheral edge of the exposed portion 67 of the lower surface 60B of the control board 60, and supports the control board 60 from below. A seal material with flexibility, such as silicone or rubber, is applied to the upper end of the protruding portion 75c. The seal material is applied to the entire periphery of the protruding portion 75c, and surrounds the second opening portion 75. Therefore, when the control board 60 is pressed against the protruding portion 75c from above by fastening a screw, the seal material applied to the protruding portion 75c closely adheres to the control board 60. Hence, the gap between the resin case 70 and the control board 60 around the second opening portion 75 is filled with the seal material.

[0060] Thus, the opening portion 35a is sealed closed by the control board 60, the resin case 70, the gasket 42a, and the seal material on the protruding portion 75c.

[1-2. Operation]

[0061] Next, the operation and function of the heat pump device 1 configured as described above will be described.

[0062] In the heat pump device 1, when the flammable refrigerant leaks from the heat exchanger 20 or the like, the flammable refrigerant scatters inside the housing 10, and the flammable refrigerant also spreads to the surrounding of the electrical component box 30. Therefore, the connectors 69 mounted on the exposed portion 67 exposed to the outside of the electrical component box 30 are exposed to the flammable refrigerant. Only the wiring with a small current value is connected to the connectors 69. Hence, even when the connectors 69 are exposed to the flammable refrigerant, ignition of the flammable refrigerant is prevented.

[0063]  Further, the opening portion 35a for providing communication between the inside and outside of the electrical component box 30 is sealed by the control board 60 and the resin case 70. Furthermore, the gap between the lower surface 70A of the resin case 70 and the electrical component box body 32 is filled with the gasket 42a, and the gap between the protruding portion 75c of the resin case 70 and the lower surface 60B of the control board 60 is filled with the seal material. Therefore, the flammable refrigerant leaked from the refrigerant circuit is prevented from entering the inside of the electrical component box 30 through the opening portion 35a.

[1-3. Effects]

[0064] As described above, in the present embodiment, the heat pump device 1 has: the refrigerant circuit in which the flammable refrigerant is sealed and circulated, and to which the compressor 22 and the heat exchanger 20 are connected; the pressure sensors PS1, PS2, the temperature sensors TS1, TS2, and the refrigerant sensor RS1 attached to the respective portions of the refrigerant circuit; the control board 60 that is connected to the pressure sensors PS1, PS2, the temperature sensors TS1, TS2 and the refrigerant sensor RS1, and controls driving of the compressor 22; and the electrical component box 30 storing the control board 60, wherein the control board 60 is disposed at a location for closing the opening portion 35a provided on the electrical component box 30, and the connectors 69 for connecting the pressure sensors PS1, PS2, the temperature sensors TS1, TS2, and the refrigerant sensor RS1 to the control board 60 are mounted on the exposed portion 67 that is a portion of the control board 60 exposed from the electrical component box 30 through the opening portion 35a.

[0065] Consequently, the connections between the control board 60 and the pressure sensors PS1, PS2, the temperature sensors TS1, TS2, and the refrigerant sensor RS1 through which a current small enough not to ignite the flammable refrigerant flows can be realized by a simple structure, and the opening portion 35a can be closed by the control board 60. Therefore, it is easy to ensure airtightness of the electrical component box 30, and it is easy to assemble the electrical component box 30.

[0066] Moreover, in the present embodiment, the control board 60 is connected to the electrical component box 30 through the resin case 70 made of a resin, the resin case 70 has the second opening portion 75 overlapping the opening portion 35a, the gasket 42a surrounding the opening portion 35a is interposed and held between the resin case 70 and the electrical component box 30, and the seal material surrounding the exposed portion 67 is provided at a portion where the resin case 70 and the control board 60 contact each other.

[0067] Consequently, the airtightness of the electrical component box 30 can be further improved, and, even when the flammable refrigerant leaks from the refrigerant circuit, the flammable refrigerant does not easily enter the inside of the electrical component box 30. Therefore, it is easier to ensure the airtightness of the electrical component box 30, and it is easy to assemble the electrical component box 30.

[0068] Further, in the present embodiment, the control board 60 has the relay 63 and the capacitor 65 for controlling the driving of the compressor 22, and the relay 63 and the capacitor 65 are disposed on the upper surface 60A on the opposite side to the exposed portion 67 on which the connectors 69 are disposed.

[0069] Consequently, it is easy to locate the control board 60 close to the opening portion 35a. Thus, it is easy to make a dimension of the electrical component box 30 smaller. Furthermore, since the opening portion 35a is easily closed by the control board 60, it is easy to improve the airtightness of the electrical component box 30.

[0070]  Moreover, in the present embodiment, the blower chamber 12 in which the blower 21 is installed, and the mechanical chamber 13 in which the compressor 22 is installed are separated by the partition plate 11, and the exposed portion 67 is disposed in the mechanical chamber 13.

[0071] Consequently, condensed water or the like of the heat exchanger 20 does not easily adhere to the connectors 69 disposed on the exposed portion 67. Therefore, there is no need to attach a new member or the like for preventing the connectors 69 from getting wet, during assembling, and it is possible to simplify the assembling of the electrical component box 30.

[0072] Further, in the present embodiment, the power supply line 48 for supplying power supply to the control board 60 is pulled out of the electrical component box 30 using the cable gland 49.

[0073] Consequently, the power supply line 48 through which a large current flows can be pulled out of the electrical component box 30 while ensuring the airtightness with the cable gland 49. Therefore, it is possible to minimize the number of cable glands 49, and it is possible to prevent ignition of the flammable refrigerant while simplifying the assembling of the electrical component box 30.

[0074] Furthermore, in the present embodiment, the flammable refrigerant is R32 or a mixed refrigerant containing 70 weight percent or more of R32, or propane or a mixed refrigerant containing propane.

[0075] Consequently, it is possible to reduce ignition of refrigerant while using the low-GWP refrigerant.

(Another Embodiment)

[0076] As described above, Embodiment 1 is explained as an example of the technology disclosed in the present application. However, the technology of the present disclosure is not limited to this, and can also be applied to embodiments in which modifications, replacements, additions, omissions, etc. are made. Moreover, it is possible to make a new embodiment by combining the components explained in Embodiment 1.

[0077] Hence, another embodiment will be described hereinbelow as an example.

[0078] In Embodiment 1, although the control board 60 is described as being attached to the electrical component box body 32 through the resin case 70, this is one example.

[0079] Figure 9 is a cross-sectional view of the control board 60 in another embodiment, and shows the control board 60 in the same cross section as in Figure 7. As shown in Figure 9, the control board 60 may be attached to the electrical component box body 32 by a screw, without the resin case 70. In this case, as shown in Figure 9, disposed around the bottom surface opening portion 35 is a seal member 142 having a larger dimension in the height direction than that of the seal member 42 in Embodiment 1. The seal member 142 is interposed between the peripheral edge portion of the bottom surface opening portion 35 of the electrical component box body 32 and a portion surrounding the inverter element 64 on the lower surface 60B of the control board 60, thereby filling the gap between the lower surface 60B and the electrical component box body 32. Similarly, a second seal member 143 is disposed on the peripheral edge of the heat sink 71 to fill the gap between the heat sink 71 and the peripheral edge of the inverter element 64 on the lower surface 60B.

[0080] Moreover, as shown in Figure 9, a gasket 142a having a larger dimension in the height direction than that of the gasket 42a in Embodiment 1 may be disposed around the opening portion 35a. The gasket 142a is interposed between the peripheral edge of the opening portion 35a of the electrical component box body 32 and the peripheral edge of the exposed portion 67 of the lower surface 60B of the control board 60, thereby filling the gap between the lower surface 60B and the electrical component box body 32.

[0081] In short, the heat pump device 1 may be configured to interpose and hold, between the electrical component box 30 and the control board 60, the gasket 142a surrounding the exposed portion 67.

[0082] Consequently, the airtightness of the electrical component box 30 can be further improved, and, even when the flammable refrigerant leaks from the refrigerant circuit, the flammable refrigerant does not easily enter the inside of the electrical component box 30. Therefore, it is easier to ensure the airtightness of the electrical component box 30, and it is easy to assemble the electrical component box 30.

[0083] Moreover, as shown in Figure 9, a cover 90 for covering the opening portion 35a from the lower side and the blower chamber 12 side may be attached to the outer surface of the electrical component box body 32. With the cover 90, it is possible to further reduce adhesion of foreign matter such as water to the exposed portion 67.

[0084] Further, in Embodiment 1, although the connectors 69 are explained as being female connectors, and connected to the wiring 80 or the like extending from the sensors such as the pressure sensors PS1, PS2, the temperature sensors TS1, TS2, and the refrigerant sensor RS1, this is one example. The connectors 69 may be male connectors, and may be connected to devices other than the sensors. For example, an actuator, such as the four-way valve 27 installed in the refrigerant circuit, which is activated with a low current equal to or less than the reference current I may be connected to the connector 69. Further, the reference current I is not limited to 15A, and may be set depending on the type and the mix ratio of the flammable refrigerant, the volume of the housing 10, etc. Furthermore, as shown in Figure 9, wiring 81 which is directly connected to the control board 60 without using the connector 69 may be disposed on the exposed portion 67.

[0085] In Embodiment 1, although the wiring, such as the power supply line 48 and the compressor connection line, through which the current equal to or greater than the reference current I can flow is explained as being pulled out from the upper surface 60A of the control board 60, this is one example. The wiring through which the current equal to or greater than the reference current I can flow just needs to be connected to the control board 60 inside the electrical component box 30. Therefore, the wiring, such as the power supply line 48 and the compressor connection line, through which the current equal to or greater than the reference current I can flow just needs to be pulled out from a portion other than the exposed portion 67 of the control board 60. Moreover, in Embodiment 1, although the power supply line 48 and the compressor connection line are explained as being pulled out of the electrical component box 30 through the cable glands 49 as seal means, this is one example. The seal means is just required to allow the power supply line 48 and the compressor connection line to be pulled out of the electrical component box 30 while keeping airtightness, and a structural body other than the cable gland 49 may be used as the seal means.

[0086] Further, it is not necessarily to construct the control board 60 by a single piece of board as described in Embodiment 1, and the control board 60 may be constructed by a plurality of boards.

[0087]  Note that since the above-described embodiments are for describing examples of the technologies of the present disclosure, it is possible to make various modifications, replacements, additions, omissions and so on within the scope of claims for patent or the scope of equivalence thereof.

[Configurations Supported by the Embodiments]

[0088] The above-described embodiments support the following configurations.

(Supplement)

[0089] (Technology 1) A heat pump device including: a refrigerant circuit inside which a flammable refrigerant is sealed and circulated, and to which a compressor and a heat exchanger are connected; a sensor attached to each portion of the refrigerant circuit; a control board that is connected to the sensor, and controls driving of the compressor; and an electrical component box storing the control board, wherein the control board is disposed at a location for closing an opening portion provided on the electrical component box, and a connector for connecting the sensor and the control board is mounted on an exposed portion of the control board that is a portion exposed from the electrical component box through the opening portion.

[0090] Consequently, the connection between the control board and the sensor through which a current small enough not to ignite the flammable refrigerant flows is realized by a simple structure, and the opening portion can be closed by the control board. Therefore, it is easy to ensure airtightness of the electrical component box, and it is easy to assemble the electrical component box.

[0091] (Technology 2) The heat pump device according to technology 1, wherein a gasket surrounding the exposed portion is interposed and held between the electrical component box and the control board.

[0092] Consequently, the airtightness of the electrical component box can be further improved, and, even when the flammable refrigerant leaks from the refrigerant circuit, the flammable refrigerant does not easily enter the inside of the electrical component box. Therefore, it is easier to ensure the airtightness of the electrical component box, and it is easy to assemble the electrical component box.

[0093] (Technology 3) The heat pump device according to technology 1, wherein the control board is attached to the electrical component box through a resin case made of a resin, the resin case has a second opening portion that overlaps the opening portion, a gasket surrounding the opening portion is interposed and held between the resin case and the electrical component box, and a seal material surrounding the exposed portion is provided at a portion where the resin case and the control board contact each other.

[0094] Consequently, the airtightness of the electrical component box can be further improved, and, even when the flammable refrigerant leaks from the refrigerant circuit, the flammable refrigerant does not easily enter the inside of the electrical component box. Therefore, it is easier to ensure the airtightness of the electrical component box, and it is easy to assemble the electrical component box.

[0095] (Technology 4) The heat pump device according to any one of technologies 1 to 3, wherein the control board has an electrical part for controlling driving of the compressor, and the electrical part is disposed on a surface on an opposite side to the exposed portion on which the connector is disposed.

[0096] Consequently, it is easy to locate the control board close to the opening portion. Therefore, it is easy to make a dimension of the electrical component box smaller. Furthermore, since the opening portion is easily closed by the control board, it is possible to improve the airtightness of the electrical component box.

[0097] (Technology 5) The heat pump device according to any one of technologies 1 to 4, wherein a blower chamber in which a blower is installed and a mechanical chamber in which the compressor is installed are separated by a partition plate, and the exposed portion is disposed in the mechanical chamber.

[0098] Consequently, condensed water or the like on the heat exchanger does not easily adhere to the connector disposed on the exposed portion. Therefore, there is no need to attach a new member or the like for preventing the connector from getting wet, during assembling, and it is possible to simplify the assembling of the electrical component box.

[0099] (Technology 6) The heat pump device according to any one of technologies 1 to 5, wherein a power supply line for supplying power supply to the control board is pulled out of the electrical component box using seal means.

[0100] Consequently, the power supply line through which a large current flows can be pulled out of the electrical component box while ensuring the airtightness by the seal means. Therefore, it is possible to minimize the number of pieces of the seal means, and it is possible to prevent ignition of the flammable refrigerant while simplifying the assembling of the electrical component box.

[0101] (Technology 7) The heat pump device according to any one of technologies 1 to 6, wherein the flammable refrigerant is R32 or a mixed refrigerant containing 70 weight percent or more of R32, or propane or a mixed refrigerant containing propane.

[0102] Consequently, it is possible to reduce ignition of the refrigerant while using the low-GWP refrigerant.

Industrial Applicability

[0103] The present disclosure is applicable to heat pump devices using a flammable refrigerant. Specifically, the present disclosure is applicable to outdoor units of heatpump water heaters or air conditioners, as well as to heat pump hot water heaters.

Reference Signs List

[0104] 

1 heat pump device

10housing

10A back surface

10B side surface

11partition plate

12blower chamber

13mechanical chamber

14bottom plate

15side panel

16front panel

16a opening

17top plate

20heat exchanger

21blower

22compressor

23 water heat exchanger

24expansion device

25refrigerant piping

26cut-out portion

27four-way valve

28water supply piping

29 fan support frame

29a electrical component box support plate

30 electrical component box

31 opening

32 electrical component box body

32A blower-side portion

32B mechanical-side portion

32F flange

33 lid member

33A blower-side portion

33B mechanical-side portion

35 bottom surface opening portion

35A opening portion

37 securing screw

38 O-ring

39 partition member

42 seal member

42a gasket

48 power supply line

49 cable gland (seal means)

60 control board

60A upper surface

60B lower surface

63 relay (electrical part)

64 inverter element

65 capacitor (electrical part)

67 exposed portion

69 connector

70 resin case

70A lower surface

71 heat sink

73 heat dissipation opening

73a guide portion

73b seal groove

75 second opening portion

75a second guide portion

75b gasket groove

75c protruding portion

80 wiring

81 wiring

90 cover

142 seal member

142a gasket

143 second seal member

PS1 pressure sensor (sensor)

PS2 pressure sensor (sensor)

RS1 refrigerant sensor (sensor)

TS1 temperature sensor (sensor)

TS2 temperature sensor (sensor)

Claims

1. A heat pump device comprising:

a refrigerant circuit inside which a flammable refrigerant is sealed and circulated, and to which a compressor (22) and a heat exchanger (20) are connected;

a sensor (PS1, PS2, TS1, TS2) attached to each portion of the refrigerant circuit;

a control board (60) that is connected to the sensor, and controls driving of the compressor; and

an electrical component box (30) storing the control board, characterized in that

the control board is disposed at a location for closing an opening portion (35a) provided on the electrical component box, and

a connector (69) for connecting the sensor and the control board is mounted on an exposed portion (67) of the control board that is a portion exposed from the electrical component box through the opening portion.

2. The heat pump device according to claim 1, wherein a gasket (142a) surrounding the exposed portion is interposed and held between the electrical component box and the control board.

3. The heat pump device according to claim 1, wherein

the control board is attached to the electrical component box through a resin case (70) made of a resin,

the resin case has a second opening portion (75) that overlaps the opening portion,

a gasket (42a) surrounding the opening portion is interposed and held between the resin case and the electrical component box, and

a seal material surrounding the exposed portion is provided at a portion where the resin case and the control board contact each other.

4. The heat pump device according to any one of claims 1 to 3, wherein

the control board has an electrical part (63, 65) for controlling driving of the compressor, and

the electrical part is disposed on a surface on an opposite side to the exposed portion on which the connector is disposed.

5. The heat pump device according to any one of claims 1 to 3, wherein

a blower chamber (12) in which a blower (21) is installed and a mechanical chamber (13) in which the compressor is installed are separated by a partition plate (11), and

the exposed portion is disposed in the mechanical chamber.

6. The heat pump device according to any one of claims 1 to 3, wherein a power supply line (48) for supplying power supply to the control board is pulled out of the electrical component box using seal means (49).

7. The heat pump device according to any one of claims 1 to 3, wherein the flammable refrigerant is R32 or a mixed refrigerant containing 70 weight percent or more of R32, or propane or a mixed refrigerant containing propane.

Drawing