JP3229678B2 - Method of manufacturing drain pan for air conditioner - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a plastic drain pan manufactured by molding.

[0002]

2. Description of the Related Art As shown in FIG. 6, a plastic drain pan 13 for receiving drain water from a heat exchanger is known (for example, Japanese Utility Model Publication No. 57-9616). In this type, when the drain pan 13 is installed in the air conditioner, a curved surface portion (tongue portion) 37a having a predetermined shape is formed on the outer surface of the wall portion 37 facing the blower.

[0003] Incidentally, since this kind of plastic drain pan 13 is molded using a mold, a complicated design taking into account the arrangement of the mold at the time of design is generally performed conventionally. is there.

[0004]

To explain with reference to the example of FIG. 6, in forming the receiving portion 25 of the drain pan 13,
For example, there is a problem that an extra slide mold 51 is required in addition to the slide mold 35. Reference numerals 31 and 33 denote a core and a mold, respectively.

In consideration of cooling performance after molding, it is desirable that the thickness t of all parts of the drain pan 13 to be molded is kept uniform, and the slide mold 51 shown in FIG. , If you make that part a thick part,
There is a problem that the cooling of the thick portion after forming is delayed and the drain pan 13 is twisted.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method of manufacturing a drain pan for an air conditioner, which can solve the above-mentioned problems of the prior art, reduce the number of molds to be used, and can manufacture at low cost. To provide.

[0007]

In order to achieve the above object, the present invention receives drain water generated in a heat exchanger.
A plastic drain pan having a receiving portion ,
In the method for manufacturing a drain pan of an air conditioner having a curved surface portion having a predetermined shape on an outer surface of a wall portion of the receiving portion, a slide die is disposed on an inner surface of the wall portion in consideration of a draft angle of the die.
Then, on the outer surface of the wall, a frame corresponding to a curved surface having a predetermined shape is formed.
Arrange the mold and insert the mold between the core mold and the slide mold.
Inject stick resin and surround between core mold and slide mold
A gas is sealed in a part of the wall part which has become rare and thick,
And this <br/> to double-wall structure having a substantially uniform wall thickness and the wall portion in which the features.

[0008]

According to the present invention, since the flat surface is formed on the inner surface of the wall in consideration of the draft of the slide, the design and manufacture of the mold are facilitated when the drain pan is formed. Since the wall has a double wall structure and the wall thickness is made uniform at all parts, when cooling the drain pan after molding, all parts are cooled at almost the same speed. The twisting of the drain pan does not occur.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of a method for manufacturing a drain pan of an air conditioner according to the present invention will be described below with reference to FIGS.

In FIG. 1, reference numeral 1 denotes an air conditioner, and the air conditioner 1 is mounted on a wall surface 3 or the like in a room. A suction port 5 is opened on the front and upper surfaces of the air conditioner 1, and the air in the room sucked from the suction port 5 is blown through a heat exchanger 7 and a blower 9 as shown in FIG. It is blown out from the outlet 11.

FIG. 3 shows the structure of the outlet 11. The outlet 11 is connected to a drain pan 13 on which the heat exchanger 7 is mounted.
And a front edge 17 of a scroll portion 15 provided below the blower 9 and guiding the wind direction to the air outlet 11. The outlet 11 is provided with two horizontal wind direction changing blades 19 for changing the wind direction up and down, and a plurality of vertical wind direction changing blades 21 for changing the wind direction left and right. The wind direction is controlled by the changing blades 19 and 21.

According to this embodiment, however, the structure of the drain pan 13 is characterized, and the manufacture of the drain pan 13 is facilitated because of this structure.

The drain pan 13 has a receiving portion 25 for receiving drain water, and is formed of a plastic resin. Hereinafter, features of the drain pan 13 will be described according to the manufacturing procedure.

As shown in FIG. 4, the drain pan 13 is integrally formed with a support frame 23 for supporting the vertical wind direction changing blades 19 in a mold. Referring to FIG. 5, drain pan 13 is manufactured roughly using molds for core 31, cabinet 33, and slide 35. First, a plastic resin is injected into these molds. The procedure for injecting the plastic resin follows a well-known procedure. The feature of this embodiment is that, in order to form a cavity 39 to be described later in the one wall portion 37 of the drain pan 13, the resin injection amount in that portion is about 70%. It is suppressed to.

Next, 140 is attached to the wall 37 of the drain pan 13.
A high-pressure N ₂ gas of about 200 kg / cm ² is sealed, and the above-mentioned cavity 39 is formed therein by employing a known floating method. Thereafter, the molds of the core 31, the mold 33, and the slide 35 are pulled out in the directions of the arrows, and the formed drain pan 13 is taken out.

At the stage of manufacturing in this way, it is important to make the wall portion 37 a double wall structure having a substantially uniform wall thickness t in consideration of the cooling performance after molding.

That is, when a part of the thickness t becomes thicker, the cooling of the part is delayed. On the contrary, when a part of the thickness t becomes thinner, the cooling of the part becomes faster than the other parts. If the time required for cooling changes in this way, the formed drain pan 13 will be twisted. In order to make the thickness t of all the parts substantially equal, if necessary,
It is natural that the above-mentioned resin injection amount suppressed to 70% is appropriately changed.

Generally, in this type of drain pan 13, one wall portion 37, that is, the wall portion 37 on the side facing the blower 9 is used.
On the outer surface, a curved surface portion 37a having a predetermined shape that conforms to the shape of the blower 9 is formed in order to create an ideal wind flow.

In the prior art, as shown in FIG.
7 is bent to form the curved surface portion 37a. However, according to this, an extra slide 51 is required as a molding die in addition to the above-described slide 35, and an extra cost is required.

In this embodiment, however, it is important to form a flat surface 37b on the inner surface of the wall 37 in consideration of the draft of the slide 35, as shown in FIG.

According to this, the conventional slide 51 (FIG. 6) becomes unnecessary, and the manufacturing cost can be reduced accordingly.

As is apparent from the above, according to the present embodiment, since the flat surface 37a is formed on the inner surface of the wall portion 37 in consideration of the draft of the slide 35, the extra slide 51 is unnecessary at the time of molding. Therefore, manufacturing can be facilitated.
Further, since the wall portion 37 has a double wall structure and has a uniform thickness t, when the drain pan 13 is cooled after molding, all portions are cooled at substantially the same speed.
Effects such as no twisting of the molded product are obtained.

Although the present invention has been described based on one embodiment, it is apparent that the present invention is not limited to this. For example, in the above embodiment, the drain pan 13
And the support frame 23 are integrated,
It goes without saying that the present invention is also applied to the case where only the drain pan 13 is used.

[0024]

As is clear from the above description, according to the present invention, since a flat surface is formed on the inner surface of the wall in consideration of the draft of the slide, no extra slide is required at the time of molding. The manufacture of the drain pan mold can be facilitated.
In addition, since the wall has a double wall structure and its wall thickness is uniform, when cooling the drain pan after molding, all parts are cooled at almost the same speed, so that the molded product will not be twisted. Absent.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of an air conditioner.

FIG. 2 is a sectional view of the air conditioner shown in FIG.

FIG. 3 is a sectional view of an air outlet of the air conditioner shown in FIG.

FIG. 4 is a perspective view of a drain pan of the air conditioner shown in FIG.

FIG. 5 is a cross-sectional view for explaining a procedure for manufacturing the drain pan shown in FIG.

FIG. 6 is a diagram corresponding to FIG. 5 of the related art.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Air conditioner 7 Heat exchanger 13 Drain pan 23 Support frame 31 Core 33 Cabinet 35 Slide 37 Wall 37a Curved surface 37b Flat surface 39 Cavity

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Masao Koseki 2--18 Keihanhondori, Moriguchi-shi, Osaka Sanyo Electric Co., Ltd. (72) Inventor Kensuke Matsumoto 2--18 Keihanhondori, Moriguchi-shi, Osaka Yoyo Electric Co., Ltd. (72) Inventor Yasutomo Akutsu 2-18-18 Keihanhondori, Moriguchi-shi, Osaka Sanyo Electric Co., Ltd. (56) References JP-A-4-45909 (JP, A) −37323 (JP, U) Japanese Utility Model Application Hei 3-37324 (JP, U) (58) Fields surveyed (Int. Cl. ⁷ , DB name) F24F 1/00-1/02

Claims (1)

(57) [Claims] 1. Receiving drain water generated by a heat exchanger
A plastic drain pan having a receiving portion ,
In the method for manufacturing a drain pan of an air conditioner having a curved surface portion having a predetermined shape on an outer surface of a wall portion of the receiving portion, a slide die is disposed on an inner surface of the wall portion in consideration of a draft angle of the die.
Then, on the outer surface of the wall, a frame corresponding to a curved surface having a predetermined shape is formed.
Arrange the mold and insert the mold between the core mold and the slide mold.
Inject stick resin and surround between core mold and slide mold
A gas is sealed in a part of the wall part which has become rare and thick,
Method for producing a drain pan of this <br/> air conditioner, characterized in that a double wall structure having a substantially uniform wall thickness and that wall portion.