Ceiling-embedded air conditioner

Abstract

A ceiling-embedded air conditioner includes: a ceiling-embedded casing body that has an air suction path at the center of a lower surface and has an air blowoff path around the air suction path; a turbo fan that is disposed inside the casing body; a heat exchanger that is disposed inside the casing body on an outer peripheral side of the turbo fan; a bell-mouth that guides air sucked from the air suction path toward the inside of the turbo fan; and a rectifier that is provided on a back surface side of the bell-mouth at the air suction path side opposite to an air suction surface of the bell-mouth, the rectifier suppressing swirling airflows generated by part of air blown from the turbo fan swirling along the back surface of the bell-mouth in the same direction as a rotation direction of the turbo fan.

Claims

1. A ceiling-embedded air conditioner comprising: a ceiling-embedded casing body that has an air suction path at a center of a lower surface and has an air blowoff path around the air suction path; a turbo fan that is disposed inside the casing body; a heat exchanger that is disposed inside the casing body on an outer peripheral side of the turbo fan; a bell-mouth that guides air sucked from the air suction path toward an inside of the turbo fan; and a rectifier that is provided to erect on a back surface side of the bell-mouth at an air suction path side opposite to an air suction surface of the bell-mouth, the rectifier directing swirling airflows generated by part of air blown from the turbo fan swirling along the back surface of the bell-mouth to the heat exchanger, wherein the rectifier has a first rectifying side vertically and linearly erected on the back surface of the bell-mouth as a base end and a second rectifying side horizontally and linearly extended from a leading end of the first rectifying side, and the first rectifying side is formed in parallel to a ventilation surface of the heat exchanger.

2. The ceiling-embedded air conditioner according to claim 1, wherein the rectifier is formed integrally with the bell-mouth and is also provided as a reinforcement plate for reinforcing strength of the bell-mouth.

3. The ceiling-embedded air conditioner according to claim 1, further comprising a drain pan that is provided inside the casing body to receive dew condensation water generated by the heat exchanger, wherein the rectifier is erected on the drain pan.

4. The ceiling-embedded air conditioner according to claim 1, wherein the heat exchanger has first to fourth heat exchange portions, the bell-mouth includes a base portion with a square shape, and a suction guide portion with a trumpet shape disposed in the base portion and extending upwardly from the base portion, a distance from an outer side of the base portion to the suction guide portion, in a straight radial line passing through the center of the circumference delimited by the trumpet portion of the suction guide portion changes, and the rectifier is positioned such that, in the rectifier location in the bell-mouth, a distance between the outer side of the base portion and a boundary portion of the suction guide portion is shortest.

5. The ceiling-embedded air conditioner according to claim 1, wherein the first rectifying side is located at a position where a distance between one outer side of a base portion in a rectangular shape of the bell-mouth and a boundary portion of the base portion with respect to a suction guide portion having a cylindrical shape and erecting from the base portion is shortest.

6. The ceiling-embedded air conditioner according to claim 1, wherein the rectifier includes only four members 90 degrees spaced apart each other around the bell-mouth.

7. The ceiling-embedded air conditioner according to claim 1, wherein the turbo fan includes a shroud disposed over the bell mouth, and the second rectifying side of the rectifier extends from behind the bell mouth to a position under an outer edge of the shroud.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a casing body of a ceiling-embedded air conditioner according to one embodiment of the present disclosure as seen from the lower side;

(2) FIG. 2 is a perspective view of the casing body illustrated in FIG. 1 from which a decorative panel is removed;

(3) FIG. 3 is a cross-sectional view of inner structure of the casing body;

(4) FIG. 4A is a perspective view of a bell-mouth as seen from the front side, and FIG. 4B is a perspective view of the bell-mouth as seen from the rear side;

(5) FIG. 5A is a front view of the bell-mouth and FIG. 5B is a rear view of the bell-mouth;

(6) FIG. 6 is a bottom view illustrating the positional relation between a heat exchanger and an electrical equipment box;

(7) FIG. 7 is a cross-sectional view illustrating the mode in which a rectifier is provided on a drain pan side; and

(8) FIG. 8 is an illustrative diagram for describing the rectifying effect of the rectifiers provided on the back surface of the bell-mouth.

DESCRIPTION OF THE EMBODIMENTS

(9) In the following detailed description, for purpose of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.

(10) An object of the present disclosure is to provide a ceiling-embedded air conditioner as described below. That is, the ceiling-embedded air conditioner prevents the retention of the air and realizes higher heat-exchange efficiency by suppressing occurrence of swirling airflows in the space between the turbo fan and the heat exchanger.

(11) A ceiling-embedded air conditioner (the air conditioner) according to one embodiment of the present disclosure includes: a ceiling-embedded casing body that has an air suction path at the center of a lower surface and has an air blowoff path around the air suction path; a turbo fan that is disposed inside the casing body; a heat exchanger that is disposed inside the casing body on an outer peripheral side of the turbo fan; a bell-mouth that guides air sucked from the air suction path toward the inside of the turbo fan; and a rectifier that is provided on a back surface side of the bell-mouth at the air suction path side opposite to an air suction surface of the bell-mouth, the rectifier suppressing swirling airflows generated by part of air blown from the turbo fan swirling along the back surface of the bell-mouth in the same direction as a rotation direction of the turbo fan.

(12) As a preferable embodiment, the rectifier is erected on the back surface of the bell-mouth.

(13) As a more preferable embodiment, the rectifier has a first rectifying side vertically erected on the back surface of the bell-mouth as a base end and a second rectifying side horizontally extended from the leading end of the first rectifying side. The first rectifying side is formed in parallel to a ventilation surface of the heat exchanger.

(14) Further, the rectifier is preferably formed integrally with the bell-mouth and is also provided as a reinforcement plate for reinforcing strength of the bell-mouth.

(15) As another preferable embodiment, the air conditioner further includes a drain pan that is provided inside the casing body to receive dew condensation water generated by the heat exchanger. The rectifier is erected on the drain pan.

(16) In addition, the heat exchanger preferably has first to fourth heat exchange portions. The rectifier is preferably disposed to be opposed to the first to fourth heat exchange portions with predetermined spacing therebetween and is positioned such that a distance between the ventilation surface of each of the heat exchange portions and an end surface of the rectifier opposed to the ventilation surface is the shortest.

(17) According to the air conditioner, the rectifiers are provided on the back surface of the bell-mouth. By contacting swirling airflows on the rectifiers, the swirling airflows can be forcibly pushed out toward the heat exchanger on the outside of the bell-mouth. This suppresses the occurrence of swirling airflows in the space between the turbo fan and the heat exchanger and prevents the retention of the air. That is, pushing out the swirling airflows toward the heat exchanger increases the heat-exchange efficiency.

(18) Next, an embodiment of the present disclosure will be described with reference to the accompanying drawings. However, the present disclosure is not limited to this.

(19) As illustrated in FIGS. 1 to 3, a ceiling-embedded air conditioner 1 includes a cuboid-shaped casing body 2. The cuboid-shaped casing body 2 is stored in the space formed between a ceiling slab and a ceiling panel. The casing body 2 is a box-shaped container having a top plate 21, four side plates 22a to 22d (hereinafter, referred to as first to fourth side plates 22a to 22d), and a bottom surface 20. The top plate 21 has a regular square shape with chamfered corners. The first to fourth side plates 22a to 22d are extended downward from the respective sides of the top plate 21. The bottom surface 20 (lower surface in FIG. 1) is opened. In this embodiment, the corners of the casing body 2 are chamfered according to the shape of the top plate 21.

(20) The bottom surface 20 of the casing body 2 is opened to the inside of the room. An air suction path 23 that is square in cross section is formed at the center of the bottom surface 20. An air blowoff path 24 is formed on the bottom surface 20 of the casing body 2 to surround the four sides of the air suction path 23.

(21) A decorative panel 3 is screwed to the bottom surface 20 of the casing body 2. The decorative panel 3 is made of a synthetic resin and has a flat regular square shape. A square air inlet 31 is provided at the center of the decorative panel 3. The air inlet 31 communicates with the air suction path 23 of the casing body 2. Rectangular air outlets 32 are disposed around the air inlet 31 at four places along the respective sides of the air inlet 31. The air outlets 32 communicate with the air blowoff path 24 at the back surface side (ceiling surface side).

(22) A suction grill 4 is provided to cover the air inlet 31. The suction grill 4 is a synthetic resin molded component. The suction grill 4 is formed in a flat regular square shape to cover the bottom surface 20 of the casing body 2.

(23) In this embodiment, the air outlets 32 are respectively covered with electrically opening and closing wind direction plates 321. During air-conditioning operation, the wind direction plates 321 are opened by a rotation member not illustrated provided on the back surface side of the decorative panel 3 to make the air outlets 32 appear.

(24) The casing body 2 stores a turbo fan 5 as a blowing fan and a heat exchanger 6 therein. A bell-mouth 7 is disposed in the air suction path 23 ranging from the air inlet 31 to the turbo fan 5. The bell-mouth 7 guides the air taken in from the air inlet 31 to the turbo fan 5.

(25) As illustrated in FIGS. 2 and 3, the turbo fan 5 includes a main plate 52, a shroud 53, and a plurality of blades 54. The main plate 52 has a hub 521. A rotation shaft 511 of a drive motor 51 is fixed to the center of the hub 521. The shroud 53 is disposed to be opposed to the main plate 52 along the direction of axis of the rotation shaft 511. The plurality of blades 54 is disposed between the main plate 52 and the shroud 53. An opening 531 is provided at the center of the shroud 53 for inserting a part of the bell-mouth 7 into the turbo fan 5.

(26) The turbo fan 5 is disposed at almost the center of inside of the casing body 2. The turbo fan 5 is hung and held by the drive motor (fan motor) 51 mounted on the top plate 21. Accordingly, as the turbo fan 5 is driven to rotate, the bell-mouth 7 is under negative pressure at the air inlet 31 side (lower side in FIG. 3). Therefore, the air taken in from the air inlet 31 is sucked into the turbo fan 5 through the bell-mouth 7, and is blown toward the outer peripheral direction through the blades 54.

(27) As illustrated in FIGS. 3 and 6, the heat exchanger 6 is vertically extended from the top plate 21 to the opening in a bottom surface 20. The heat exchanger 6 is formed in a square frame shape to surround the outer periphery of the turbo fan 5. The heat exchanger 6 has a first heat exchange portion 6a, a second heat exchange portion 6b, a third heat exchange portion 6c, and a fourth heat exchange portion 6d. The first heat exchange portion 6a is disposed in parallel to the first side plate 22a. The second heat exchange portion 6b is disposed in parallel to the second side plate 22b. The third heat exchange portion 6c is disposed in parallel to the third side plate 22c. The fourth heat exchange portion 6d is disposed in parallel to the fourth side plate 22d.

(28) In this embodiment, the heat exchanger 6 includes an elongated square plate-like body with four bent portions. The heat exchanger 6 has a heat-radiation fin group 61 including a large number of strip-shaped heat-radiation fins. The large number of heat-radiation fins is disposed at predetermined spacing therebetween. In the heat exchanger 6, a large number of heat-transfer tubes 62 are inserted into the heat-radiation fin group 61 in parallel to one another.

(29) As illustrated in FIG. 6, the heat exchanger 6 has four bent portions 6e to 6h. Of these bent portions, the first bent portion 6e is formed between the first heat exchange portion 6a and the second heat exchange portion 6b. The second bent portion 6f is formed between the second heat exchange portion 6b and the third heat exchange portion 6c. The first bent portion 6e is bent such that the angle formed by the first heat exchange portion 6a and the second heat exchange portion 6b is a right angle. The second bent portion 6f is bent such that the angle formed by the second heat exchange portion 6b and the third heat exchange portion 6c is a right angle.

(30) The third bent portion 6g and the fourth bent portion 6h are positioned between the third heat exchange portion 6c and the fourth heat exchange portion 6d. The third bent portion 6g and the fourth bent portion 6h are bent such that, when the third bent portion 6g and the fourth bent portion 6h are combined with each other, the angle formed by the third heat exchange portion 6c and the fourth heat exchange portion 6d is a right angle to provide an installation space for a drain pump (not illustrated). The fourth bent portion 6h may not be provided between the third heat exchange portion 6c and the fourth heat exchange portion 6d. In this case, the third bent portion 6g, which is disposed between the third heat exchange portion 6c and the fourth heat exchange portion 6d, may be bent such that the angle formed by the third heat exchange portion 6c and the fourth heat exchange portion 6d is a right angle.

(31) The end portions of the heat-transfer tubes 62 are drawn from both end portions 63 and 64 of the heat exchanger 6. A U-shaped tube (not illustrated) is coupled to the one end portion 63. At the other end portion 64, gas-side tubes are united into one collective tube and coupled to a gas-side pipe G, and liquid-side tubes are united into one collective tube and coupled to a liquid-side pipe L.

(32) In this embodiment, the heat exchanger 6 is formed in a square shape in a plane view of FIG. 6 by bending one heat exchanger. Instead of this, the heat exchanger 6 may be formed by coupling four small-sized heat exchangers at the end portions.

(33) As described above, the heat exchanger 6 is bent at the first to fourth bent portions 6e to 6h. Accordingly, the heat exchanger 6 is bent in a square shape in a plane view. In addition, the heat exchanger 6 has the end portions 63 and 64 disposed at a predetermined spacing therebetween.

(34) In this embodiment, as illustrated in FIG. 6, the end portions 63 and 64 are disposed at an upper right corner A of the casing body 2. The gas-side pipe G and the liquid-side pipe L are drawn outward from the corner A of the casing body 2.

(35) The heat exchanger 6 is connected to a reversible refrigeration cycle circuit not illustrated that allows cooling operation and heating operation. The heat exchanger 6 serves as an evaporator to cool the air during cooling operation. Meanwhile, the heat exchanger 6 serves as a condenser to heat the air during heating operation.

(36) Drain pans 8 are provided at the lower end side of the heat exchanger 6 to receive dew condensation water generated by the heat exchanger 6. The drain pans 8 are provided inside the casing body 2 and are provided with gutters 81. The gutters 81 store the lower end side of the heat exchanger 6. The dew condensation water dropped from the heat exchanger 6 is received at the gutters 81 and drawn up by a drain pump not illustrated.

(37) The bell-mouth 7 is composed of a synthetic resin molded component. The bell-mouth 7 includes a base portion 71 and a suction guide portion 72 as illustrated in FIGS. 4A, 4B, 5A, and 5B. The bell-mouth 7 is screwed into the drain pans 8. The base portion 71 is disposed at a front surface (air suction surface) 7A side (plane side in FIG. 4A), and is formed in a square shape corresponding to the shape of the air inlet 31. The suction guide portion 72 is formed in a trumpet shape from the center of the base portion 71 toward the inside of the turbo fan 5.

(38) The base portion 71 is a concave formed in a square shape corresponding to the shape of the air inlet 31. A storage concave portion 73, in which the electrical equipment box 9 described later is to be disposed, is formed in a part of the base portion 71. The storage concave portion 73 has a corner positioned above the corner A of the casing body 2 (refer to FIG. 2). The storage concave portion 73 is extended from the corner as a center in parallel to the first heat exchange portion 6a and the fourth heat exchange portion 6d. The electrical equipment box 9 is stored in the storage concave portion 73.

(39) The suction guide portion 72 is formed in a trumpet shape (funnel shape) to be gradually smaller in outer diameter with increasing proximity to the center of the rotation shaft 511 of the turbo fan 5. The suction guide portion 72 has a round edge 721 at the upper end side. The edge 721 is inserted into the opening 531 of the turbo fan 5.

(40) The back surface 7B of the bell-mouth 7 (plane side in FIG. 4B) is shaped according to the shapes of the base portion 71, the suction guide portion 72, and the storage concave portion 73. The back surface 7B is opposite to the front surface (air suction surface) 7A of the bell-mouth 7 at the air suction path 23 side. Rectifiers 74 are provided on the back surface 7B of the bell-mouth 7. The rectifiers 74 suppress swirling airflows generated by part of the air blown from the turbo fan 5 swirling along the back surface 7B of the bell-mouth 7 in the same direction as the rotation direction of the turbo fan 5.

(41) The rectifiers 74 are formed in a plate shape. Each of the rectifiers 74 has a first rectifying side 741 and a second rectifying side 742. The first rectifying side 741 is vertically extended from the back surface of the bell-mouth 7 (base portion 71) in the vicinity of a boundary portion 711 between the base portion 71 and the suction guide portion 72. That is, the rectifier 74 is erected on the back surface 7B of the bell-mouth 7. The second rectifying side 742 is horizontally extended from the upper end of the first rectifying side 741 to the edge 721 of the suction guide portion 72. In this example, the rectifiers 74 are provided at four positions by 90 degrees.

(42) The first rectifying side 741 of the rectifier 74 is a side vertical to the base portion 71 as described above. As illustrated in FIG. 3, the first rectifying side 741 is disposed in parallel to a ventilation surface 65 of the heat exchanger 6 opposed to the first rectifying side 741. The rectifier 74 is positioned such that the distance between the first rectifying side 741 and the ventilation surface 65 of each of the heat exchange portions 6a to 6d is the shortest (the first rectifying side 741 and the ventilation surface 65 of each of the heat exchange portions 6a to 6d are closest to each other). In this embodiment, the rectifier 74 is positioned such that the distance between the circular-shaped boundary portion 711 and the outer periphery 712 of the square base portion 71 is the shortest.

(43) Of the rectifiers 74, a rectifier 74a disposed on the back surface side of the storage concave portion 73 is formed on the storage concave portion 73. Accordingly, the base portion of the rectifier 74a (portion in contact with the storage concave portion 73) is shifted toward the round edge 721 according to the shape of the storage concave portion 73. Therefore, the first rectifying side 741 of the rectifier 74a is shorter than the first rectifying sides 741 of the other rectifiers 74. Meanwhile, the second rectifying sides 742 of the rectifiers 74 are flush with one another.

(44) According to this, as illustrated in FIG. 8, the rectifiers 74 stem swirling airflows along the back surface of the bell-mouth 7 and push forcibly the air out to the outside of the bell-mouth 7. Accordingly, it is possible to suppress swirling airflows generating in the space between the turbo fan 5 and the heat exchanger 6, prevent the retention of the air, and push the swirling airflows out toward the heat exchanger side. This enhances the efficiency of heat exchange.

(45) The rectifiers 74 are formed integrally with the bell-mouth 7 to serve also as reinforcement plates for reinforcing the strength of the bell-mouth 7. That is, the rectifiers 74 improve the strength of the bell-mouth 7. This suppresses thermal deformation of the bell-mouth 7 at the time of molding, and increases the dimensional accuracy of the bell-mouth 7. Therefore, the gap between the bell-mouth 7 and 53 can be further narrowed. As a result, the recirculation of the air from the gap to the turbo fan 5 is decreased to further enhance the efficiency of heat exchange.

(46) In this embodiment, the rectifiers 74 are formed integrally with the back surface of the bell-mouth 7. Note that the rectifiers 74 may be merely disposed in the ceiling-embedded air conditioner 1 to block swirling airflows along the back surface of the bell-mouth 7. Accordingly, the positions of the rectifiers 74 may not be limited to the bell-mouth 7.

(47) Specifically, as illustrated in FIG. 7, second rectifiers 82 are erected on the drain pans 8. The second rectifiers 82 shut off swirling airflows in cooperation with the rectifiers 74 (hereinafter, referred to as first rectifiers 74). The second rectifiers 82 are plate bodies screwed to the upper ends of the gutters 81 at the turbo fan 5 side to be opposed to the respective first rectifiers 74. The second rectifiers 82 are disposed in parallel to the first rectifiers 74.

(48) The second rectifiers 82 are aligned in height to the second rectifying sides 742 of the first rectifiers 74. The second rectifiers 82 are disposed in abutment with the first rectifying sides 741 of the first rectifiers 74. Accordingly, each of the first rectifiers 74 and each of the second rectifiers 82 serve as one large rectifier. Swirling airflows contacting the first rectifiers 74 move to the vicinity of the heat exchanger 6 from the first rectifiers 74 through the second rectifiers 82. This further enhances the efficiency of heat exchange.

(49) In the embodiment illustrated in FIG. 7, the corresponding first rectifiers 74 and second rectifiers 82 are combined to form one large rectifier. Alternatively, either the first rectifiers 74 or the second rectifiers 82 may be disposed in the ceiling-embedded air conditioner 1. In this case, the disposed first rectifiers 74 or second rectifiers 82 are preferably formed in a large size. The respective second rectifiers 82 may be disposed to be opposed to the first to fourth heat exchange portions 6a to 6d at predetermined spacing, such that the distances between the ventilation surfaces 65 of the heat exchange portions 6a to 6d and the end surfaces of the rectifiers 82 opposed to the ventilation surfaces 65 are the shortest.

(50) As illustrated in FIGS. 2 and 6, the electrical equipment box 9 includes a box body 91 and a lid portion 92. The box body 91 has an opened upper surface and stores a substrate and/or electrical equipment (both not illustrated). The lid portion 92 closes the opened surface of the box body 91. In this embodiment, the electrical equipment box 9 is formed by bending a metal plate, for example.

(51) The box body 91 has a first storage portion 91a and a second storage portion 91b. The box body 91 is formed in an L shape such that the first storage portion 91a and the second storage portion 91b are orthogonal to each other. A temperature-humidity sensor 93 is erected on the side wall of the first storage portion 91a opposed to the suction guide portion 72.

(52) The lid portion 92 is formed in an L shape adapted to the opening of the box body 91. The lid portion 92 includes a first lid portion 92a covering the first storage portion 91a and a second lid portion 92b covering the second storage portion 91b. The lid portion 92 is horizontally formed along the open surface of the box body 91. A tapered surface 94 is formed at a corner of the lid portion 92 opposed to the suction guide portion 72. The height of the tapered surface 94 is gradually lower from the upstream to downstream sides of the blowing direction.

(53) Accordingly, the air flowing along the surface of the electrical equipment box 9 can be smoothly guided to the bell-mouth 7 through the tapered surface 94. This reduces ventilation resistance and suppresses decrease in heat exchange efficiency.

(54) As described above, according to the embodiment of the present disclosure, the rectifiers are provided on the back surface of the bell-mouth. By contacting swirling airflows on the rectifiers, it is possible to suppress swirling airflows generated in the space between the turbo fan 5 and the heat exchanger 6 and prevent the retention of the air. That is, the efficiency of heat exchange can be enhanced by pushing swirling airflows out toward the heat exchanger.

(55) The expressions herein indicating shapes or states such as regular square, rectangular, square, circular, vertical, parallel, right angle, 90 degrees, the same, orthogonal, and horizontal, signify not only strict shapes or states but also approximate shapes or states shifted from the strict shapes or states, without deviating from the scope in which the operations and effects of these shapes or states can be achieved.

(56) The foregoing detailed description has been presented for the purposes of illustration and description. Many modifications and variations are possible in light of the above teaching. It is not intended to be exhaustive or to limit the subject matter described herein to the precise form disclosed. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims appended hereto.