WO2003021154A1

WO2003021154A1 - Air conditioner

Info

Publication number: WO2003021154A1
Application number: PCT/JP2002/008567
Authority: WO
Inventors: Tetsuro Ozawa
Original assignee: Toshiba Carrier Corporation
Priority date: 2001-08-28
Filing date: 2002-08-26
Publication date: 2003-03-13
Also published as: CN1261722C; CN1549911A; JP2003074965A

Abstract

A unit main body (1) has a front suction port (3) and upper suction port (2). An air filter (15) is detachably attached to the inner surface of the unit main body (1) to oppose the front suction port (3) and upper suction port (2). The air filter (15) includes a pleated filter member (17) folded in a zigzag manner and having pleats, a crosspiece member (18) formed at a side end of the pleated filter member (17) along the pleats, and a frame member (20) formed across tops of the pleats on one side of the crosspiece member (18), thus forming a flexible air filter.

Description

D E S C R I P T I O N

AIR CONDITIONER

Technical Field

The present invention relates to an air conditioner comprised of an indoor unit and outdoor unit and, more particularly, to an improvement of an air filter which catches and removes dust from indoor air drawn by suction into the main body of the indoor unit .

Background Art An air conditioner comprised of an indoor unit and outdoor unit is used often. The indoor unit has a suction port and supply port in its main body. A heat exchanger, blower, and the like are housed in the main body. According to the recent trend, as a -heat exchanger, a curved front heat exchanger portion and a straight rear heat exchanger portion are combined to form, e.g., an inverted V shape when seen from the side surface. This aims at increasing the heat exchange area and to reduce the height of the main body.

The indoor unit with this heat exchanger has a front suction port and upper suction port. The front suction port opposes the front heat exchanger portion. The upper suction port opposes the rear heat exchanger portion. Dust floats in any room and is inevitably drawn by suction into the main body together with the indoor air. If such dust directly flows through the main body together with the air, it attaches to the heat exchanger, blower, or air channel to cause various types of troubles. For this reason, an air filter is attached to that rear side of the main body which opposes the front and upper suction ports, so it catches the dust. When the air filter is used over a long period of time, it causes clogging naturally.

Thus, the filter must be removed and the clogging dust must be removed.

To form a conventionally used air filter, a very thin frame member made of a resin material is formed on the periphery of a flat plate-like filter member.

Then, a plurality of reinforcing crosspieces are formed in the area of the filter member. Therefore, the air filter is entirely soft and flexible. The air filter is inserted from the upper edge of the suction port in the lower portion of the main body, and is integrally formed to extend across the front and upper suction ports .

The operation of removing clogging of the air filter is naturally performed by the user side. If possible, the smaller the number of times of removing operation to provide a so-called long life, the better. In this respect, with a flat plate-like filter member, the filtration area is small, and clogging occurs comparatively soon.

In contrast to this, with, e.g., a ceiling hung- type air conditioner, the conditioner itself is located at a high location and is inconvenient to handle.

Hence, a so-called pleated air filter is used to enable a long life. A pleated air filter has a filter member which is bent a plurality of times in a zigzag manner in a predetermined direction to form pleats (bends) . The effective filtration area of the pleated air filter is several times that of a flat plate-like filter.

This filter member is attached and fixed to a frame member having a U-shaped section at its periphery, so it entirely forms a flat plate-like rigid body. To attach the filter member to a ceiling hung- type air conditioner, no problem will arise. However, this filter member is inappropriate as an air filter which is detachable from the upper end of the suction port and which is flexible to oppose the front and upper suction ports, as described above.

Disclosure of Invention The present invention has been made in view of the above situation, and has as its object to provide an air conditioner in which a pleated filter member is employed as an air filter for catching and removing dust so a long life can be obtained, and which has a flexible arrangement so an operability is improved by smoothing attaching/detaching operation.

In order to achieve the above object, according to the first means of the present invention, in an air conditioner comprising an air conditioner main body which houses a heat exchanger and a blower, a front suction port formed in a front portion of the air conditioner main body and an upper suction port formed in an upper portion thereof, and an air filter which is detachably attached to an inner surface of the air conditioner main body to oppose the front suction port and the upper suction port and which catches and removes dust from air drawn by suction into the main body, the air filter comprises a pleated filter member folded in a zigzag manner and having pleats, a crosspiece member formed at a side end of the pleated filter member along the pleats, and a frame member formed across tops of the pleats on one side of the crosspiece member, thus forming a flexible air filter. According to the second means, in the above air filter, that portion of the pleated filter member which opposes the front suction port and that portion of the pleated filter member which opposes the upper suction port are molded to have different pleat heights.

According to the third means, the above pleated filter member is fabricated to have the same pleat height throughout an entire length thereof, and is partly extended when being molded together with the crosspiece member so as to have a different height.

According to the fourth means, the upper suction port formed in the upper portion of the air conditioner main body is partitioned into a plurality of spaces by a plurality of crosspieces fitted therein to form predetermined gaps in a back-and-forth direction, and that portion of the pleated filter member which opposes the upper suction port is attached such that tops of the pleats thereof oppose substantially intermediate portions of the spaces.

When these means that solve the problem are employed, a pleated filter member is employed as an air filter which catches and removes dust, so a long life can be obtained. Also, since the pleated filter member is flexible, the operability can be improved by smooth attaching/detaching operation.

Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter. Brief Description of Drawings FIG. 1 is a schematic sectional view showing an indoor unit which forms an air conditioner according to one embodiment of the present invention; FIG. 2 is a perspective view showing a state wherein the front panel of the indoor unit is open;

FIG. 3 is a perspective view showing an air filter built in the indoor unit; FIG. 4A is a side view showing the air filter;

FIG. 4B is an enlarged side view showing part of the air filter;

FIG. 5 is a perspective view showing part of the air filter; and FIG. 6 is a perspective view showing part of the air filter from the rear side.

Best Mode for Carrying Out of the Invention An embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a view schematically showing a section of an indoor unit that forms an air conditioner. Referring to FIG. 1, reference numeral 1 denotes a unit main body (air conditioner main body) . The unit main body 1 has an upper suction port 2 in its upper surface and a front suction port 3 in its front surface. A plurality of crosspieces 2a are fitted in the upper suction port 2 to form predetermined gaps in the back-and-forth direction. The upper suction port 2 is partitioned into a plurality of spaces by the crosspieces 2a. The front suction port 3 is opened/closed by part of a front panel 6 supported by an opening/closing driving mechanism 5. A supply opening 7 is formed along the lower portion of the front suction port 3. The supply opening 7 is opened/closed by two supply louvers 8a and 8b pivotally controlled independently of each other. A heat exchanger 9 formed of a front heat exchanger portion 9a and rear heat exchanger portion 9b into a substantially inverted V shape is arranged in the unit main body 1. The front heat exchanger portion 9a is curved to be substantially parallel to the front panel 6 at a gap from it. The rear heat exchanger portion 9b is straight but is obliquely inclined to oppose the upper suction port 2.

An electric dust collector 10 is attached to the front surface of the front heat exchanger portion 9a of the heat exchanger 9. The electric dust collector 10 is formed of a charging electrode and dust-collecting electrode. The charging electrode applies charges to dust in the air. The dust-collecting electrode attracts the charged dust, thereby removing the dust. A blower 11 is arranged between the front and rear heat exchanger portions 9a and 9b of the heat exchanger 9 and between the heat exchanger 9 and supply opening 7. The blower 11 is comprised of a horizontal-flow fan and a fan motor. The horizontal-flow fan has an axial size substantially the same as the width of the heat exchanger 9, and is arranged to oppose the heat exchanger 9. The fan motor rotatably drives the horizontal-flow fan.

The lower end of the front heat exchanger portion 9a rests on a front drain pan 12a, and that of the rear heat exchanger portion 9b rests on a rear drain pan 12b. The front drain pan 12a and rear drain pan 12b receive drain water dripping down from the front heat exchanger portion 9a and rear heat exchanger portion 9b, respectively. The received drain water can be drained to the outside through a drain hose (not shown) .

The outer surface of the side wall of part of the front drain pan 12a and that of the rear drain pan 12b are located at positions close to the blower 11, so they form a nose against the fan of the blower 11. Those side wall portions of the front and rear drain pans 12a and 12b which form the nose and the respective sides of the supply opening 7 are connected to each other through a partition member 13. The space surrounded by the partition member 13 forms an air supply channel 14 through which the nose and the supply opening 7 communicate with each other.

A filter 15 is attached to oppose the front suction port 3 and upper suction port 2 and between the front suction port 3 and the front heat exchanger portion 9a and between the upper suction port 2 and upper heat exchanger portion 9b. The filter 15 is inserted and attached through the lower end of the open front panel 6 at the upper end of the supply opening 7, and can be removed when necessary through this portion. FIG. 2 is a perspective view showing the unit main body 1 and the air filter 15 inserted and attached in the unit main body 1 with the front panel 6 being opened. Two air filters 15, i.e., one with a comparatively large area and one with a small area, are attached on the right and left sides of the unit main body 1 side by side when the unit main body 1 is seen from the front surface. The air filter 15 with a comparatively large area opposes the electric dust collector 10. A secondary filter such as a deodorizing filter (not shown) is arranged to oppose the filter 15 with the small area. Each air filter 15 integrally has a thumb knob 16 at the lower end of its surface. With the front panel 6 being opened, when the thumb knob 16 is held and operated along a filter guide, the air filter 15 can be attached to and detached from the unit main body 1. FIG. 3 is a perspective view of either one air filter 15 (e.g., the left air filter), FIG. 4A is a side view of the same, and FIG. 4B is an enlarged view of part of the same. The right and left filters have different areas due to the different horizontal widths but have the same structure.

FIG. 5 shows part of the air filter 15, and FIG. 6 shows part of the air filter 15 shown in FIG. 5 inside out. In this case, the air filter 15 is formed of one pleated filter member 17, crosspiece members 18, and a frame member 20. The crosspiece members 18 are formed integrally with the side ends and intermediate portions of the pleated filter member 17. The frame member 20 is formed integrally with part of the crosspiece members 18 to form the peripheral side end of the air filter 15. The pleated filter member 17 is formed of a mesh-like material which actually allows air to flow through it and catches dust contained in air. One end of the pleated filter member 17 forms a flat plate while its other portion is folded in a zigzag manner in the longitudinal direction to form a large number of pleats. First, the pleated filter member 17 is fabricated to have the same pleat height throughout its entire length. When the pleated filter member 17 is to be molded together with the crosspiece members 18, it is partially extended to have a different height, as will be described later. This is one characteristic feature of the present invention.

The crosspiece member 18 formed at each side end of the pleated filter member 17 along the pleats is made of a synthetic resin material. More specifically, each side end of the pleated filter member 17 which has pleats is inserted and fixed in a mold that molds the crosspiece member 18. The resin material is injected into the mold. Thus, the pleated filter member 17 and crosspiece member 18 are integrally molded.

Of the entire length of the pleated filter member 17 and crosspiece member 18 from one end to the other end, about 2/3 forms a shape with a high pleat height and narrow top-to-top gap, while about 1/3 which remains forms a shape with a low pleat height and large top-to-top gap. Horizontal reinforcing crosspieces 19 are formed at appropriate portions, e.g., at the position of a boundary through which the pleat heights differ. The reinforcing crosspieces 19 divide portions with different pleat heights on its right and left sides .

The frame member 20 is formed by using the same mold as that for the crosspiece members 18, is made of the same synthetic resin material as that of the crosspiece members 18, and is molded integrally with the crosspiece members 18. The frame member 20 is formed across the tops of the pleats on one side of the crosspiece members 18.

In FIGS. 3 and 5, the frame member 20 is formed across the tops of the lower pleats of the crosspiece members 18. In FIGS. 4A and 4B, the frame member 20 is formed across the left tops of the pleats of the crosspiece members 18. In FIG. 6, the front and rear sides in FIG. 5 are reversed. Thus, the frame member 20 is formed across the upper tops of the pleats of the crosspiece members 18. In other words, the crosspiece members 18 and pleated filter member 17 appear as if their pleats projected from one surface of the frame member 20. The frame member 20 is formed along the two side ends in the longitudinal direction of the pleated filter member 17 and crosspiece members 18. Non-pleated filter 17 portion and the crosspiece members 18 extend along one side of the frame member 20, where a thumb knob (not shown) is formed integrally.

The air filter 15 formed in this manner particularly has the frame member 20 across the tops of the pleats on one side of the crosspiece members 18. Hence, the air filter 15 is soft in the longitudinal direction and thus is flexible.

As shown in FIG. 1 again, with the air filters 15 being attached to the predetermined portions of the main body 1, that portion of the pleated filter member which opposes the front suction port 3 has a large pleat height and narrow top-to-top gap. That portion of the pleated filter member 17 which opposes the upper suction port 2 has a small pleat height and wide top-to-top gap. In particular, the plurality of crosspieces 2a are fitted in the upper suction port 2 to form the predetermined gaps in the back-and-forth direction, as described above. Thus, the upper suction port 2 is partitioned into a plurality of spaces by the crosspieces 2a. The pleated filter member 17 is attached such that its tops oppose substantially the intermediate portions of these spaces.

Regarding the structure of the unit main body 1, that portion of the unit main body 1 where the front suction port 3 is formed is curved, so the air filter 15 opposing this portion is preferably soft so it can yield easily. That portion of the unit main body 1 where the upper suction port 2 is formed is almost flat. The air filter 15 which opposes this portion is preferably flat and hard. The air filters 15 have optimal shapes and structures to correspond to the front suction port 3 and upper suction port 2. This is one characteristic feature of the present invention.

The indoor unit of the air conditioner formed in this manner operates in the following manner. More specifically, when the operation switch of the remote controller is turned on, part of the front panel 6 opens the front suction port 3. The supply louvers 8a and 8b provided to the supply opening 7 pivot in response to the selecting operation between the cooling and heating operations, and their postures are set. At the same time, the blower 11 blows air. Meanwhile, the compressor of the outdoor unit is driven to start refrigerating cycle operation. Indoor air is guided into the unit main body 1 from the upper suction port 2 and front suction port 3, and flows through the air filters 15. Dust contained in the indoor air is caught by the air filters 15. Dust-removed air passes through the heat exchanger 9 to perform heat exchange.

Heat-exchanged air is guided along the air supply channel 14, is guided by the supply louvers 8a and 8b, and is blown into the room through the supply opening 7, so efficient air conditioning operation is performed. When the electric dust collector 10 is operated, dust that is not caught even by the air filters 15 is caught completely. The cleaned air is blown into the room from the supply opening 7 through the heat exchanger 9.

The pleated filter member 17 of the air filter 15 which is folded in a zigzag manner to have several pleats catches dust. Therefore, the filtration area becomes several times that of the conventional air filter which has a mere flat plate-like filter member 17. Hence, the filtration efficiency can be largely improved.

That portion of the pleated filter member 17 which has a large pleat height and narrow top-to-top gap opposes the front suction port 3 having a large open area. That portion of the pleated filter member 17 which has a small pleat height and large top-to-top gap opposes the upper suction port 2 which has a small open area. Thus, the pleated filter member 17 can have an optimal filtration capability corresponding to the ratio in open area of the suction port 2 to the suction port 3.

In particular, that portion of the pleated filter member 17 which opposes the upper suction port 2 is attached such that the tops of its pleats oppose the spaces among the crosspieces 2a of the upper suction port 2. Therefore, air can be smoothly introduced into the unit main body 1 through the spaces, and the dust catching effect is improved.

The frame member 20 is formed across the tops of the pleats on one side of the crosspiece members 18. Thus, the air filters 15 can be flexible and soft. When clogging occurs, the air filters 15 can be detached and attached easily, thus improving the operability.

The pleated filter member 17 is formed to have the same pleat height throughout its entire length. When molding the air filter 17, it is partially extended. Therefore, fabrication of the air filter 15 itself can be performed without cumbersome operation. The productivity is high, and less adverse influence is applied on the cost.

In the embodiment described above, the pleated filter member 17 of the air filter 15 is formed of a mesh-like material made of a synthetic resin material. The surface of the mesh-like material can be coated with a deodorizing/antibacterial agent, or the mesh-like material can be provided with a deodorizing/ antibacterial function.

Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.

Industrial Applicability According to the present invention, an air conditioner can be obtained, which employs a pleated filter member as an air filter which catches and removes dust from indoor air drawn by suction into the main body of the indoor unit, so a long life can be obtained. Also, since the pleated filter member is flexible, the operability is improved by smooth attaching/detaching operation.

Claims

C L A I M S

1. An air conditioner comprising an air conditioner main body which houses a heat exchanger and a blower, a front suction port formed in a front portion of said air conditioner main body and an upper suction port formed in an upper portion thereof, and an air filter which is detachably attached to an inner surface of said air conditioner main body to oppose said front suction port and said upper suction port and which catches and removes dust from air drawn by suction into said main body, wherein said air filter is characterized by comprising a pleated filter member folded in a zigzag manner and having pleats, a crosspiece member formed at a side end of said pleated filter member along the pleats, and a frame member formed across tops of the pleats on one side of said crosspiece member, thus forming a flexible air filter.

2. An air conditioner according to claim 1, characterized in that, in the air filter, that portion of said pleated filter member which opposes said front suction port and that portion of said pleated filter member which opposes said upper suction port are molded to have different pleat heights.

3. An air conditioner according to claim 2, characterized in that said pleated filter member is fabricated to have the same pleat height throughout an entire length thereof, and is partly extended when being molded together with said crosspiece member so as to have a different height.

4. An air conditioner according to claim 1, characterized in that said upper suction port formed in the upper portion of said air conditioner main body is partitioned into a plurality of spaces by a plurality of crosspieces fitted therein to form predetermined gaps in a back-and-forth direction, and that portion of said pleated filter member which opposes said upper suction port is attached such that tops of the pleats thereof oppose substantially intermediate portions of the spaces.