Abstract:
An air conditioner indoor unit which includes a heat exchanger; a fan; a drain pan provided under the heat exchanger, the drain pan retrieving drain water condensed on the heat exchanger; an outlet nozzle member provided under the drain pan, the outlet nozzle member providing an air path for blowing off air supplied by the fan and a hollow space between the drain pan and the outlet nozzle member; a drain pan drainage formed in the drain pan, the drain pan drainage draining drain water stored in the drain pan; a hollow space drainage formed in the outlet nozzle member at a location close to the drain pan drainage, the hollow space drainage draining drain water stored in the hollow space; and a drain hose connected to the drain pan drainage and the hollow space drainage.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an improvement in the assembly operation, a reduction in the cost of and an improvement in the environmental issue of an air conditioner. 
     2. Discussion of the Background 
     In FIG. 24 is shown a part of a conventional air conditioner, which includes a drain pan having a hollow space therein for thermal insulation, and which has been disclosed in JP-A-611148 for instance. The conventional air conditioner decreases the amount of a thermal insulation material to reduce fabrication steps, and the drain pan  24  is prepared so as to include an outer layer  25  made of ABS resin and the hollow space  26  formed therein by known gas injection molding. 
     The function of the drain pan will be explained as follows. In general, the inner side  28  of the drain pan  24  has the tendency to have a lower surface temperature than the outer side  27  since the inner side is close to a heat exchanger and contacts cooled droplets. However, the gas in the hollow space  26  inside the outer layer  25  has a superior thermal insulation property. Even if there is a temperature difference between the inner side  28  and the outer side  27 , the gas in the hollow space  26  shuts off the heat transfer therebetween. By this arrangement, the air close to the outer side  27  is not noticeably cooled and vapor condensation is not provided on the outer side  27 . 
     In FIG. 25 is shown a conventional plug arrangement for an air conditioner drain pipe, which has been disclosed in JP-A-58-33980 for instance, which is shown in exploded fashion. In this Figure, reference numeral  101  designates a drain pan, reference numeral  102  designates a drain pipe, which is connected to the drain pan so as to pass therethrough, and reference numeral  103  designates a blind plug to be mounted to the drain pipe for clogging the drain pipe. 
     The function of the blind plug will be explained as follows. Referring to FIG. 25, the drain pipe  102  is inserted in the drain pan  101  to be engaged therewith, and the blind plug  103  is forcibly capped on the drain pipe  102  to be engaged therewith. 
     In FIG. 26 is shown an exploded perspective view of essential portions of another conventional plug arrangement for a drain pipe, in FIG. 27 is shown a cross-sectional view to explain how a drain pipe joint is mounted, in FIG. 28 is shown a perspective view of the rain pipe joint, and in FIG. 29 is shown cross-sectional view to explain how a blind plug is mounted. In FIG. 30 is shown a perspective view of the blind plug. In these Figures, reference numeral  101  designates a drain pan, reference numeral  102  designates a drain pipe joint, which passes through and is engaged with a hole  101   a  formed in the drain pan  101 , reference numeral  102   a  designates a flange of the drain pipe joint  102 , reference numeral  102   b  designates the tubular body of the drain pipe joint  101 , reference numeral  102   c  designates a stopper, which is provided on an end of the tubular body of the joint and has a leading edge provided with a conical portion, and reference numeral  102   d  designates a through hole in the drain pipe joint. 
     If the drain pipe joint  102  is not needed, the blind plug  103  is inserted into the hole  101   a  in the drain pan  101  to be engaged therewith as shown in FIG.  29 . If the joint is needed, the joint  102  is inserted into the hole  101   a  in the drain pan  101  to be engaged therewith as shown in FIG. 27. A hose  104  for leading drain water to outside is engaged with the joint  102  as shown in FIG. 31 to drain the water from the drain pan to outside through the through hole in the joint  102  and the hose. 
     The drainage for a drain pan thus prepared is used in an air conditioner as in the fashion shown in FIG.  32 . 
     Since the conventional drainage is thus constructed, the blind plug and the joint must be exchanged as required, which takes some time to exchange the parts, or which means that the plural parts are required to be ready all the time, that is wasteful. 
     Since the conventional air conditioner is configured to be provided with the hollow space by gas injection, the air layer can not be provided so as to have a certain thickness or a greater thickness which means that a great deal of thermal insulation cannot be provided. Costs, such as a molding cost, are required. 
     From the viewpoint that the environmental issue has been presently discussed, it is recommended that used parts can be easily separated according to type. When an insulation material or a similar member is provided on a lower side of a heat exchanger to prevent secondary air from being sucked, there has been created a problem in that separation of the insulating material for disposal is troublesome. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to eliminate these problems, and to improve the thermal insulation property of a drain pan. 
     It is another object of the present invention to provide required parts at a low cost. 
     It is a further object of the present invention to provide drainage treatment with more reliable fashion. 
     It is a still further reject of the preset invention to facilitate separation of parts for disposal from the viewpoint of product assessment. 
     The present invention provides an air conditioner indoor unit comprising a heat exchanger; a fan; a drain pan provided under the heat exchanger, the drain pan retrieving drain water condensed on the heat exchanger; an outlet nozzle member provided under the drain pan, the outlet nozzle member providing an air path for blowing off air supplied by the fan and a hollow space between the drain pan and the outlet nozzle member; a drain pan drainage formed in the drain pan, the drain pan drainage draining drain water stored in the drain pan; a hollow space drainage formed in the outlet nozzle member at a location close to the drain pan drainage, the hollow space drainage draining drain water stored in the hollow space; and a drain hose connected to the drain pan drainage and the hollow space drainage. In accordance with the present invention, the hollow space can work for thermal insulation between the drain pan and the outlet nozzle member to dispense with a thermal insulation material and to eliminate the problem of dew drops due to peeling of a thermal insulation material, carrying out drainage in more reliable fashion. 
     The drain pan drainage and the hollow space drainage may be provided in concentric fashion so that the drain pan drainage is located inside the hollow space drainage. 
     The drain pan drainage may have a leading edge provided with a trough-shaped guide. This arrangement can direct the drain water from the drain pan drainage to the drain hose in more reliable fashion. 
     The drain pan drainage and the hollow space drainage may be combined so as to provide a pair of drainages, and a rubber plug with dual concentric flanges may be provided on the pair of drainages when the drainages are not in use. By this arrangement, both drainages can be closed by the single rubber plug. 
     The outlet nozzle member and the drain pan may be made of different materials, and the drain pan may be made of polypropylene resin. By this arrangement, the occurrence of a creak between parts due to thermal shrinkage can be restrained. 
     The heat exchange may have a lower end provided with an insulation member to separate a space under the heat exchanger into a primary side and a secondary side, the drain pan may be provided with a rib, and the insulation member is engaged with the rib. By this arrangement, it is possible to remove the insulation member easily for disposal, facilitating the separation of parts. 
     The insulation member may have angular holes and slots formed therein, the rib may have projections in a triangular shape alternately provided on both lateral sides thereof, and the angular holes may receive the projections in alternate fashion. 
     The drain pan may be provided with two ribs, one of ribs may have a lateral side facing the other rib provided with projections in a triangular shape, the insulation member may have angular holes formed therein, and the insulation member may be inserted into a gap between the ribs with the ribs fitted into the angular holes. 
     The drain pan may include an additional drainage, which has a drain pipe joint inserted thereinto. The drain pipe joint may comprise a tubular body with a bore formed therein, a stopper provided on one end of the tubular body and having a conical leading edge, a flange provided on the tubular body at a location close to the stopper, and a wall provided on the other end of the tubular body to close the bore. This arrangement can carry out an operation for connecting a drain hose in effective fashion, and offer an advantage in that the number of required parts is reduced. 
     The drain pipe joint may be formed from an elastic material. The drain pipe joint can work as a joint and a blind plug in a single use, offering an advantage in that the number of required parts is reduced. 
     The drain pipe joint may have a cutting groove provided thereon at a location close to the wall. The single drain pipe joint can work as a joint and a blind plug in a single use, offering an advantage in that the number of required parts is reduced. 
     The wall of the drain pipe joint may be made of a breakable material so that the wall can be broken when the joint is used for drainage. The drain pipe joint can work as a joint and a blind plug in a single use, offering advantages in that the number of required parts is reduced and that an operation for connecting a connecting hose can be simplified. 
     The drain pan may include an additional drainage with a drain pipe joint inserted thereinto, and the drain pipe joint may comprise a tubular body with a bore formed therein, a stopper provided on one end of the tubular body and having a conical leading edge, a flange provided on the tubular body at a location close to the stopper, and a wall provided on the one end of the tubular body to close the bore. This arrangement can attach the drain pipe joint to the drain pan from inside the drain pan, simplifying the attaching operation. 
     The drain pipe joint may have a connecting portion with a connecting hose formed so as to have a larger outer diameter than an inner diameter of the connecting hose. This arrangement can ensure that the connecting hose is connected to the joint after the wall has been broken. 
     The drain pipe joint is configured so as to be attachable to the drain pan from inside the drain pan. This arrangement can offer an advantage in that the attaching operation in a narrow space is simplified. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
     FIG. 1 is a cross-sectional view of essential portions of the air conditioner according to a first embodiment of the present invention; 
     FIG. 2 is a cross-sectional view of essential portions of the air conditioner according to the first embodiment; 
     FIG. 3 is a cross-sectional view of essential portions of the air conditioner according to the first embodiment; 
     FIG. 4 is a front view of essential portions of the air conditioner according to the first embodiment as viewed from the direction indicated by an arrow A in FIG. 3; 
     FIG. 5 is a cross-sectional view of essential portions of the air conditioner according to a second embodiment of the present invention; 
     FIG. 6 is a cross-sectional view of essential portions of the air conditioner according to a third embodiment of the present invention; 
     FIG. 7 is a cross-sectional view of essential portions of the air conditioner according to a fourth embodiment of the present invention; 
     FIG. 8 is a cross-sectional view of essential portions of the air conditioner according to a fifth embodiment of the present invention; 
     FIG. 9 is a cross-sectional view of essential portions of the air conditioner according to the fifth embodiment; 
     FIG. 10 is a cross-sectional view of essential portions of the air conditioner according to a sixth embodiment of the present invention; 
     FIG. 11 is a cross-sectional view of essential portions of the air conditioner according to the sixth embodiment; 
     FIG. 12 is a cross-sectional view of the drain pipe joint for an additional drainage in a drain pan according to a seventh embodiment of the present invention; 
     FIG. 13 is a cross-sectional view of the drain pipe joint according to the seventh embodiment, wherein the joint is cut at a line A indicated in FIG. 12; 
     FIG. 14 is a cross-sectional view of the drain pipe joint according to the seventh embodiment, wherein the joint is used as a plug; 
     FIG. 15 is a cross-sectional view of the drain pipe joint according to the seventh embodiment, wherein the joint is used for drainage; 
     FIG. 16 is a cross-sectional view of the drain pipe joint according to an eighth embodiment of the present invention; 
     FIGS.  17 ( a ) and ( b ) are cross-sectional views of the drain pipe joint according to a ninth embodiment of the present invention; 
     FIG. 18 is a cross-sectional view of the drain pipe joint according to the seventh embodiment to show how to attach the joint into the drain pan; 
     FIG. 19 is a cross-sectional view of the drain pipe joint according to a tenth embodiment of the present invention; 
     FIG. 20 is a cross-sectional view of the drain pipe joint according to the tenth embodiment to show how to attach the joint into the drain pan; 
     FIG. 21 is a cross-sectional view of the drain pipe joint according to an eleventh embodiment of the present invention; 
     FIG. 22 is a cross-sectional view of the drain pipe joint according to a twelfth embodiment of the present invention; 
     FIG. 23 is a cross-sectional view of the drain pipe joint according to the twelfth embodiment, wherein the joint is used for drainage; 
     FIG. 24 is a cross-sectional view of a part of a conventional air conditioner; 
     FIG. 25 is an exploded cross-sectional view of a conventional drain pipe plug arrangement; 
     FIG. 26 is an exploded cross-sectional view of another conventional drain pipe plug arrangement; 
     FIG. 27 is a cross-sectional view of a conventional drain pipe joint to show how to attach the joint into the drain pan; 
     FIG. 28 is a perspective view of the conventional drain pipe joint; 
     FIG. 29 is a cross-sectional view of a conventional blind plug to show how to attach the plug into the drain pan; 
     FIG. 30 is a perspective view of the conventional blind plug; 
     FIG. 31 is a cross-sectional view of the drain pipe joint, wherein the joint is used for drainage; and 
     FIG. 32 is a perspective view wherein the conventional drain pipe joint is applied to an air conditioner. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Now, preferred embodiments of the present invention will be described in detail, referring to the accompanying drawing. 
     EMBODIMENT 1 
     A first embodiment of the present invention will be explained, referring to the drawings. 
     In FIGS. 1 through 4 is shown the first embodiment. In FIG. 1 is shown a cross-sectional view of a wall-hung air conditioner as a whole, in FIGS. 2 and 3 are shown cross-sectional views of essential portions of the air conditioner, and in FIG. 4 is shown a front view of essential portions of the embodiment. In these Figures, reference numeral  1  designates a heat exchanger, reference numeral  2  designates a flap, reference numeral  4  designates a drain pan, reference numeral  5  designates drain water that has moved from the heat exchanger  1  and has been stored in the drain pan, reference numeral  3  designates an outlet nozzle member that is fitted on the drain pan to be combined therewith, reference numeral  8  designates drain water that has been stored in a hollow space  7  due to vapor condensation, reference numeral  9  designates a first drainage as a drain pan drainage for the drain water  5  in the drain pan  4 , and reference numeral  10  designates a second drainage as a hollow space drainage that is provided so as to be concentric with the first drainage  9  and drains the drain water  8  in the hollow space. The drain water in the drain pan and the hollow space is retrieved by a drain hose  11 . 
     The function of the device according to this embodiment will be explained. An outlet nozzle of the air conditioner is provided by the drain pan  4  and the outlet nozzle member  3  fitted on and combined with the drain pan. The drain water  5  that has been stored in the drain pan  4  is drained through the first drainage  9 . Since the hollow space  7  defined by the drain pan  4  and the outlet nozzle member  3  has air leaked thereinto through a gap  6  between the drain pan and the outlet nozzle member, the drain water  8  is deposited on the inner wall of the hollow space  7 , and the drain water is stored in the hollow space  7 . As shown in FIG. 4, the second drainage  10  for the drain water  8  in the hollow space  7  is provided so as to be concentric with the first drainage  9  to retrieve the drain water  8  in the hollow space  7  together with the drain water  5  in the drain pan through the single drain hose  11 , preventing the drain water  8  in the hollow space  7  from overflowing the hollow space or dropping out of the hollow space. 
     Since no foamed material or a similar material is used, it is possible to disengage the outlet nozzle member  3  from the drain pan  4  easily, and therefore to carry out separation of the parts simply for disposal. 
     Although the second drainage  10  for the drain water  8  in the hollow space  7  is shown to be concentric with the first drainage  9  for the drain pan  4 , the second drainage is not limited to the concentric fashion as long as the second drainage is located close to the first drainage  9 . 
     According to this embodiment, the hollow space can be provided so as to offer a required thermal insulation by the two parts. 
     No use of a thermal insulation material eliminates the problem of dew drops due to peeling of a thermal insulation material, and drainages treatment can be carried out in more reliable fashion. This embodiment can offer an advantage in that the device can be provided at a low cost. The disengagement of the parts is easy to improve the separation of the parts for disposal. 
     EMBODIMENT 2 
     In FIG. 5 is shown a cross-sectional view of essential portions of the air conditioner according to a second embodiment. In this Figure, reference numeral  12  designates a trough-shaped guide, which is provided on a leading edge of the first drainage  9  for the drain water  5  in the drain pan  4 . The trough-shaped guide  12  can be provided to the leading edge of the first drainage  9  for the drain water  5  according to the first embodiment to reliably direct the drain water  5  to the drain hose  11  without allowing the drain water  5  to flow into the hollow space  7  even if the leading edges of the first and second drainages  9  and  10  are located at the same projecting position. 
     EMBODIMENT 3 
     In FIG. 6 is shown a cross-sectional view of essential portions of the air conditioner according to a third embodiment of the present invention. As shown in this Figure, a rubber plug  13  is used to clog the first drainage  9  and the second drainage  10  that are not in use. 
     Air conditioners are usually provided with drainages at two locations. One of the drainages is ready for use on installation, and the drainage that is not in use is clogged with a rubber plug. 
     The rubber plug  13  can be provided with concentric flanges  14  and  15  to clog the respective drainages  9  and  10 , thereby clogging both drainages with the single rubber plug. 
     EMBODIMENT 4 
     In FIG. 7 is shown a cross-sectional view of essential portion of the air conditioner according to a fourth embodiment of the present invention. In this Figure, reference numeral  16  designates a nozzle fixing portion, which is used to fix the drain pan  4  thereto. The outlet nozzle member  3  and the drain pan  4  are made of different materials, respectively. The drain pan  4  is made of polypropylene, allowing engagement with other parts to be carried out with the presence of the polypropylene material. Due to the presence of the polypropylene material, almost no creaking, which is normally produced between parts due to thermal shrinkage, is generated. 
     EMBODIMENT 5 
     In FIGS. 8 and 9 are shown a perspective view and a cross-sectional view of essential portions of the air conditioner according to a fifth embodiment of the present invention. In these Figures, reference numeral  17  designates a rib that is provided on the drain pan  4 , reference numeral  18  designates projections in a triangular cross-sectional shape, reference numeral  19  designates an insulating member, reference numeral  20  designates a plurality of angular holes formed in the insulating member  19 , and reference numeral  21  designates slots. 
     The insulating member  19 , which separates a primary side and a secondary side at a lower end of the heat exchanger  1 , has a plurality of angular holes  20  and the plural slots  21  formed therein. The single rib  17  is provided on a side of the drain pan  4  close to the heat exchanger, and the rib has both lateral sides alternately provided with the projections  18  in a triangular cross-sectional shape. The projections  18  are zigzag fitted into the angular holes  20  in the insulating member  19 . 
     Since it is possible to remove the insulating member  19  easily for disposal, the separation of parts can be improved. 
     In the conventional air conditioner, the insulating member for separating a primary side and a secondary side at a lower end of the heat exchanger is fixed to the drain pan  4  by an adhesive. 
     EMBODIMENT 6 
     In FIGS. 10 and 11 are shown a perspective view and a cross-sectional view of essential portions of the air conditioner according to a six embodiment of the present invention. In this Figure, reference numeral  22  designates an insulating member, and reference numeral  23  designates ribs. 
     The two ribs  23  are provided on the drain pan  4 , and one of the ribs has a lateral side close to the other rib provided with a plurality of projections  18  in a triangular cross-sectional shape. The insulating member  22  is fitted between and fixed to the ribs  23 , having the projections  18  received in angular holes  20  formed in the insulating member. 
     As in the fifth embodiment, it is possible to remove the insulating member  22  easily for disposal, thus improving separation of the parts. 
     In the explanation of the third embodiment, it has been stated that the drain pan of an air conditioner is usually provided with drainages at two locations. In the case wherein the drain pan includes an additional drainage in addition to the drainage  9 , drain pipe joints according to the following embodiment are appropriate to the additional drainage. 
     EMBODIMENT 7 
     Now, the drainage for the drain pan according to a seventh embodiment of the present invention will be explained, referring to the drawings. In FIG. 12 is shown a cross-sectional view of the drain pipe joint according to the seventh embodiment, in FIG. 13 is shown a cross-sectional view of the drain pipe joint as taken along line A shown in FIG. 12, in FIG. 14 is shown a cross-sectional view to explain how the drain pipe joint is used as a drain plug, and in FIG. 15 is shown a cross-sectional view to explain how the drain pan drainage according to the seventh embodiment is used. In these Figures, reference numeral  101  designates the drain pan, reference numeral  102  designates the drain pipe joint, which is inserted into and engaged with a hole  101   a  formed in the drain pan  101 , and which is molded from an elastic material, such as rubber, reference numeral  102   a  designates a flange, which is provided on the drain pipe joint  102 , reference numeral  102   b  designates a tubular body of the drain pipe joint  102 , reference numeral  102   c  designates a stopper, which is provide on an end of the tubular body and has a conical leading edge, reference numeral  102   e  designates a bore in the drain pipe joint  102 , and reference numeral  102   f  designates a wall, which is provided on the tubular body at the end remote from the stopper  102   c.    
     The function of the drain pipe joint will be explained, referring to FIGS. 12 through 15. The drain pipe joint  102  is engaged with the hole  101   a  formed in the drain pan  101 . Since the drain pipe joint  102  has the wall  102   f  provided at the end remote from the stopper, the joint performs a clogging function to prevent drain water from leaking out of the drain pan as shown in FIG. 14, wherein the joint  102  is used as a blind plug. If the drain pipe joint  102  is used as a joint, the drain pipe joint is cut at the position shown in the line A to cut off the wall  102   f  from the tubular body as shown in FIG. 13, and a drain hose  104  is connected to the cut end. 
     EMBODIMENT 8 
     Although the wall  102   f  is cut at the position indicated by the line A of FIG. 12 in the seventh embodiment, the drain pipe joint  102  has a groove  105  provided at an outer periphery thereon at a portion close to the wall  102   f  as a hose connecting portion to clarify the cutting position, allowing the wall to be accurately separated in an eighth embodiment shown in FIG.  16 . 
     EMBODIMENT 9 
     Although the joint has the end close to the wall cut and separated in the seventh and eighth embodiment, the wall  102   f  of the drain pipe joint  102  may be broken by a sharp instrument  106  to form a broken hole  107  as shown in FIGS.  17 ( a ) and ( b ), offering a similar effect. 
     EMBODIMENT 10 
     Although the drain pipe joint  102  according to the seventh through ninth embodiment is inserted into the drain pan  101  from an outer side of the drain pan as shown in FIG. 18, the end of the drain pipe joint  102  with the wall  102   f  is formed in a sharp angular shape and the flange  102   a  has a side provided with a tapered surface  102   g  as shown in FIG.  19 . The drain pipe joint  102  is engaged with the hole in the drain pan  101  from an inner side of the drain pan as shown in FIG.  20 . 
     EMBODIMENT 11 
     In FIG. 21 is shown the drain pipe joint for the additional drainage according to an eleventh embodiment, wherein the wall  102   f  of the joint  102  has an outer diameter A formed so as to be larger than the inner diameter B of the connecting hose  104 . 
     EMBODIMENT 12 
     In FIGS. 22 and 23 is shown the drain pipe joint for the additional drainage according to a twelfth embodiment of the present invention. Reference numeral  102   h  designate a wall, which is provided on the drain pipe joint  102  at the end with the stopper  102  so as to close the bore  102   e  at the leading edge of the stopper  102   c.    
     When the drain pipe joint according to the twelfth embodiment is used as a drain pipe, the wall  102   h  is broken by an instrument to form a through hole  108 , allowing drain water to be drained.