Patent Publication Number: US-8979513-B2

Title: Lead wire engaging structure and electric apparatus

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Filed 
     The present invention relates to a lead wire engaging structure configured to engage lead wires at an electric apparatus casing, and also relates to an electric apparatus. 
     2. Background Art 
     Japanese Patent Application Publication No. 11-230083 (JP11-230083A) discloses a centrifugal fan (electric apparatus) in which a groove portion is formed in an outer wall of a wall portion opposite to a suction port of a casing to receive a plurality of lead wires in the groove portion. A nail-like projection extends along an opening portion of the groove portion to prevent the lead wires from coming out of the groove portion. 
     Japanese Patent Application Publication No. 2005-303015 (JP2005-303015A) discloses a lead wire engaging structure in which lead wires are received in a groove portion provided in a web of an axial flow fan, and in which the lead wires extending out of the groove portion are engaged at a hook provided on an outer wall of a casing. 
     Japanese Patent Application Publication No. 2010-7545 (JP2010-007545A) discloses a lead wire engaging structure in which lead wires are housed in a groove portion provided in a web of an axial flow fan, and in which the lead wires extending out of the groove portion are engaged with lead wire engaging portions provided on an outer wall of a casing. 
     In the conventional lead wire engaging structures, when the lead wires receive a force in the direction of pushing the lead wires along the longitudinal direction of the lead wires into the electric apparatus casing, the lead wires may be partially raised at portions located on the side where the lead wires are drawn out with respect to the lead wire engaging portion. If the electric apparatus is installed with the lead wires thus raised, the raised portions of the lead wires may hinder installation of the electric apparatus, or may cause noise. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a lead wire engaging structure in which lead wires are not raised even if the lead wires receive a force in the direction of pushing the lead wires into the electric apparatus casing, and to provide an electric apparatus including the lead wire engaging structure. 
     Another object of the present invention is to provide a lead wire engaging structure in which lead wires extending from the lead wire engaging structure do not hinder installation of an electric apparatus, and to provide an electric apparatus including the lead wire engaging structure. 
     The present invention is directed to a lead wire engaging structure configured to engage one or more lead wires at an electric apparatus casing including a first casing wall portion from which the one or more lead wires are led out and a second casing wall portion continuously formed with the first casing wall portion and extending in an intersecting direction intersecting a direction in which the first casing wall portion extends. The one or more lead wires have an insulating coating, and are engaged at the second casing wall portion. If the electric apparatus is a fan, for example, the electric apparatus casing is a casing having an air channel of the fan. The lead wire engaging structure according to the present invention includes a first engaging portion and a second engaging portion. The first engaging portion is fixed to the electric apparatus casing to form a first gap between the first engaging portion and the second casing wall portion and to engage the one or more lead wires in cooperation with the second casing wall portion. The first gap allows the one or more lead wires to pass therethrough. The second engaging portion is fixed to the electric apparatus casing or the first engaging portion to form a second gap between the second engaging portion and the first engaging portion. The second gap allows the one or more lead wires to pass therethrough. In the lead wire engaging structure according to the present invention, the one or more lead wires are bent at an angled portion between the first casing wall portion and the second casing wall portion and then routed to pass through the first gap and then through the second gap to engage the one or more lead wires at the electric apparatus casing. In the lead wire engaging structure according to the present invention, when the one or more lead wires receive a force that pushing the lead wires in the longitudinal direction thereof into the casing, portions of the lead wires located in the second gap are moved toward the second casing wall portion. Then, portions of the lead wires located between the second gap and the first gap are brought into abutment with the second casing wall portion. The force presses the lead wires against the second casing wall portion, but does not press out the portions of the lead wires held in the first gap between the first engaging portion and the second casing wall portion. Therefore, according to the lead wire engaging structure of the present invention, the lead wires are not raised even if the lead wires receive a force in the direction of pushing the lead wires into the casing. 
     The first casing wall portion may include a groove portion formed to open toward an outer wall surface of the first casing wall portion and an outer wall surface of the second casing wall portion and to receive a part of the one or more lead wires. Preferably, the first engaging portion and the second engaging portion are entirely located in a space located in an extending direction in which the second casing wall portion extends with respect to an imaginary plane including the outer wall surface of the first casing wall portion, and are shaped such that a lead wire passage space allowing the one or more lead wires to pass therethrough is defined between the second engaging portion and the imaginary plane. According to the above structure, the lead wires does not hinder installation of the electric apparatus in installing the electric apparatus such that the first casing wall portion of the electric apparatus casing contacts the installation surface. By forming the lead wire passage space allowing the lead wires to pass therethrough between the second engaging portion and the imaginary plane, in particular, the lead wires extending out of the lead wire engaging structure do not hinder installation of the electric apparatus. 
     As in a first aspect of the present invention, the second casing wall portion may include an extending portion to which one end portion of the first engaging portion and one end portion of the second engaging portion are fixed. By providing such extending portion, the first engaging portion and the second engaging portion can be easily provided. The other end portion of the first engaging portion and the other end portion of the second engaging portion, which are located in the extending direction, may be coupled to each other by a coupling portion. The second engaging portion may include one slit formed at a center area of the second engaging portion and allowing one of the lead wires to pass therethrough while the insulating coating of the one lead wire is deformed by compression in the slit. This configuration allows the one or more lead wires having passed through the first gap to be inserted into the second gap through the slit. The slit is significantly effective if the lead wires are long. Because the slit is sized to allow one of the lead wires to pass therethrough only while the insulating coating of the one lead wire is deformed by compression in the slit, the one or more lead wires inserted into the second gap do not come out of the second gap unless the lead wires are intentionally pulled out through the slit. Thus, this configuration facilitates engagement of the lead wires, and prevents the lead wires from slipping out. 
     As in a second aspect of the present invention, the second casing wall portion may include an extending portion to which one end portion of the first engaging portion and one end portion of the second engaging portion are fixed, and the other end portion of the first engaging portion and the other end portion of the second engaging portion may be not fixed to act as a free end portion. After the one or more lead wires pass through the first gap, the one or more lead wires are inserted into the second gap between the first engaging portion and the second engaging portion from a space between the free end portions of the first and second engaging portions to prevent the one or more lead wires from slipping out of the first gap. This configuration provides a simple structure. 
     Further, as in a third aspect of the present invention, the second casing wall portion may include an extending portion to which one end portion of the first engaging portion is fixed and which forms a third gap between the extending portion and one end portion of the second engaging portion. The third gap allows the one or more lead wires to pass therethrough. The other end portion of the first engaging portion and the other end portion of the second engaging portion may be coupled to each other by a coupling portion. After the one or more lead wires pass through the first gap, the one or more lead wires are inserted into the second gap between the first engaging portion and the second engaging portion through the third gap. Because the third gap is formed between the extending portion and an end portion of the second engaging portion, the one or more lead wires inserted into the first gap do not slip out of the first gap during an engaging operation. 
     In both of the second and third aspects of the present invention, the second engaging portion may integrally be provided with a projection extending toward the imaginary plane. The projection prevents the one or more lead wires passing through the second gap and extending along the imaginary plane from coming off from the second engaging portion. 
     The present invention may also be implemented as an electric apparatus including a lead wire engaging structure. The electric apparatus according to the present invention includes an electric apparatus casing including: a first casing wall portion having an outer wall surface to be disposed in contact with an installation surface; a second casing wall portion continuously formed with the first casing wall portion and extending in an intersecting direction intersecting a direction in which the first casing wall portion extends; and a third casing wall portion formed continuously with the second casing wall portion and disposed opposite to the first casing wall portion. An electric device is housed in the electric apparatus casing. When the electric apparatus is a fan, the electric device is a motor and an impeller. One or more lead wires are connected to the electric device and extend out of the first casing wall portion. A groove portion is formed in the first casing wall portion of the electric apparatus casing to open toward an outer wall surface of the first casing wall portion and an outer wall surface of the second casing wall portion and to receive a part of the one or more lead wires. The electric apparatus includes a lead wire engaging structure provided to the second casing wall portion to engage the one or more lead wires extending out of the groove portion. The lead wire engaging structure is configured as discussed above. 
     The electric apparatus may be a centrifugal fan including a suction port formed in the third casing wall portion of the electric apparatus casing and a discharge port formed in the second casing wall portion. In the centrifugal fan, the second casing wall portion includes first and second straight wall portions continuously formed with the discharge port and disposed opposite to each other with a predetermined gap therebetween, and an arcuate wall portion continuously formed with the first and second straight wall portions. A first portion of the arcuate wall portion that is adjacent to one of the first and second straight wall portions that is the longer is integrally provided with a mounting portion, which corresponds to the extending portion, including one or more screw holes each allowing passage of a mounting screw for fixing the electric apparatus casing to the installation surface. The first and second engaging portions are integrally provided at the mounting portion. By adopting such a configuration in the centrifugal fan, the overall size of the centrifugal fan can be made compact even if a lead wire engaging structure is provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view showing the back side of a centrifugal fan according to a first embodiment of the present invention. 
         FIG. 2  is a perspective view showing the back side of the centrifugal fan according to the first embodiment from which lead wires have been removed. 
         FIG. 3  is a perspective view showing the front side of the centrifugal fan according to the first embodiment from which lead wires have been removed. 
         FIG. 4  is a side view of the centrifugal fan according to the first embodiment from which lead wires have been removed. 
         FIGS. 5A to 5D  are each a partial enlarged view of a lead wire engaging structure as enlarged and seen from a plurality of directions. 
         FIGS. 6A and 6B  are each a partial enlarged view of the lead wire engaging structure at which lead wires are engaged. 
         FIG. 7  illustrates the function of the lead wire engaging structure. 
         FIGS. 8A to 8C  are each a partial enlarged view of a lead wire engaging structure according to a second embodiment of the present invention as enlarged and seen from a plurality of directions. 
         FIGS. 9A and 9B  are each a partial enlarged view of the lead wire engaging structure of  FIGS. 8A to 8C  at which lead wires are engaged. 
         FIGS. 10A to 10C  are each a partial enlarged view of a lead wire engaging structure according to a third embodiment of the present invention as enlarged and seen from a plurality of directions. 
         FIGS. 11A and 11B  are each a partial enlarged view of the lead wire engaging structure of  FIGS. 10A to 10C  at which lead wires are engaged. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A plurality of electric apparatuses each including a lead wire engaging structure according to embodiments of the present invention will be described with reference to the drawings.  FIG. 1  is a perspective view showing the back side of a centrifugal fan according to a first embodiment of the present invention.  FIGS. 2 to 4  is a perspective view showing the back side, a perspective view showing the front side, and a side view, respectively, of the centrifugal fan according to the first embodiment from which lead wires have been removed.  FIGS. 5A to 5D  are each a partial enlarged view of a lead wire engaging structure as enlarged and seen from a plurality of directions.  FIGS. 6A and 6B  are each a partial enlarged view of the lead wire engaging structure at which lead wires  7  are engaged.  FIG. 7  illustrates the function of the lead wire engaging structure. As shown in the drawings, a centrifugal fan  1  according to the embodiment includes a fan casing  3  serving as an electric apparatus casing, and an impeller  5  ( FIGS. 3 and 4 ) fixed to a rotary shaft  6  of a motor (not shown), which is disposed inside the fan casing  3 , to be rotatable. The fan casing  3  is molded from an insulating resin to be divided into two parts, and includes a first casing wall portion  9  from which four lead wires  7  having an insulating coating are led out, a second casing wall portion  11  continuously formed with the first casing wall portion  9  and extending in an intersecting direction intersecting (in the embodiment, orthogonally) the direction in which the first casing wall portion  9  extends, and a third casing wall portion  13  disposed opposite to the first casing wall portion  9 . A suction port  15  is formed at the third casing wall portion  13 , and a discharge port  17  is formed at the second casing wall portion  11 . The impeller  5  includes a plurality of blades designed to suck air from the suction port  15  in the axial direction of the rotary shaft and discharge the air from the discharge port  17  after changing the direction of the air flow to a direction orthogonal to the axis of the rotary shaft  6  when the rotary shaft  6  of the motor rotates. 
     In the centrifugal fan  1 , the second casing wall portion  11  includes first and second straight wall portions  12 A and  12 B continuously formed with the discharge port  17  and disposed opposite to each other with a predetermined gap therebetween, and an arcuate wall portion  12 C continuously formed with the first and second straight wall portions  12 A and  12 B. A first portion of the arcuate wall portion  12 C that is adjacent to one of the first and second straight wall portions  12 A and  12 B that is the longer, namely the first straight wall portion  12 A, is integrally provided with a first mounting portion  14 A, which corresponds to an extending portion, including two mounting screw through holes  19  each allowing passage of a mounting screw for fixing the fan casing  3  to an installation surface. The arcuate wall portion  12 C is also integrally provided with second to fourth mounting portions  14 B to  14 D each located a predetermined distance away from the first mounting portion  14 A in the circumferential direction. One or more mounting screw through holes  19  are formed in each of the second to fourth mounting portions  14 B to  14 D. 
     The first casing wall portion  9  includes a groove portion  10  formed to open toward an outer wall surface  9 A of the first casing wall portion  9  and an outer wall surface  11 A of the second casing wall portion  11  and to receive a part of the four lead wires  7 . A lead wire engaging structure  21  is integrally provided to the first mounting portion  14 A to face the groove portion  10 . The configuration of the lead wire engaging structure  21  will be described below with reference to  FIGS. 5A to 5D . The lead wire engaging structure  21  according to the present embodiment includes a first engaging portion  23  and a second engaging portion  25 . One end of the first engaging portion  23  and one end of the second engaging portion  25  are integrally provided to the first mounting portion  14 A integrally provided at the second casing wall portion  11 . The first engaging portion  23  and the second engaging portion  25  are entirely located in a space located in an extending direction in which the second casing wall portion  11  extends with respect to an imaginary plane S (see  FIG. 7 ) including the outer wall surface  9 A of the first casing wall portion  9 . The first engaging portion  23  and the second engaging portion  25  according to the embodiment each have the shape of a long and narrow plate extending in the peripheral direction along the second casing wall portion  11 . 
     The first engaging portion  23  forms a first gap  27  between the first engaging portion  23  and the second casing wall portion  11 , and holds the four lead wires  7  in the first gap  27  in cooperation with the second casing wall portion  11 . The first gap  27  allows the four lead wires  7  to pass therethrough. The second engaging portion  25  forms a second gap  29  between the second engaging portion  25  and the first engaging portion  23 . The second gap  29  allows the four lead wires  7  to pass therethrough. The other end portion of the first engaging portion  23  and the other end portion of the second engaging portion  25  are coupled to each other by a coupling portion  31 . The second engaging portion  25  includes one slit  33  formed at a center area of the second engaging portion  25  and allowing one of the lead wires  7  to pass therethrough while the insulating coating of the one lead wire  7  is deformed by compression in the slit  33 . The slit  33  enables the four lead wires  7  having passed through the first gap  27  to pass through the slit  33  to be inserted into the second gap  29 . Therefore, the slit  33  is significantly effective if the lead wires  7  are long. Because the slit  33  is sized to allow one of the lead wires  7  to pass therethrough only while the insulating coating of the one lead wire  7  is deformed by compression in the slit  33 , the four lead wires  7  inserted into the second gap  29  do not come out of the second gap  29  unless the lead wires  7  are intentionally pulled out through the slit  33 . 
     In the embodiment, as shown in  FIG. 7 , the second engaging portion  25  is shaped such that a lead wire passage space  35  allowing the lead wires  7  to pass is defined between the second engaging portion  25  and the imaginary plane S including the outer wall surface  9 A of the first casing wall portion  9 . That is, the second engaging portion  25  is shaped such that an end surface  25 A of the second engaging portion  25  on the bottom surface side is father than an end surface  23 A of the first engaging portion  23  on the bottom surface side from the imaginary plane S. According to such structure, the lead wires  7  does not hinder installation of the centrifugal fan  1  in installing the centrifugal fan  1  such that the first casing wall portion  9  of the fan casing  3  contacts the installation surface (at the location at which the centrifugal fan  1  is to be installed). By forming the lead wire passage space  35  allowing the lead wires  7  to pass therethrough between the second engaging portion  25  and the imaginary plane S, in particular, the lead wires  7  extending out of the lead wire engaging structure  21  can be reliably prevented from hindering installation of the centrifugal fan  1 . 
     In the lead wire engaging structure  21  according to the embodiment, as shown in  FIGS. 6 and 7 , the four lead wires  7  are bent at an angled portion between the first casing wall portion  9  and the second casing wall portion  11  and then routed to pass through the first gap  27  and then sequentially inserted into the second gap  29  from the slit  33  provided in the second engaging portion  25  to engage the four lead wires  7  at the fan casing  3 . In the lead wire engaging structure  21 , when the four lead wires  7  receive a force that presses the lead wires  7  in the longitudinal direction thereof (a force in the direction indicated by the arrow F in  FIG. 7 ), portions of the lead wires  7  located in the second gap  29  are moved toward the second casing wall portion  11 . Then, portions of the lead wires  7  located between the second gap  29  and the first gap  27  are brought into abutment with the second casing wall portion  11 . The force presses the lead wires  7  against the second casing wall portion  11 , but does not press out portions of the lead wires  7  held in the first gap  27  between the first engaging portion  23  and the second casing wall portion  11 . Therefore, according to the lead wire engaging structure  21 , the lead wires  7  are not raised even if the lead wires  7  receive a force in the direction indicated by an arrow F in  FIG. 7 . 
       FIGS. 8A to 8C  are each an enlarged perspective view of a lead wire engaging structure according to a second embodiment of the present invention.  FIGS. 9A and 9B  are each an enlarged perspective view in which lead wires are engaged in the second embodiment. In the figures, components similar to the components in the first embodiment shown in  FIGS. 1 to 7  are denoted by reference numerals obtained by adding 100 to the reference numerals affixed to their counterparts in  FIGS. 1 to 7 . In the second embodiment, the second casing wall portion  111  is provided with a first mounting portion  114 A, which forms an extending portion, to which one end of the first engaging portion  123  and one end of the second engaging portion  125  are fixed. In the embodiment, the other end portion of the first engaging portion  123  and the other end portion of the second engaging portion  125  each act as a free end portion. Thus, the first gap  127  and the second gap  129  are open in the direction in which the second casing wall portion  111  extends and in the direction opposite to the first mounting portion  114 A. A projection  124  extending in the direction in which the second casing wall portion  111  extends is integrally provided at the other end portion of the first engaging portion  123 . A projection  126  extending in the direction opposite to the direction in which the second casing wall portion  111  extends is integrally provided at the other end portion of the second engaging portion  125 . In the embodiment, after the lead wires  7  pass through the first gap  127 , the lead wires  7  are inserted into the second gap  129  between the first engaging portion  123  and the second engaging portion  125  from a space between the free end portions of the first and second engaging portions  123  and  125  while the lead wires  7  are prevented from slipping out of the first gap  127 . As shown in  FIGS. 9A and 9B , the projections  124  and  126  engage the lead wires  7  to prevent the lead wires  7  from slipping out of the first and second gaps  127  and  129 . 
       FIGS. 10A to 10C  are each an enlarged perspective view of a lead wire engaging structure according to a third embodiment of the present invention.  FIGS. 11A and 11B  are each an enlarged perspective view in which lead wires are engaged in the third embodiment. In the figures, components similar to the components in the first embodiment shown in  FIGS. 1 to 7  are denoted by reference numerals obtained by adding 200 to the reference numerals affixed to their counterparts in  FIGS. 1 to 7 . In the third embodiment, the second casing wall portion  211  is provided with a first mounting portion  214 A, which forms an extending portion, to which one end of the first engaging portion  223  is fixed. In the embodiment, the other end portion of the first engaging portion  223  and the other end portion of the second engaging portion  225  are coupled to each other by a coupling portion  231 . One end of the second engaging portion  225  acts as a free end portion, and a third gap  237  is formed between one end of the second engaging portion  225  and the second casing wall portion  211 . The third gap  237  allows the lead wires  7  to pass. 
     The second engaging portion  225  according to the embodiment has a triangular shape, and a projection  226  extending in the direction opposite to the direction in which the second casing wall portion  211  extends is integrally provided at the other end of the second engaging portion  225 . In the embodiment, after the one or more lead wires  7  pass through the first gap  227 , the lead wires  7  are inserted into the second gap  229  between the first engaging portion  223  and the second engaging portion  225  through the third gap  237 . Because the third gap  237  is formed between the first mounting portion  214 A and the second engaging portion  225 , the lead wires  7  inserted into the first gap  227  do not slip out of the first gap  227  during an engaging operation. 
     In the embodiments described above, the present invention is applied to a centrifugal fan. It is a matter of course, however, that the lead wire engaging structure according to the present invention may be applied to any electric apparatus other than centrifugal fans that includes an electric apparatus casing including a first casing wall portion along which lead wires extend and a second casing wall portion extending from the first casing wall portion in an intersecting direction intersecting the direction in which the first casing wall portion extends. 
     While certain features of the invention have been described with reference to example embodiments, the description is not intended to be construed in a limiting sense. Various modifications of the example embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains, are deemed to lie within the spirit and scope of the invention.