Patent Description:
In recent years, from the viewpoint of safety, more stringent electrical regulations require outdoor units of air-conditioning apparatuses to be additionally equipped with a thermal relay. Normally, an outdoor unit is provided with a control box. In the control box, various types of devices that serve as a controller configured to control the air-conditioning apparatus are accommodated (for example, Patent Literature <NUM>). In the control box, many electrical components are accommodated. Examples of the electrical components include a control substrate, an inverter, a capacitor, and a terminal.

Since this control box is operated by a worker during trial run of the air-conditioning apparatus, in general, the control box needs to be installed at a location that is easily accessible for the worker. In addition, in the control box, many heat-producing devices are accommodated, such as an inverter and a capacitor. For this reason, the control box needs to be installed at a location where the internal heat-producing devices can be sufficiently cooled by air introduced from the outside. Furthermore, in view of work efficiency for a worker and the necessity to avoid the influence of rain that rebounds from the bottom side of the outdoor unit, the control box needs to be positioned at a given height or more from the installation surface of the outdoor unit.

Patent Literature <NUM> relates to a heat exchanger unit includes an electric equipment box in which electric equipment and for controlling equipment or the like are housed. The electrical equipment box comprises a first electrical equipment box and a second electrical equipment box. The electrical equipment substrate of the second electric equipment box provided on the bottom plate of the unit is attached to an attaching plate. The attaching plate and an electrical equipment cover form the second electrical equipment box. An attaching means connected to the attaching plate by a screw and a cover form the first electric equipment box. The first electrical equipment box is housed in a main unit and the second electrical equipment box is provided on the bottom plate, namely, on the lower surface of the unit. Thus, the heat exchanger unit is installed in a chamber facing an outdoor part called a pipe shaft of a multiple dwelling house or an apartment, etc..

Patent Literature <NUM>, according to its abstract, relates to an outdoor unit for a refrigeration apparatus, the outdoor unit being capable of suppressing decrease in reliability and increase in cost. The outdoor unit includes: an outdoor unit casing; an electric component including a high-voltage component and a low-voltage component; an electric component box disposed in the outdoor unit casing; a high-voltage wire configured to carry a voltage or a current between the high-voltage component and a device corresponding to the high-voltage component; a low-voltage wire configured to carry a voltage or a current between the low-voltage component and a device corresponding to the low-voltage component, the voltage or current being smaller in value than the voltage or current fed to the high-voltage wire; and a cover unit configured to suppress the entry of liquid into the electric component box. The electric component box has in its lateral side a high-voltage wire through-hole through which the high-voltage wire is drawn into the electric component box, and a low-voltage wire through-hole through which the low-voltage wire is drawn into the electric component box. The cover unit (a first side face cover) is disposed on an outer face of the electric component box, is located along the high-voltage wire through-hole and the low-voltage wire through-hole, and covers both the high-voltage wire through-hole and the low-voltage wire through-hole from above and from sideward.

Patent Literature <NUM>, according to its abstract, states that, to provide a refrigeration cycle device and a method of controlling the same, capable of selectively driving an electric fan corresponding to a drive control circuit of a refrigerant circuit during operation, of enhancing a power-saving effect, and of preventing deposition of dust on the drive control circuit, a refrigeration cycle device comprises: an electric component; and an electric fan for sending cooling air to the electric component. A temperature of the electric component is calculated, and an operation of the electric fan is controlled depending on the calculated temperature.

Patent Literature <NUM>, according to its abstract, relates to an air conditioner electrical box assembly, which comprises a first electrical box, a second electrical box and electrical elements used for controlling an air conditioner, wherein parts of the electrical elements are positioned in the first electrical box, and the other parts of the electrical elements are positioned in the second electrical box; calorific value in each electrical element positioned on the second electrical box is greater than the calorific value in any electrical element positioned on the first electrical box; the first electrical box is nearer to a fan than the second electrical box. The electrical elements are more reasonably arranged and more conveniently, the inner space of an air conditioner is saved, and meanwhile, more convenience is brought to the electrical elements. This document also provides an air conditioner outdoor unit comprising the air conditioner electrical box assembly. On other aspects, this document also provides an upper-air-out air conditioner outdoor unit.

In a case where an outdoor unit is additionally equipped with a thermal relay, it is conceivable in general that the thermal relay is also accommodated in the control box along with various types of electrical components. However, there are many electrical components accommodated in the control box. Accordingly, it is difficult to additionally accommodate the thermal relay in the control box.

It is also conceivable to increase the size of the control box to additionally accommodate the thermal relay therein. However, it is difficult to ensure a space sufficient to install the control box with an increased size at such a regular installation location as to satisfy the limitations described above.

The present invention thereafter referred to as disclosure has been made in view of the above problems associated with the known technique, and it is an object of the present disclosure to provide an outdoor unit of an air-conditioning apparatus in which a thermal relay can be accommodated properly in the outdoor unit without affecting the installation location of a control box.

According to the present disclosure, an outdoor unit of an air-conditioning apparatus as defined in independent claim <NUM> is provided. Further embodiments of the claimed invention are defined in the dependent claims. Although the claimed invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the claimed invention.

As described above, according to the present disclosure, the devices producing a smaller amount of heat are accommodated in the electrical box that is formed separately from the control box. With this configuration, while the control box is maintained at its installation location, additional thermal relays can be properly installed in the outdoor unit.

Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. The present disclosure is not limited to the embodiment described below, and can be variously modified without departing from the scope of the present invention as defined in the claims. In addition, the present disclosure includes all combinations of configurations that can be combined among the configurations shown in the embodiment described below as long as falling within the scope of the claims. The shape, size, location, and other factors of the constituent components described in each of the drawings may be appropriately changed within the scope of the present disclosure.

In the descriptions below, terms that represent directions (for example, "up," "down," "right," "left," "front," and "rear") are appropriately used for the sake of easily understanding the present disclosure. However, these terms are used merely for description purposes, and the present disclosure is not limited by these terms. In the embodiment described below, the terms such as "up," "down," "right," "left," "front," and "rear" are used in a state where the installation plate is viewed from the front. Note that the relative relationship of sizes of the constituent components, the shapes of the constituent components, and the like in the drawings may differ from those of actual ones.

An outdoor unit of an air-conditioning apparatus according to the present Embodiment <NUM> is described below. The outdoor unit according to the present Embodiment <NUM> is connected to an indoor unit by a heat medium pipe to allow a heat medium such as water or brine to circulate through the heat medium pipe. This outdoor unit is used as, for example, a heat source unit of a heat pump device.

<FIG> is a schematic view illustrating an example of the exterior appearance of the outdoor unit of an air-conditioning apparatus according to the present Embodiment <NUM>. <FIG> is a schematic cross-sectional view of the outdoor unit in <FIG> when viewed in the direction from the front. <FIG> is a schematic cross-sectional view of the outdoor unit in <FIG> when viewed in the direction from the top. Note that <FIG> omits illustrations of a lower portion of a front panel 2B for the sake of easily understanding the internal structure of the outdoor unit <NUM>. <FIG> schematically illustrate various types of devices provided inside the outdoor unit.

As illustrated in <FIG>, the outdoor unit <NUM> is formed into, for example, a cuboid shape, and the outer shell of the outdoor unit <NUM> is made up of a housing <NUM>. The housing <NUM> is made up of a top panel 2A, a front panel 2B, a rear panel 2C, two side panels 2D, and a bottom panel 2E. The bottom panel 2E also serves as a drain pan through which drain water, and rain water or other liquid having entered the inside of the outdoor unit <NUM> is discharged to the outside. Note that the drain pan is not limited to this example, and may be provided separately from the bottom panel 2E as another example.

Suction ports <NUM> are provided on the front panel 2B, the rear panel 2C, and the two side panels 2D to introduce the outside air through the suction ports <NUM>. At least one of the surfaces defined by the front panel 2B, the rear panel 2C, and the two side panels 2D is used as a work surface when a worker performs maintenance work. In this example, the surface defined by the front panel 2B is used as the work surface.

The front panel 2B, the rear panel 2C, and the two side panels 2D are provided along the peripheral edge portion of the bottom panel 2E, extending upward from the bottom panel 2E. The top panel 2A is provided on top of these panels. A discharge port <NUM> is provided on the top panel 2A to discharge air in the outdoor unit <NUM> to the outside through the discharge port <NUM>. The discharge port <NUM> is made up of a fan 4A that serves as a discharge mechanism, and a fan guard 4B provided to cover the fan 4A and its surroundings. A heat-source-side heat exchanger <NUM> is provided at the peripheral edge portion on three sides of the bottom panel 2E, other than one side near the front panel 2B, such that the heat-source-side heat exchanger <NUM> extends along the rear panel 2C and the two side panels 2D.

Next, the internal structure of the outdoor unit <NUM> is described. <FIG> is a schematic view illustrating an example of the internal structure of the outdoor unit according to the present Embodiment <NUM>. Note that for the sake of easily understanding the internal structure of the outdoor unit <NUM>, <FIG> omits illustrations of the housing <NUM> and devices which do not need to be described.

In the housing <NUM> of the outdoor unit <NUM>, various types of refrigeration cycle-related devices are accommodated. Examples of the refrigeration cycle-related devices include a compressor <NUM> that compresses refrigerant, a pressure reducing device (not illustrated) that reduces the pressure of refrigerant, and a water heat exchanger <NUM> that exchanges heat between the refrigerant and the heat medium. These devices, including the compressor <NUM>, the heat-source-side heat exchanger <NUM>, the pressure reducing device, and the water heat exchanger <NUM>, are connected by a refrigerant pipe to allow the refrigerant to circulate through these devices. This refrigerant pipe is also accommodated in the housing <NUM>. A heat medium pipe <NUM> through which the heat medium circulates is connected to the water heat exchanger <NUM>. The heat medium pipe <NUM> is also accommodated in the housing <NUM>. The outdoor unit <NUM> has a control box <NUM> and an electrical box <NUM> accommodated therein.

In the control box <NUM>, electrical components are accommodated. The electrical components serve as a controller configured to control the refrigeration cycle-related devices such as the compressor <NUM> and the pressure reducing device provided in the air-conditioning apparatus including the outdoor unit <NUM>. Examples of the electrical components accommodated in the control box <NUM> include a control substrate, an inverter, a capacitor, and a terminal.

Since the control box <NUM> is operated by a worker during trial run of the air-conditioning apparatus, the control box <NUM> needs to be installed at a location that is easily accessible for the worker. In the control box <NUM>, many heat-producing devices such as an inverter and a capacitor are accommodated. The heat-producing devices produce a relatively large amount of heat and thus need heat dissipation means. Accordingly, it is necessary to position the internal heat-producing devices at a location where they can be sufficiently cooled. Furthermore, in consideration of work efficiency for a worker, the influence of rain that rebounds from the bottom panel 2E, and other factors, the control box <NUM> needs to be installed at a given height or more from the bottom panel 2E. Therefore, in the outdoor unit <NUM> according to the present Embodiment <NUM>, the control box <NUM> is installed, extending along the front panel 2B that is a panel as the work surface, while being installed at a given height or more from the bottom panel 2E.

<FIG> is a schematic view illustrating an example of the internal configuration of the electrical box in <FIG>. As illustrated in <FIG>, thermal relays <NUM> are accommodated in the electrical box <NUM>. In this example, two thermal relays 21a and 21b are accommodated in the electrical box <NUM>.

The thermal relays <NUM> are provided to protect motors from burnout caused by an overcurrent flow due to an overload on the motors or other reasons. In the outdoor unit <NUM> according to the present Embodiment <NUM>, motors are mounted in the compressor <NUM> and the fan 4A. The thermal relays <NUM> are provided to protect these motors from burnout. Note that the outdoor unit <NUM> of an air-conditioning apparatus uses a plurality of rotational elements with different capacities, such as the compressor <NUM> and the fan 4A. In view of that, preferably a plurality of thermal relays <NUM> are provided corresponding to the individual rotational elements.

In the electrical box <NUM>, devices that produce a relatively small amount of heat, including the plurality of thermal relays <NUM>, as well as devices that do not need regular maintenance are accommodated. The "devices that produce a relatively small amount of heat" refer to a device that does not need heat dissipation means. Examples of the device include a device that produces a smaller amount of heat and thus does not need to be cooled by a heatsink, compared to the electrical components accommodated in the control box <NUM> such as an inverter and a variable voltage regulator.

<FIG> is a schematic view illustrating an example of the connection state of wires to the electrical box in <FIG>. As illustrated in <FIG>, a plurality of electric wires <NUM> are connected to the devices accommodated in the electrical box <NUM>. These electric wires <NUM> are connected from the lower side of the electrical box <NUM>. This can prevent rain water or other liquid from entering the electrical box <NUM> via the wires.

The electric wires <NUM> include a first electric wire 22a that is a power wire, and a second electric wire 22b other than the power wire. On the lower side of the electrical box <NUM>, a first wire connection port 23a and a second wire connection port 23b are formed. The first wire connection port 23a is a connection port for the first electric wire 22a. The second wire connection port 23b is a connection port for the second electric wire 22b.

In the present Embodiment <NUM>, the connection ports for the electric wires <NUM> are provided in such a manner as to separate the connection port for a power wire from the connection port for a wire other than the power wire. This can reduce the likelihood of improper wiring at the time of manufacturing the outdoor unit <NUM>. This also helps a worker to easily distinguish between the wires during on-site work.

Preferably, the electrical box <NUM> is installed between motor-mounted devices, for example, between the compressor <NUM> and the fan 4A. This allows the compressor <NUM> and the fan 4A to be connected to the electrical box <NUM> with a shortest distance between them, so that the length of the wire can be minimized and work efficiency for a worker can be improved.

When refrigerant leaks in the outdoor unit <NUM>, the refrigerant is stagnant in the lower portion of the outdoor unit <NUM>. The reason for this is that the refrigerant is heavier than air. Accordingly, when flammable refrigerant is used as the refrigerant, the electrical box <NUM> is installed at a height equal to or greater than the set height of approximately <NUM> from the installation surface of the outdoor unit <NUM> to prevent the occurrence of fire caused by the stagnant refrigerant.

As described above, in the electrical box <NUM>, devices that produce a relatively small amount of heat and thus do not need heat dissipation means are accommodated. As the devices do not need heat dissipation means, these devices do not need regular maintenance. Consequently, the electrical box <NUM> does not need to be installed at a location that is accessible for a worker. For example, the electrical box <NUM> may be installed at a location where it is difficult for a worker to see the work spot during work and where it is difficult to access the electrical box <NUM>.

<FIG> is a schematic view illustrating an example of the internal structure of the outdoor unit in <FIG> when viewed in the direction from the rear. As illustrated in <FIG>, for example, the electrical box <NUM> may be installed at such a location that the electrical box <NUM> extends along the rear panel 2C facing the front panel 2B that is a panel as the work surface, or may be installed on the back side (rear side) of a compressor box in which the compressor <NUM> is accommodated or on the back side (rear side) of the control box <NUM> when viewed from the front side.

The devices that do not need regular maintenance are accommodated in the electrical box <NUM>. Accordingly, there are no limitations on the installation location of the electrical box <NUM>, so that the electrical box <NUM> can be installed at a location where it is difficult for a worker to access it. For this reason, the electrical box <NUM> can be installed at any location without taking the space in the outdoor unit <NUM> into consideration.

In the outdoor unit <NUM>, for example, the heat medium pipe <NUM> is accommodated. Since a heat medium with heat circulates through the heat medium pipe <NUM>, the temperature in the vicinity of the heat medium pipe <NUM> can possibly be increased compared to the temperature at other locations. In the present Embodiment <NUM>, maintenance-free devices that produce a relatively small amount of heat are accommodated in the electrical box <NUM>. In view of that, the electrical box <NUM> can still be installed even in the vicinity of the heat medium pipe <NUM> that can possibly heat the inside of the electrical box <NUM> as described above.

As having been explained in the section "Background Art," it is considered normal to accommodate a thermal relay in the control box <NUM> when the thermal relay is added compared to the known technique. The control box <NUM> needs to increase its size to accommodate the thermal relay therein. However, assuming that the control box <NUM> is maintained at its known installation location that satisfies the limitations on its installation, it is difficult to increase the size of the control box <NUM> from the viewpoint of insufficient space.

In contrast to this, in the present Embodiment <NUM>, the plurality of thermal relays <NUM> are accommodated in the electrical box <NUM> that is formed separately from the control box <NUM>, and the electrical box <NUM> is installed at a different location from the control box <NUM>. This allows additional thermal relays to be installed in the outdoor unit <NUM>, while the control box <NUM> is maintained at its installation location.

As described above, in the outdoor unit <NUM> of an air-conditioning apparatus according to the present Embodiment <NUM>, devices that produce a relatively small amount of heat are accommodated in the electrical box <NUM> that is formed separately from the control box <NUM>. This allows additional thermal relays <NUM> to be installed in the outdoor unit <NUM>, while the control box <NUM> is maintained at its installation location.

In the outdoor unit <NUM>, the electric wires <NUM> for the devices accommodated in the electrical box <NUM> are connected from the lower side of the electrical box <NUM>. This can prevent rain water or other liquid from entering the electrical box <NUM> via the electric wires <NUM>.

In the outdoor unit <NUM>, the electrical box <NUM> includes the first wire connection port 23a that is a connection port for the first electric wire 22a, and the second wire connection port 23b that is a connection port for the second electric wire 22b. As described above, the connection ports for the electric wires <NUM> are provided in such a manner as to separate the connection port for a power wire from the connection port for a wire other than the power wire. This can reduce the likelihood of improper wiring at the time of manufacturing the outdoor unit <NUM>, and can help a worker to easily distinguish between the wires during on-site work.

In the outdoor unit <NUM>, the electrical box <NUM> is installed between the compressor <NUM> and the fan 4A, each of which has a motor mounted therein. This allows the compressor <NUM> and the fan 4A to be connected to the electrical box <NUM> with a shortest distance between them, so that the length of the wire can be minimized and work efficiency for a worker can be improved.

In the outdoor unit <NUM>, the electrical box <NUM> is installed at a height equal to or greater than the set height from the installation surface. This can prevent the occurrence of fire caused by stagnant refrigerant when the refrigerant leaks.

In the outdoor unit <NUM>, the electrical box is installed in the vicinity of the heat medium pipe <NUM>. The devices that do not need heat dissipation means or regular maintenance are accommodated in the electrical box <NUM>. Therefore, the electrical box <NUM> can still be installed even in the vicinity of the heat medium pipe <NUM> that can possibly heat the inside of the electrical box <NUM>.

Claim 1:
An outdoor unit (<NUM>) of an air-conditioning apparatus, wherein
the outdoor unit (<NUM>) has a housing (<NUM>) constituting an outer shell of the outdoor unit (<NUM>), a control box (<NUM>) and an electrical box (<NUM>), the control box (<NUM>) and the electrical box (<NUM>) being accommodated in the housing (<NUM>),
in the control box (<NUM>), devices serving as a controller configured to control refrigeration cycle-related devices are accommodated, and
in the electrical box (<NUM>), devices are accommodated, characterized in that
the devices accommodated in the electrical box (<NUM>) include a thermal relay (<NUM>),
the devices accommodated in the electrical box (<NUM>) produce a smaller amount of heat compared to the devices accommodated in the control box (<NUM>), and
the electrical box (<NUM>) is formed separately from the control box (<NUM>).