Patent ID: 12188664

DETAILED DESCRIPTION

Embodiments described in the disclosure and configurations shown in the drawings are merely examples of the embodiments of the disclosure, and may be modified in various different ways at the time of filing of the application to replace the embodiments and drawings of the disclosure.

In addition, the same reference numerals or signs shown in the drawings of the disclosure indicate elements or components performing substantially the same function.

Also, the terms used herein are used to describe the embodiments and are not intended to limit and/or restrict the disclosure. The singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. In this disclosure, the terms “including”, “having”, and the like are used to specify features, numbers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more of the features, elements, steps, operations, elements, components, or combinations thereof.

It will be understood that, although the terms first, second, third, etc., may be used herein to describe various elements, elements are not limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the disclosure, a first element may be termed as a second element, and a second element may be termed as a first element.

The term of “and/or” includes a plurality of combinations of relevant items or any one item among a plurality of relevant items. For example, the scope of the expression or phrase “A and/or B” includes the item “A”, the item “B”, and the combination of items “A and B”.

In addition, the scope of the expression or phrase “at least one of A and B” is intended to include all of the following: (1) at least one of A, (2) at least one of B, and (3) at least one A and at least one of B. Likewise, the scope of the expression or phrase “at least one of A, B, and C” is intended to include all of the following: (1) at least one of A, (2) at least one of B, (3) at least one of C, (4) at least one of A and at least one of B, (5) at least one of A and at least one of C, (6) at least one of B and at least one of C, and (7) at least one of A, at least one of B, and at least one of C.

When it is stated in the disclosure that one element is “connected to” or “coupled to” another element, the expression encompasses an example of a direct connection or direct coupling, as well as a connection or coupling with another element interposed therebetween.

In the following detailed description, the terms of “upper portion”, “lower portion” and the like may be defined by the drawings, but the shape and the location of the component is not limited by the term.

In addition, a case in which a fan is applied to a ceiling-type air conditioner will be described as an example, but the fan may be appliable to other types of air conditioners such as a stand-type air conditioner or a wall-mounted air conditioner, and other home appliances such as a refrigerator and a cleaner.

The disclosure relates to providing a fan having an improved performance, an air conditioner including the fan, and a method for manufacturing the fan.

According to examples of the disclosure described herein, because a fan may be formed as a single piece, it is possible to reduce the number of points, in which energy loss may occur, in comparison with a case in which a fan is manufactured by manufacturing each component of the fan. Therefore, it is possible to improve the performance of the fan.

According to examples of the disclosure described herein, because a fan is formed in such a way that an inlet part is formed along an air flow direction, it is possible to reduce energy loss due to turbulence.

Hereinafter example embodiments of the disclosure will be described in detail with reference to the accompanying drawings.

FIG.1is a view illustrating an air conditioner according to an embodiment of the disclosure.FIG.2is a longitudinal sectional view of the air conditioner shown inFIG.1.

Referring toFIGS.1and2, an air conditioner1according to an embodiment of the disclosure may be installed on a ceiling C. At least a portion of the air conditioner1may be embedded in the ceiling C.

The air conditioner1may include a housing10including a housing inlet20and a housing outlet21, a heat exchanger30provided inside the housing10, and a fan100configured to move air.

The housing10may have a rectangular housing shape that is opened downward to allow components of the air conditioner1to be accommodated therein. The housing10may include an upper housing11located inside the ceiling C, and a lower housing13coupled to a lower side of the upper housing11.

The housing inlet20, through which air is introduced, may be formed in a central portion of the lower housing13, and the housing outlet21, through which air is discharged, may be formed at an outer circumference (periphery) of the housing inlet20. An inlet flow path P1, in which air, which is introduced through the housing inlet20, flows, may be provided between the housing inlet20and the fan100, and an outlet flow path P2, in which air, which is discharged by the fan100, flows, may be provided between the housing outlet21and the fan100.

The housing outlet21may be formed adjacent to each edge so as to correspond to the outer circumference of the lower housing13. For example, four housing outlets21may be formed as illustrated inFIG.1, on each side of the lower housing13which may have a rectangular or square shape. That is, two housing outlets21may be formed in an X-axis direction and two housing outlets21may be formed in a Y-axis direction. The four housing outlets21are arranged to discharge air to all four sides of a room, respectively. With the structure, the air conditioner1may suction air from a lower side, cool or heat the suctioned air, and then discharge the cooled or heated air to the lower side again.

A grill17may be coupled to a bottom of the lower housing13to filter out dust in the air introduced into the housing inlet20.

The housing10may include an inlet guide19. The inlet guide19may be provided to guide air, which is introduced through the housing inlet20, to the fan100.

The heat exchanger30may be formed in a rectangular ring shape and located on an outer side of the fan100in the housing10. The heat exchanger30is not limited to a rectangular ring shape, and may be provided in various shapes, such as a circular shape, an oval shape, or a polygonal shape.

The heat exchanger30may be placed on (or above) a drain tray16, and thus condensed water generated in the heat exchanger30may be collected in the drain tray16. The drain tray16may be formed in a shape corresponding to a shape of the heat exchanger30. That is, when the heat exchanger30has a rectangular ring shape, the drain tray16may also have a rectangular ring shape, and when the heat exchanger30has a circular shape, the drain tray16may also have a circular shape.

The fan100may be installed in a substantially central portion of the housing10. The fan100may be located inside the heat exchanger30. The fan100may be a centrifugal fan configured to suction air in an axial direction and discharge the air in a radial direction. A fan motor109configured to drive the fan100may be provided in the air conditioner1.

With the configuration, the air conditioner1may suction air from the room, cool the suctioned air, and then discharge the cooled air to the room, or heat the suctioned air, and then discharge the heated air to the room.

FIG.3is a view illustrating the fan shown inFIG.2.FIG.4is a sectional view taken along line B-B shown inFIG.3.FIG.5is a view illustrating a lower portion of the fan shown inFIG.3.FIG.6is an enlarged view of a portion A shown inFIG.2.FIG.7is a sectional view taken along line F-F shown inFIG.5.FIG.8is a sectional view taken along line G-G shown inFIG.5.FIG.9is a sectional view taken along line C-C shown inFIG.4.FIG.10is a sectional view taken along line D-D shown inFIG.4.FIG.11is a sectional view taken along line E-E shown inFIG.4.

Referring toFIGS.3to5, the fan100may include an inlet part110, a blade120, and a base130. The inlet part110, the blade120, and the base130may be integrally formed. The fan100may be injection molded as a single piece.

The inlet part110may be formed in a substantially circular shape. The inlet part110may have a substantially doughnut shape with an open center. The inlet part110may form a fan inlet119. Air may be introduced into the fan100through the fan inlet119. The inlet part110has a shape provided to guide the air, which is introduced through the fan inlet119, to be discharged through a fan outlet139. The inlet part110may have a shape in which the inlet part110is widened outward in the radial direction as the inlet part110is close to an upper end.

Referring toFIGS.4and6, an end portion118forming the fan inlet119of the inlet part110may be formed to be inclined at a predetermined angle (a) with respect to a rotation axis direction. The end portion118of the inlet part110may have a shape that is narrowed inward in the radial direction as the end portion118is close to a lower end. The end portion118of the inlet part110may extend along a direction in which air is introduced and discharged. The end portion118of the inlet part110may be formed to allow air, which is introduced through the fan inlet119, to be smoothly moved toward the fan outlet139.

The inlet guide19may be formed to correspond to the fan inlet119of the inlet part110. The inlet guide19may be inclined at a predetermined angle (b) with respect to the rotation axis direction of the fan100. The inlet guide19may have a shape that is widened outward in the radial direction as the inlet guide19is close to a position in which air is introduced. The inlet guide19may be inclined in substantially the same direction as the end portion118of the inlet part110.

The inlet part110may include a core guide116, and the core guide116is provided to guide outer cores243and244(seeFIGS.12-19) in response to the outer cores243and244of a manufacturing apparatus2being separated in a process of manufacturing the fan100. The core guide116may be formed in a plane substantially perpendicular to the rotation axis of the fan100. The core guide116may be formed substantially parallel to the base130. The core guide116may be formed on a portion, which is in contact with a first surface121of the blade120, of the inlet part110. In response to a second outer core244being separated after a first outer core243is separated from the fan100, the core guide116may guide the second outer core244. The second outer core244may be easily separated from the fan100by the core guide116.

The blade120may be positioned between the inlet part110and the base130. The blade120may extend from the base130to the inlet part110. The blade120may be spaced apart by a predetermined distance along a circumference of the fan100and may be provided in plurality. The blade120may include the first surface121on which a positive pressure is formed as the fan100is rotated, and a second surface122on which a negative pressure is formed as the fan100is rotated. The first surface121may be formed to face outward in the radial direction, and the second surface122may be formed to face inward in the radial direction. As the fan100is rotated by the fan motor109, the fan100may suction air by the negative pressure formed on the second surface122and discharge the air by the positive pressure formed on the first surface121.

The second surface122may include a first guide surface122aand a second guide surface122b, and the first guide surface122amay guide separation of the outer cores243and244and the second guide surface122bmay guide separation of inner cores241and242and separation of a second mold220. The first guide surface122amay be inclined in a direction different from a direction of the second guide surface122b.

Referring toFIG.7, the first guide surface122amay be formed to correspond to a direction in which the outer cores243and244are separated. The first guide surface122amay be inclined to the outside in the radial direction as the first guide surface122ais close to or adjacent to an upper end of the blade or fan. The first guide surface122amay be inclined to the outside in the radial direction as the first guide surface122ais close to or adjacent to the base130.

Referring toFIG.8, the second guide surface122bmay be formed to correspond to a direction in which the inner cores241and243and the second mold220are separated. The second guide surface122bmay be inclined to the outside in the radial direction as the second guide surface122bis close to a lower end.

The blade120may include stepped portions123and124formed at a portion where the first guide surface122aand the second guide surface122b, which are inclined in different directions, are in contact with each other. The stepped portions123and124may be positioned at a boundary between the first guide surface122aand the second guide surface122b.

Referring toFIG.9illustrating a sectional view taken along line C-C shown inFIG.4when viewed from above, a first stepped portion123may be formed on an upper portion of the blade120. The second guide surface122bmay be inclined to the outside in the radial direction as the second guide surface122bis close to the inlet part110. Because the first guide surface122ais inclined to the outside in the radial direction as the first guide surface122ais close to the upper portion of the blade120, the second guide surface122bprotrudes relatively more than the first guide surface122a. Accordingly, the first stepped portion123is formed to include a surface facing the first guide surface122a.

Referring toFIG.10illustrating a sectional view taken along line D-D shown inFIG.4when viewed from above, the first guide surface122aand the second guide surface122bmay be in contact with each other to form substantially the same plane in a substantially central portion of the blade120.

Referring toFIG.11illustrating a sectional view taken along line E-E shown inFIG.4when viewed from above, the second stepped portion124may be formed at a lower portion of the blade120. Because the second guide surface122bis inclined to the outside in the radial direction as the second guide surface122bis close to a lower portion of the blade120, the first guide surface122aprotrudes relatively more than the second guide surface122b. Accordingly, the second stepped portion124is formed to include a surface facing the second guide surface122b.

The blade120according to an embodiment of the disclosure includes the first guide surface122aand the second guide surface122bformed with different inclinations toward the base130from a substantially central portion between the base130and the inlet part110, and the first guide surface122aand the second guide surface122bare formed with different inclinations toward the inlet part110from a substantially central portion between the base130and the inlet part110. Therefore, it is possible to reduce the size of the stepped portion by 1/2 in comparison with a case in which the first guide surface122aand the second guide surface122bare formed with different inclinations from the base130to the inlet part110or a case in which the first guide surface122aand the second guide surface122bare formed with different inclinations from the inlet part110to the base130. Accordingly, the fan100including the blade120according to an embodiment of the disclosure may have an effect of reducing resistance, noise, and/or vibration according to the air flow.

The base130may have a substantially disk shape. The base130may include a fan motor receiving portion134positioned in a substantially central portion of the base130. The fan motor receiving portion134may be formed to receive the fan motor109. The fan motor receiving portion134may extend along the rotation axis direction of the fan100.

The fan outlet139may be formed between the inlet part110and the base130. The base130may form the fan outlet139together with the inlet part110. The fan outlet139may be formed along the circumference of the fan100.

FIG.12is a view illustrating a state, in which the fan shown inFIG.3is molded using a mold, on the sectional view ofFIG.8.FIG.13is a view illustrating a state, in which the fan shown inFIG.3is molded using a mold, on the sectional view ofFIG.9.FIG.14is a view illustrating a state, in which the fan shown inFIG.3is molded using a mold, on the sectional view ofFIG.11.FIG.15is a view illustrating a state, in which an inner core shown inFIG.12is separated from the fan.FIG.16is a view illustrating a state in which an inner mold shown inFIG.15is separated from the fan.FIG.17is a view illustrating a state, in which the fan shown inFIG.7is molded using a mold, on the sectional view ofFIG.7.FIG.18is a view illustrating a state in which a second outer core is separated after a first outer core shown inFIG.17is separated.FIG.19is a sectional view taken along line H-H shown inFIG.18.

A process of molding the fan100using the molds220,241,242,243, and244will be described with reference toFIGS.12to19. However, for convenience of description, components for molding one blade120will be described, and although not illustrated, the components described below may be provided to correspond to each of the plurality of blades. The fan100may be injection molded by injecting resin into the molds220,241,242,243, and244.

Referring toFIG.12, the molds220,241,242,243, and244may include an inner mold220and inner cores241and242for molding an interior of the fan100. The inner mold220and a second inner core242may be provided to mold a portion of the second surface122of the blade120.

A first inner core241may be provided to be slidable with respect to the second inner core242. A first outer core243may be provided to be slidable with respect to a second outer core244.

The first outer core243and the second outer core244may be coupled to each other to form the first surface121of the blade120. The first outer core243may be located above the second outer core244.

The inner mold220and the second inner core242may be coupled to each other to form the second surface122of the blade120. The second mold220and the second inner core242may be located in a vertical direction.

Referring toFIGS.13and14, the molds220,241,242,243, and244may include the inner mold220, the second inner core242and the outer cores243and244for molding the second surface122of the blade120. The outer cores243and244come into contact with the first guide surface122aof the blade120. The inner mold220and the second inner core242come into contact with the second guide surface122b.

For example, referring toFIG.13, the inner mold220and the first outer core243may mold an upper portion of the blade120. The inner mold220and the first outer core243may come into contact with each other at a location corresponding to the first stepped portion123of the blade120. Accordingly, the inner mold220and the first outer core243may be easily separated from the fan100. The first outer core243is provided to mold the first stepped portion123.

Referring toFIG.14, the second inner core242and the second outer core244may mold a lower portion of the blade120. The second inner core242and the second outer core244may come into contact with each other in the second stepped portion124of the blade120. Accordingly, the second inner core242and the second outer core244may be easily separated from the fan100. The second inner core242is provided to mold the second stepped portion124.

Referring toFIG.15, as the first inner core241is lowered, the second inner core242is moved toward the rotation axis of the fan100. Accordingly, the second inner core242may be separated from the fan100.

Referring toFIG.16, as the second inner core242is separated from the fan100, the inner mold220may be separated from the fan100. At this time, because the second guide surface122bof the blade120is inclined so as to be away from the rotation axis of the fan100in the radial direction as the second guide surface122bis close to a lower end, the inner mold220may be easily separated toward the lower side of the fan100.

Referring toFIGS.17and19, the outer cores243and244may be separated from the fan100after the inner mold220and the inner cores241and242are separated.

Referring toFIG.19, the first outer core243may be separated from the fan100in a direction substantially perpendicular to the rotation axis of the fan100. For example, referring toFIG.3again, the first outer core243molding the blade marked with reference number122may be guided by the core guide116and then separated from the fan100. The first outer core243may be separated from the fan100in a direction substantially perpendicular to the rotation axis of the fan100, and thus the core guide116may be formed in a plane substantially perpendicular to the rotation axis of the fan100.

Referring toFIGS.18and19, as the first outer core243is separated from the fan100, the second outer core244may be separated from the fan100. For example, as the first outer core243is separated from the fan100, the second outer core244may be moved upward. The second outer core244may be separated from the inlet part110of the fan100while being moved upward. The second outer core244separated from the inlet part110of the fan100may be separated from the fan100in a direction substantially perpendicular to the rotation axis of the fan100in the same manner as the first outer core243.

In this case, because the first guide surface122aof the blade120is inclined so as to be away from the rotation axis of the fan100in the radial direction as the first guide surface122ais close to an upper end, the second outer core244may be easily separated to the upper side of the inlet part110of the fan100.

While the disclosure has been described with reference to example embodiments, it should be understood by those of skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the disclosure.