Manufacturing method of cooler

Abstract

To provide a manufacturing method of a cooler, in which a coolant is hardly contaminated during use.SOLUTION: A manufacturing method of a cooler, for fixing a first metal plate, a metal material having an uneven structure, and a second metal plate by a convex part of the metal material, comprises a step of selectively bonding a flux to the convex part of the metal material. The manufacturing method of the cooler for fixing the first metal plate, the metal material having the uneven structure, and the second metal plate by the convex part of the metal material, comprises step of: scattering a powder like flux to an uneven surface of the metal material; fixing the first metal plate, the metal material, and the second metal plate to the convex part of the metal material after the scattering; and removing the flux bonded to a concave part by splaying gas to the concave part after the fixing.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a cooler. [Background technology]

[0002] For example, roll-bonded panel-type coolers made of aluminum, which is lightweight and has excellent thermal conductivity, are used as heat exchangers for automobiles.

[0003] In the manufacturing method of such a cooler, the metal plates are fixed together, and in order to promote bonding between the metal plates, a chemical called flux, which is used to remove the oxide film formed on the surface of the metal plates, is sometimes used.

[0004] Patent Document 1 discloses "a method for applying flux to components to be brazed, the method comprising the steps of: heating the components; applying a mixed liquid of the flux to the components; and vaporizing a liquid component of the mixed liquid by the heat of the components brought about by the heating." [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2001-259522 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, in the above-mentioned conventional manufacturing method for a cooler, since the flux is applied to the entire surface of the metal plate, there was a problem that the flux remains in the refrigerant flow path inside the cooler after the cooler is manufactured, and the flux easily contaminates the refrigerant during use, for example by increasing the electrical conductivity of the refrigerant.

[0007] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to provide a method for manufacturing a cooler that is less likely to contaminate a refrigerant during use. [Means for solving the problem]

[0008] Means for solving the above problems include the following aspects. <1> A method for manufacturing a cooler, comprising the steps of: fixing a first metal plate, a metal material having a concave-convex structure, and a second metal plate together at convex portions of the metal material, the method comprising the steps of: A method for manufacturing a cooler, comprising the step of selectively applying flux to the protruding portions of the metal material. <2> The step of selectively depositing flux on the protruding portions of the metal material includes: selectively applying a solvent to the protruding portions of the metal material; spraying flux onto the uneven surface of the metal material; removing the flux adhering to the recessed portion of the metal material; Including, <1> A method for manufacturing the cooler according to claim 1. <3> The method further includes, after the removing step, a step of fixing the first metal plate, the metal material, and the second metal plate at the protruding portion of the metal material. <2> The manufacturing method of the cooler according to the present invention <4> A method for manufacturing a cooler, comprising the steps of: fixing a first metal plate, a metal material having a concave-convex structure, and a second metal plate together at convex portions of the metal material, the method comprising the steps of: Spraying a powdered flux onto the uneven surface of the metal material; After spraying, a step of fixing the first metal plate, the metal material, and the second metal plate by the convex portion of the metal material; a step of blowing a gas into the recessed portion after immobilization to remove the flux adhering to the recessed portion; A method for manufacturing a cooler comprising the steps of: <5> The step of blowing gas into the recesses after the immobilization to remove the flux attached to the recesses includes a step of pressurizing either the first metal plate or the second metal plate in a plate thickness direction at a pressure of 0.1 kPa to 300 kPa. <4> A method for manufacturing the cooler according to claim 1. Effect of the Invention

[0009] According to the present invention, a method for manufacturing a cooler that is less likely to contaminate a refrigerant during use is provided. [Brief description of the drawings]

[0010] [Figure 1] Fig. 1 is a schematic diagram showing an example of a manufacturing method for a cooler according to the first embodiment of the present invention. Fig. 1(A) is a schematic diagram showing an example of a coating step in the manufacturing method for a cooler according to the first embodiment of the present invention. Fig. 1(B) is a schematic diagram showing an example of a spraying step in the manufacturing method for a cooler according to the first embodiment of the present invention. Fig. 1(C) is a schematic diagram showing an example of a removal step in the manufacturing method for a cooler according to the first embodiment of the present invention. Fig. 1(D) is a schematic diagram showing an example of a fixing step in the manufacturing method for a cooler according to the first embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic diagram showing an example of a removing step in the method for producing a cooler according to the second embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment of the present invention will be described. The description is for illustrating the embodiment, and is not intended to limit the scope of the present invention.

[0012] In this specification, a numerical range indicated using "~" indicates a range that includes the numerical values ​​before and after "~" as the minimum and maximum values, respectively. In the present specification, the upper or lower limit of one numerical range may be replaced with the upper or lower limit of another numerical range. In addition, in the present specification, the upper or lower limit of the numerical range may be replaced with a value shown in the examples.

[0013] In this specification, the term "process" includes not only an independent process but also a process that cannot be clearly distinguished from other processes as long as the intended purpose of the process is achieved.

[0014] In this specification, when an embodiment is described with reference to the drawings, the configuration of the embodiment is not limited to the configuration shown in the drawings. Furthermore, the size of the members in each drawing is conceptual, and the relative relationship between the sizes of the members is not limited to this.

[0015] In this specification, each component may contain a plurality of corresponding substances. When the amount of each component in a composition is mentioned in this specification, if a plurality of substances corresponding to each component is present in the composition, the amount means the total amount of the plurality of substances present in the composition, unless otherwise specified.

[0016] In this specification, the term "alloy number" means "the alloy number specified in JIS H 4000:2014."

[0017] <Manufacturing method of cooler> (First aspect) The manufacturing method of a cooler according to the first aspect of the present invention includes fixing a first metal plate, a metal material having a concave-convex structure, and a second metal plate at the convex parts of the metal material, and includes a step of selectively attaching flux to the convex parts of the metal material (hereinafter, also referred to as an "attaching step"). By selectively attaching flux to the convex parts, a cooler can be manufactured in a state in which flux is selectively attached to the convex parts of the metal material, and therefore a cooler that is less likely to contaminate a refrigerant during use can be obtained.

[0018] Hereinafter, the manufacturing method of the cooler according to the first aspect of the present invention will be described in detail.

[0019] -First metal plate and second metal plate- The first metal plate and the second metal plate are flat metal materials. Examples of the material include aluminum or aluminum alloys. Examples of aluminum or aluminum alloys include pure Al (alloy number: 1000 series) such as 1050, 1100, 1200, etc.; Al-Cu alloys (alloy number: 2000 series) such as 2011, 2014, 2017, 2024, etc.; Al-Mn alloys (alloy number: 3000 series) such as 3003, 3004, etc.; Al-Si alloys (alloy number: 4000 series) such as 4032, 4545, etc.; Al-Mg alloys (alloy number: 5000 series) such as 5005, 5052, 5083, 5454, etc.; Al-Mg-Si alloys (alloy number: 6000 series) such as 6061, 6063, etc.; Al-Zn alloys (alloy number: 7000 series) such as 7075, etc. When the first metal plate and the second metal plate are made of aluminum or an aluminum alloy, a plate-like body made of alloy number 3003 is preferred from the viewpoints of excellent formability, weldability, and corrosion resistance.

[0020] The size of the first metal plate and the second metal plate is not particularly limited as long as the cooler can be manufactured, and may be, for example, 600 mm×300 mm.

[0021] The thickness of the first metal plate and the second metal plate is not particularly limited as long as the cooler can be manufactured, and may be, for example, 100 μm to 1000 μm.

[0022] -Metal material with uneven structure- The metal material having an uneven structure is a metal material having an uneven structure at least in a part thereof. For example, it may be a metal plate having an uneven structure in a part or all of the in-plane direction. The uneven structure can be fixed to the first metal plate and the second metal plate to manufacture a cooler, and is preferably formed so as to form a refrigerant flow path of the cooler when the cooler is manufactured. The uneven structure may be formed by press molding. Examples of the material include the same as those exemplified for the first metal plate and the second metal plate.

[0023] The metal material having a concave-convex structure may have a single layer structure or a multi-layer structure. When the metal material having a concave-convex structure is made of aluminum or an aluminum alloy, from the viewpoint of manufacturing a cooler by fixing it to the first metal plate and the second metal plate, a three-layer clad material is preferable, which is composed of a surface layer (e.g., 80 μm thick) made of alloy number 4545 (melting point: 577°C) of an Al-Si alloy acting as a brazing material, and a middle layer (e.g., 640 μm thick) made of alloy number 3003 (melting point: 643°C to 654°C).

[0024] The size of the metal material having the uneven structure is not particularly limited as long as the cooler can be manufactured using the metal material, and may be, for example, 600 mm x 300 mm.

[0025] The thickness of the metal material having the uneven structure is not particularly limited as long as the cooler can be manufactured using the metal material, and may be, for example, 100 μm to 1000 μm.

[0026] (Attachment process) In the adhesion step, the flux is selectively adhered to the convex portions of the metal material having a concave-convex structure. The adhesion method includes coating (roll coating, etc.), immersion, and the like. When the flux is selectively adhered to the convex portions of the metal material, it is preferable that the flux is adhered only to the convex portions of the concave-convex structure. The adhesion step preferably includes a step of selectively applying a solvent to the convex portions of the metal material having a concave-convex structure (hereinafter also referred to as the "coating step"; see FIG. 1(A)).

[0027] (Coating process) In the coating process, the solvent is selectively applied to the convex portions of the metal material having a concave-convex structure. The specific manner of coating is not particularly limited as long as the solvent can be selectively applied to the convex portions of the metal material. For example, it can be appropriately selected from known coating means such as a brush or a roll coater.

[0028] -solvent- The solvent is used to improve the adhesion of the flux to the convex parts of the metal material. By applying the solvent to the convex parts, the flux is selectively attached to the convex parts, making it easier to obtain a desired cooler. Examples of the solvent include organic solvents and water. Examples of the organic solvent include methanol, ethanol, acetone, etc. The solvent is not particularly limited as long as it improves the adhesion of the flux, but among the exemplified ones, water is preferred because it has a relatively high boiling point and there is little concern that the solvent will evaporate and disappear before the flux is attached.

[0029] The adhering step preferably includes a step of selectively applying a solvent to the convex portions of the metal material (application step), followed by a step of spraying flux on the uneven surface of the metal material (hereinafter also referred to as the "spraying step", see FIG. 1(B)), and a step of removing the flux sprayed on the uneven surface of the metal material (hereinafter also referred to as the "removing step", see FIG. 1(C)). By including the spraying step and the removing step, a cooler can be manufactured in a state in which flux is selectively adhered to the convex portions of the metal material having an uneven structure, making it easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0030] (Spraying process) In the spraying step, the flux is sprayed onto the uneven surface of the metal material having an uneven structure.

[0031] -Flux- Examples of the flux to be sprayed include resin-based flux, organic flux, and inorganic flux. Examples of the resin-based flux include rosin containing abietic acid, palustric acid, dehydroabietic acid, isopimaric acid, neoabietic acid, and pimaric acid as main components, etc. Examples of the organic acid-based flux include aliphatic carboxylic acids, aromatic carboxylic acids, etc. Examples of inorganic acid fluxes include ammonium bromide, ammonium chloride, and potassium aluminate tetrafluoride (KAlF4). Among these, potassium aluminate tetrafluoride (KAlF4) is preferred when the metal material is made of aluminum or an aluminum alloy, because it melts at high temperatures (546°C) and exhibits strong activity, and is particularly useful for removing the oxide film (aluminum oxide (Al2O3) film) formed on the surface of the metal material. In addition, the flux is preferably used in a single form since there is no concern that its activity will be inhibited and there is no need to remove the binder resin by heating prior to fixation. In addition, the flux is preferably in a powder form since it is easy to remove in the removal process.

[0032] When the flux is in powder form, the particle size of the flux is preferably 3 μm to 10 μm from the viewpoints of dispersibility and adhesion to the convex parts of the metal material to which the solvent has been applied.

[0033] The method for spraying the flux on the uneven surface of the metal material is not particularly limited as long as the flux can be sprayed on the uneven surface of the metal material. The flux can be sprayed using a known coating method such as a spray coating method.

[0034] (Removal process) In the removing step, the flux attached to the recesses of the metal material having a concave-convex structure is removed. In the removing step, the entire flux attached to the recesses may be removed, or a part of the flux may be removed. When a part of the flux is removed, it is preferable that a small amount of flux remains in the recesses from the viewpoint of preventing contamination of the refrigerant during use.

[0035] The removal is preferably carried out by blowing a gas. The gas is preferably air. The removal is preferably carried out at a wind speed of 1 m / s to 5 m / s, more preferably at a wind speed of 2 m / s to 5 m / s, and even more preferably at a wind speed of 3 m / s to 4 m / s. By removing the flux at a wind speed in the above range, the flux can be selectively attached to the protruding parts of the metal material in an amount necessary for manufacturing the cooler, while the flux is unlikely to remain in the refrigerant flow path after the manufacture of the cooler, making it easier to obtain a cooler that is unlikely to contaminate the refrigerant during use.

[0036] The manufacturing method of the cooler according to the first aspect of the present invention preferably further includes, after the removing step, a step of fixing the first metal plate, the metal material, and the second metal plate at the protruding portion of the metal material (hereinafter also referred to as a "fixing step"; see FIG. 1(D)). By including the fixing step, it becomes easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0037] (immobilization process) In the fixing step, the first metal plate, the metal material, and the second metal plate are fixed together by the convex portion of the metal material.

[0038] The fixing method is not particularly limited as long as the first metal plate, the metal material, and the second metal plate can be fixed by the convex portion of the metal material. When the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, the fixing is preferably performed by brazing.

[0039] The fixing temperature is not particularly limited as long as the first metal plate, the metal material, and the second metal plate can be fixed by the convex portion of the metal material. When the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, the fixing temperature is preferably 580°C to 630°C. The fixing time is not particularly limited as long as the first metal plate, the metal material, and the second metal plate can be fixed together by the convex portion of the metal material. The fixing method is not particularly limited as long as the first metal plate, the metal material, and the second metal plate can be fixed by the convex portion of the metal material. When the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, they may be brazed in a furnace under a nitrogen atmosphere, for example.

[0040] According to the manufacturing method of a cooler according to the first aspect of the present invention described above, the present invention can provide a manufacturing method of a cooler that is less likely to contaminate the refrigerant during use.

[0041] (Second aspect) A method for manufacturing a cooler according to a second aspect of the present invention involves fixing a first metal plate, a metal material having an uneven structure, and a second metal plate at the protruding parts of the metal materials, and includes the steps of: spraying powdered flux on the uneven surfaces of the metal materials (hereinafter also referred to as the "spraying step"), fixing the first metal plate, the metal material, and the second metal plate at the protruding parts of the metal materials after the spraying (hereinafter also referred to as the "fixing step"), and removing the flux attached to the recesses by blowing gas into the recesses after the fixing (hereinafter also referred to as the "removing step"; see FIG. 2). After the flux is sprayed on the uneven surfaces including parts other than the protruding parts of the metal material, unnecessary flux remaining after the fixing step is completed is removed, so that a cooler that is less likely to contaminate the refrigerant during use can be obtained.

[0042] Hereinafter, the details of the manufacturing method for the cooler according to the second aspect of the present invention will be described.

[0043] -First metal plate and second metal plate- As the first metal plate and the second metal plate, the same metal plates as those exemplified in the manufacturing method for a cooler according to the first aspect of the present invention can be used.

[0044] -Metal material with uneven structure- As the metal material having an uneven structure, the same materials as those exemplified in the manufacturing method for a cooler according to the first embodiment of the present invention can be used.

[0045] (Spraying process) The scattering step can be carried out in the same manner as described in the manufacturing method of the cooler according to the first embodiment of the present invention, except that the flux is in powder form.

[0046] (immobilization process) The immobilization step can be carried out in the same manner as described in the manufacturing method for the cooler according to the first embodiment of the present invention.

[0047] (Removal process) In the removal step, the flux adhering to the recesses after immobilization is removed by blowing gas onto the recesses. The gas is preferably air. The removal is preferably performed at a wind speed of 1 m / s to 5 m / s, more preferably at a wind speed of 2 m / s to 5 m / s, and even more preferably at a wind speed of 3 m / s to 4 m / s. By removing the flux at a wind speed within the above range, unnecessary flux remaining in the refrigerant flow path of the cooler can be removed, and a cooler that is less likely to contaminate the refrigerant during use can be obtained.

[0048] The removing step preferably includes a step of applying pressure of 0.1 kPa to 300 kPa to either the first metal plate or the second metal plate in the plate thickness direction. In this case, the pressure is preferably 0.1 kPa to 300 kPa, more preferably 10 kPa to 250 kPa, and even more preferably 50 kPa to 200 kPa. By applying a pressure in the above range, the flux can be removed from the refrigerant flow path without damaging the cooler, and a cooler that is less likely to contaminate the refrigerant during use can be easily obtained.

[0049] According to the manufacturing method of a cooler according to the second aspect of the present invention described above, the present invention can provide a manufacturing method of a cooler that is less likely to contaminate the refrigerant during use. [Explanation of symbols]

[0050] 10 Metallic material with uneven structure 20 First metal plate and second metal plate 30 Cooler S Solvent R Roller F Flux

Claims

1. A method for manufacturing a cooler, comprising the steps of: fixing a first metal plate, a metal material having a concave-convex structure, and a second metal plate together at a convex portion of the metal material, the method comprising the steps of: A method for manufacturing a cooler, comprising the step of selectively applying flux to the protruding portions of the metal material.

2. The step of selectively depositing flux on the protruding portions of the metal material includes: selectively applying a solvent to the protruding portions of the metal material; spraying flux onto the uneven surface of the metal material; removing the flux adhering to the recessed portion of the metal material; A method for manufacturing the cooler of claim 1 comprising:

3. The method for manufacturing a cooler according to claim 2 , further comprising the step of fixing the first metal plate, the metal material, and the second metal plate together at the protruding portion of the metal material after the removing step.

4. A method for manufacturing a cooler, comprising the steps of: fixing a first metal plate, a metal material having a concave-convex structure, and a second metal plate together at a convex portion of the metal material, the method comprising the steps of: Spraying a powdered flux onto the uneven surface of the metal material; a step of fixing the first metal plate, the metal material, and the second metal plate together by the convex portion of the metal material after the spraying; a step of blowing a gas into the recessed portion after immobilization to remove the flux adhering to the recessed portion; A method for manufacturing a cooler, comprising:

5. The method for manufacturing a cooler according to claim 4, wherein the step of blowing gas into the recesses after fixation to remove the flux adhering to the recesses includes a step of pressurizing either the first metal plate or the second metal plate in a plate thickness direction at a pressure of 0.1 kPa to 300 kPa.

Images