Heat exchanger, manufacturing method for heat exchanger, and refrigeration cycle device comprising heat exchanger

Abstract

To provide a heat exchanger that improves heat exchange performance, and restrains corrosion, a manufacturing method for the heat exchanger, and a refrigeration cycle device comprising the heat exchanger.SOLUTION: A heat exchanger comprises: a plurality of flattened tubes internally having a plurality of refrigerant flow passages, and having gaps through which air flows; and a plurality of outer fins 30 each having a main body part 31 in contact with a flat part 21 of one of adjacent flattened tubes, and a pair of protruding parts protruding in a flow direction of air from the main body part. The pair of protruding parts each have a first bent part. The main body part has: a second base surface in contact with a flat part of a first flattened tube; and a second bent part. The second bent part has: a joint surface 31ba in contact with a flat part of a second flattened tube that is the other of the adjacent flattened tubes; and an inclined surface 31bb provided between the joint surface and the second base surface. The pair of protruding parts each have peak parts bent in a first direction with respect to a first base surface, and provided at both end parts of the first bent part in a second direction. At least one of the joint surface and the second base surface has an arc shape.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present disclosure relates to a heat exchanger including fins and flat tubes, a method for manufacturing the heat exchanger, and a refrigeration cycle apparatus including the heat exchanger. [Background technology]

[0002] BACKGROUND ART In a conventional heat exchanger including fins and flat tubes, the fins protrude from the flat tubes in the direction of air flow (see, for example, Patent Document 1). The heat exchanger of Patent Document 1 comprises a pair of headers arranged parallel to each other at a distance from each other, a plurality of flat tubes extending parallel to each other at a distance between the headers, and a plurality of serpentine fins arranged between the flat tubes, each of which has alternating ridges and spaces that form upper and lower ridges, each of which extends laterally in the width direction of the serpentine fin relative to the longitudinal axis of the flat tubes, the width of the serpentine fin being wider than that of the flat tubes, the ridges of the serpentine fins being arranged so as to extend outside the outermost front and rear planes formed by the outermost edges of the flat tubes, a pair of protrusions on both sides of each ridge that extend outside the front and rear outermost edges of the flat tubes, the flat tubes being arranged between these pairs of protrusions, thereby holding the serpentine fins in a predetermined position relative to the flat tubes.

[0003] The heat exchanger of Patent Document 1 is characterized by the fact that the serpentine fins are held in a predetermined position relative to the flat tubes, and the protrusions do not protrude significantly in the airflow direction. Therefore, to improve the heat exchange performance of the serpentine fins and flat tubes, it is conceivable to increase the protrusions in the airflow direction, i.e., to extend the serpentine fins directly to both sides of the airflow direction, thereby increasing the heat transfer area of ​​the serpentine fins. However, if the protrusions protrude in the airflow direction in this manner, they are more likely to deform in the direction of the flat tubes when external forces are applied to them during manufacturing or use. Such deformation of the protrusions results in a decrease in heat exchange performance. Furthermore, to improve heat exchange performance, the spacing between adjacent flat tubes needs to be narrowed. However, in conventional heat exchangers, the structure of the serpentine fins makes it difficult to narrow the spacing between the flat portions of the flat tubes. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 9-310990 Summary of the Invention [Problem to be solved by the invention]

[0005] To address this issue, a heat exchanger having a structure in which the intervals between adjacent flat tubes are narrowed to suppress deformation of the serpentine fins can be considered.

[0006] 20 and 21 , in such a heat exchanger, the serpentine fin 80 has a main body portion 81 arranged between adjacent flat tubes 70 in the first direction D1, and a pair of protrusions 82 protruding from the main body portion 81 on both sides in the third direction D3. The main body portion 81 is in contact with the flat portions of the flat tubes 70 and has a plurality of base surfaces 81a parallel to the flat portions of the flat tubes 70, and a plurality of bent portions 81b bent in one direction in the first direction D1 (to the left in FIGS. 20 and 21 ) relative to the base surface 81a. Joint surfaces, which are parts of the base surfaces 81a and bent portions 81b of the main body portion 81, are brazed to the flat portions of the flat tubes 70 and have a rectangular plate shape parallel to the flat tubes 70. The pair of protrusions 82 have a plurality of base surfaces 82a parallel to the flat portions of the flat tubes 70, a plurality of bent portions 82b bent in the other direction of the first direction D1 (to the right in FIGS. 20 and 21) relative to the base surfaces 82a, and a plurality of ridge portions 82c bent in one direction of the first direction D1 (to the left in FIGS. 20 and 21) relative to the base surfaces 82a. The ridge portions 82c are provided at both ends of the bent portions 82b in the second direction D2.

[0007] In the heat exchanger shown in FIGS. 20 and 21 , the pair of protrusions 82 have base surfaces 82a parallel to the flat portions of the flat tubes 70 and bent portions 82b bent in the first direction D1 relative to the base surfaces 82a. Thus, the protrusions 82 of the serpentine fins 80 are provided with bent portions 82b bent in the first direction D1 relative to the base surfaces 82a parallel to the flat portions of the flat tubes 70. This increases the rigidity of the protrusions 82 of the serpentine fins 80 compared to conventional designs, thereby suppressing deformation of the protrusions 82 of the serpentine fins 80 due to external forces. Furthermore, providing the bent portions 82b increases the heat transfer area of ​​the serpentine fins 80. Furthermore, the structure of the serpentine fins 80 allows the distance between the flat portions of adjacent flat tubes 70 to be narrower than conventional designs.

[0008] In the heat exchanger shown in FIGS. 20 and 21 , the protrusions 82 of the serpentine fins 80 are bent in the third direction D3 relative to the base surface 82a, with the bent portions 82b bent in the opposite direction relative to the first direction D1, and the peaks 82c bent in one direction relative to the base surface 82a, forming an M-shape. This further enhances the rigidity of the protrusions 82 of the serpentine fins 80. However, during the manufacturing process of this heat exchanger, when the serpentine fins 80 and the flat tubes 70 are stacked and compressed to set the spacing between adjacent flat tubes 70 to a predetermined value, gaps may form between the joint surfaces of the base surface 81a and the bent portions 81b of the main body 81 of the serpentine fin 80 and the flat portions of the flat tubes 70, potentially resulting in portions that are not brazed. This reduces the amount of heat conduction between the serpentine fins 80 and the flat tubes 70, potentially reducing heat exchange performance. Furthermore, if gaps are formed, water may accumulate there, which may cause corrosion of the serpentine fins 80 and the flat tubes 70.

[0009] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a heat exchanger that improves heat exchange performance and suppresses corrosion, a method for manufacturing a heat exchanger, and a refrigeration cycle device equipped with a heat exchanger. [Means for solving the problem]

[0010] A heat exchanger according to the present disclosure includes a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube that is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protruding portions protruding from the main body portion in a third direction that is the air flow direction and intersects the first direction and the second direction, the pair of protruding portions having a first base surface parallel to the flat portion of the first flat tube and a second base surface bent in the first direction with respect to the first base surface. The main body portion has a second base surface that contacts the flat portion of the first flat tube and a second bent portion that is bent in one direction of the first direction relative to the second base surface, and the second bent portion has a joint surface that contacts the flat portion of a second flat tube that is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, and the pair of protrusions are bent in the first direction relative to the first base surface and have ridge portions provided at both ends of the first bent portion in the second direction, and at least one of the joint surface and the second base surface has an arc shape.

[0011] A heat exchanger according to the present disclosure includes a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube that is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protruding portions protruding from the main body portion in a third direction that is the air flow direction and intersects the first direction and the second direction, the pair of protruding portions having a first base surface parallel to the flat portion of the first flat tube and a second base surface bent in the first direction with respect to the first base surface. The main body portion has a second base surface that contacts the flat portion of the first flat tube and a second bent portion bent in one direction in the first direction relative to the second base surface, and the second bent portion has a joint surface that contacts the flat portion of the second flat tube, which is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, and the pair of protrusions are bent in the first direction relative to the first base surface and have ridge portions provided at both ends of the first bent portion in the second direction, and the inclined surface has a second spring portion formed with a convex portion on one side and a convex portion on the other side in the first direction.

[0012] Furthermore, the method for manufacturing a heat exchanger according to the present disclosure is a method for manufacturing the above-mentioned heat exchanger, comprising a first step of stacking the flat tubes and the outer fins alternately in the first direction, and a second step of compressing the flat tubes and the outer fins in the first direction after the first step to set the spacing between adjacent flat tubes to a predetermined specified value, wherein, when the gap between the flat portion of the first flat tube and the second base surface before performing the second step is d1 and the gap between the flat portion of the second flat tube and the joining surface is d2, and the compression amount required to set the spacing between adjacent flat tubes to a predetermined specified value when performing the second step is δ, the manufacturing method satisfies d1+d2≧δ.

[0013] A refrigeration cycle device according to the present disclosure includes the above-described heat exchanger. [Effects of the Invention]

[0014] In the heat exchanger disclosed herein, at least one of the joint surface and the second base surface of the main body portion of the outer fin has an arc shape, or the inclined surface of the main body portion of the outer fin has a second spring portion formed by a convex portion on one side and a convex portion on the other side in a first direction. Therefore, when the flat tubes and the outer fin are compressed during assembly of the heat exchanger and pressure is applied to them, the outer fin acts as a leaf spring and absorbs the pressure. When a specified amount of compression is applied, the entire base surface and joint surface of the main body portion are in close contact with the flat portion of the flat tube. This prevents gaps from forming between the flat portion of the flat tube and the base surface and joint surface of the main body portion of the outer fin, preventing unbrazed portions and allowing them to be brazed. As a result, the amount of heat conduction between the flat tubes and the outer fin is increased, improving heat exchange performance. The reduced gaps prevent water retention, thereby suppressing corrosion. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic front view showing a heat exchanger according to a first embodiment. [Figure 2] FIG. 2 is a refrigerant circuit diagram of a refrigeration cycle device equipped with the heat exchanger of FIG. [Figure 3] FIG. 2 is a schematic plan view of the heat exchanger shown in FIG. [Figure 4] FIG. 2 is a schematic side view of the heat exchanger shown in FIG. [Figure 5] 5 is a cross-sectional schematic view showing the AA cross section of the heat exchange element shown in FIG. 4. FIG. [Figure 6] FIG. 2 is a perspective view of a heat exchange member of the heat exchanger according to the first embodiment. [Figure 7] 7 is an enlarged view of the portion of the heat exchanger element shown in FIG. 6 indicated by arrow B, rotated by 90°. [Figure 8] 8 is an enlarged view of the portion indicated by arrow C of the heat exchange element shown in FIG. 7 when not compressed. [Figure 9]8 is an enlarged view of the portion indicated by arrow C of the heat exchange element shown in FIG. 7 during compression. FIG. [Figure 10] FIG. 10 is a front view illustrating deformation of a heat exchange element of a conventional heat exchanger when compressed. [Figure 11] FIG. 10 is a partially enlarged view of a heat exchange member of a heat exchanger according to a second embodiment. [Figure 12] FIG. 10 is a partially enlarged view of a heat exchange member of a heat exchanger according to a third embodiment. [Figure 13] 13 is an enlarged view of a portion indicated by an arrow D of the heat exchange member shown in FIG. 12. FIG. [Figure 14] FIG. 10 is a perspective view of a heat exchange member of a heat exchanger according to a fourth embodiment. [Figure 15] 15 is an enlarged view of the portion of the heat exchange element shown in FIG. 14 indicated by arrow E, rotated by 90°. [Figure 16] 15 is an enlarged view of the portion of the heat exchange element shown in FIG. 14 indicated by arrow E and rotated by 90° during compression. FIG. [Figure 17] FIG. 11 is a perspective view of a heat exchange member of a heat exchanger according to a fifth embodiment. [Figure 18] 18 is an enlarged view of the portion indicated by arrow F of the heat exchanger element shown in FIG. 17, rotated by 90°. [Figure 19] 18 is an enlarged view of the portion indicated by arrow F of the heat exchange element shown in FIG. 17, rotated by 90°, during compression. FIG. [Figure 20] FIG. 1 is a perspective view of a heat exchange element of a conventional heat exchanger. [Figure 21] FIG. 1 is a front view of a heat exchange element of a conventional heat exchanger. DETAILED DESCRIPTION OF THE INVENTION

[0016] Heat exchangers according to embodiments 1 to 5 will be described below with reference to the drawings. Note that in the following drawings, including FIG. 1, the relative dimensional relationships and shapes of the components may differ from those in reality. In the following drawings, identical reference numerals denote identical or equivalent components, and this applies throughout the entire specification. To facilitate understanding, directional terms (e.g., "up," "down," "right," "left," "front," "rear," etc.) are used as appropriate. However, these terms are used merely for the sake of convenience and do not limit the arrangement or orientation of the device or components. In the specification, the relative positions of the components, the extension direction of each component, and the arrangement direction of each component are, in principle, those when the heat exchanger is installed and ready for use.

[0017] Embodiment 1 Fig. 1 is a schematic front view showing a heat exchanger 101 according to embodiment 1. In Fig. 1, the direction of refrigerant flow when the heat exchanger 101 is used as an evaporator is indicated by solid white arrows. As shown in Fig. 1, the heat exchanger 101 includes a plurality of heat exchange elements 10 arranged in a first direction D1, and a first header 40 and a second header 50 connected to ends of the plurality of heat exchange elements 10.

[0018] Fig. 2 is a refrigerant circuit diagram of a refrigeration cycle apparatus 100 equipped with the heat exchanger 101 of Fig. 1. As shown in Fig. 2, the heat exchanger 101 constitutes a part of a refrigerant circuit 100c of the refrigeration cycle apparatus 100.

[0019] In the first embodiment, the refrigeration cycle apparatus 100 is described as being applied to an air conditioner. However, the refrigeration cycle apparatus 100 can be applied to refrigeration cycle apparatuses other than air conditioners, such as refrigerators, freezers, vending machines, refrigeration systems, or water heaters.

[0020] The refrigeration cycle apparatus 100 has a compressor 102, a heat exchanger 101, an expansion device 105, an indoor heat exchanger 104, and a flow path switching device 103. In this example, the compressor 102, the heat exchanger 101, the expansion device 105, and the flow path switching device 103 are provided in the outdoor unit 100A, and the indoor heat exchanger 104 is provided in the indoor unit 100B.

[0021] The compressor 102, the flow switching device 103, the heat exchanger 101, the expansion device 105, and the indoor heat exchanger 104 are connected to one another via refrigerant pipes to form a refrigerant circuit 100c in which a refrigerant can circulate. In the refrigeration cycle apparatus 100, when the compressor 102 operates, a refrigeration cycle is performed in which the refrigerant circulates through the compressor 102, the heat exchanger 101, the expansion device 105, and the indoor heat exchanger 104 while undergoing a phase change.

[0022] The outdoor unit 100A is provided with an outdoor fan 107 that forcibly passes outdoor air through the heat exchanger 101. The indoor unit 100B is provided with an indoor fan 106 that forcibly passes indoor air through the indoor heat exchanger 104. In the following, the outdoor fan 107 is also referred to as a fan.

[0023] The compressor 102 draws in a low-temperature, low-pressure refrigerant, compresses the drawn refrigerant, and discharges a high-temperature, high-pressure refrigerant. The compressor 102 is, for example, an inverter compressor whose capacity, which is the amount of refrigeration delivered per unit time, is controlled by changing the operating frequency.

[0024] The heat exchanger 101 functions as an evaporator or a condenser, and exchanges heat between the refrigerant and the outdoor air generated by the operation of the outdoor fan 107, thereby evaporating the refrigerant into gas or condensing the refrigerant into liquid. The heat exchanger 101 functions as an evaporator during heating operation, and as a condenser during cooling operation.

[0025] The indoor heat exchanger 104 functions as an evaporator or a condenser, and exchanges heat between the refrigerant and the indoor air generated by the operation of the indoor fan 106, thereby evaporating the refrigerant into a gas or condensing it into a liquid. The indoor heat exchanger 104 functions as a condenser during heating operation, and as an evaporator during cooling operation.

[0026] The expansion device 105 reduces the pressure of the refrigerant to expand it. The expansion device 105 is, for example, an electronic expansion valve that can adjust the opening of the expansion valve, and by adjusting the opening, the pressure of the refrigerant flowing into the indoor heat exchanger 104 is controlled during cooling operation, and the pressure of the refrigerant flowing into the heat exchanger 101 is controlled during heating operation.

[0027] The flow path switching device 103 is, for example, a four-way valve that switches between cooling operation and heating operation by switching the direction of the refrigerant flow. Note that the flow path switching device 103 may be a combination of a two-way valve and a three-way valve instead of a four-way valve.

[0028] The indoor fan 106 is provided near the indoor heat exchanger 104 and supplies indoor air to the indoor heat exchanger 104, and the airflow rate of the indoor fan 106 is adjusted by controlling its rotation speed. The outdoor fan 107 is provided near the heat exchanger 101 and supplies outdoor air to the heat exchanger 101, and the airflow rate of the outdoor fan 107 is adjusted by controlling its rotation speed.

[0029] The operation of the refrigeration cycle apparatus 100 can be switched between cooling operation and heating operation. In Fig. 2, the direction of refrigerant flow during cooling operation is indicated by dashed arrows, and the direction of refrigerant flow during heating operation is indicated by solid arrows.

[0030] During cooling operation of the refrigeration cycle apparatus 100, the flow path switching device 103 is switched so as to guide the refrigerant from the compressor 102 to the heat exchanger 101 and guide the refrigerant from the indoor heat exchanger 104 to the compressor 102, as shown by the dashed lines in FIG. 2 . Then, the refrigerant compressed by the compressor 102 is sent to the heat exchanger 101. In the heat exchanger 101, the refrigerant releases heat to the outdoor air and is condensed. Thereafter, the refrigerant is sent to the expansion device 105, where it is decompressed, and then sent to the indoor heat exchanger 104. Thereafter, the refrigerant absorbs heat from the indoor air in the indoor heat exchanger 104 and evaporates, and then returns to the compressor 102. Therefore, during cooling operation of the refrigeration cycle apparatus 100, the heat exchanger 101 functions as a condenser, and the indoor heat exchanger 104 functions as an evaporator.

[0031] During heating operation of the refrigeration cycle apparatus 100, the flow path switching device 103 is switched so as to guide the refrigerant from the compressor 102 to the indoor heat exchanger 104 and guide the refrigerant from the heat exchanger 101 to the compressor 102, as shown by the solid lines in FIG. 2 . Then, the refrigerant compressed by the compressor 102 is sent to the indoor heat exchanger 104. In the indoor heat exchanger 104, the refrigerant releases heat to the indoor air and is condensed. Then, the refrigerant is sent to the expansion device 105, where it is decompressed, and then sent to the heat exchanger 101. Then, the refrigerant absorbs heat from the outdoor air in the heat exchanger 101 and evaporates, and then returns to the compressor 102. Therefore, during heating operation of the refrigeration cycle apparatus 100, the heat exchanger 101 functions as an evaporator, and the indoor heat exchanger 104 functions as a condenser.

[0032] FIG. 3 is a schematic plan view of the heat exchanger 101 shown in FIG. 1. FIG. 4 is a schematic side view of the heat exchanger 101 shown in FIG. 1. FIG. 5 is a schematic cross-sectional view showing the AA cross section of the heat exchange element 10 shown in FIG. 4. FIG. 6 is a perspective view of the heat exchange element 10 of the heat exchanger 101 according to the first embodiment. In FIG. 3, the direction of refrigerant flow when the heat exchanger 101 is used as an evaporator is indicated by solid white arrows. In FIGS. 3 and 4, the direction of air flow is indicated by dashed white arrows. Below, the schematic configuration of the heat exchanger 101 will be described with reference to FIGS. 1 and 3 to 6. The illustrated heat exchanger 101 is merely an example, and its configuration is not limited to the configurations described in the embodiments, and can be modified as appropriate within the scope of the technology according to the embodiments.

[0033] As shown in Fig. 6, the heat exchange element 10 is composed of flat tubes 20 and outer fins 30. The flat tubes 20 extend in a second direction D2 intersecting the first direction D1, and are arranged so that their tube axes are aligned with the second direction D2. As shown in Fig. 5, the outer fins 30 are arranged between adjacent flat tubes 20. As shown in Fig. 1, a gap G through which air flows is formed between adjacent heat exchange elements 10 in the first direction D1. Then, as shown in Figs. 3 and 4, in the heat exchanger 101, air flows along a third direction D3 intersecting the first direction D1 and the second direction D2.

[0034] In the following description, the extension direction of the heat exchange element 10 (of the flat tubes 20) shown in FIG. 1, i.e., the second direction D2, is defined as the vertical direction parallel to the direction of gravity. Furthermore, the arrangement direction of the multiple heat exchange elements 10, i.e., the first direction D1, is defined as the horizontal direction perpendicular to the direction of gravity. Furthermore, the third direction D3, which is parallel to the air flow direction in the heat exchanger 101, is defined as the depth direction perpendicular to the first direction D1 and the second direction D2. Note that the arrangement of the heat exchanger 101 is not limited to the above case.

[0035] As shown in FIG. 1 , one end 13a of each of the heat exchange members 10 in the tube axis direction is connected to a first header 40. The other end 13b of each of the heat exchange members 10 in the tube axis direction is connected to a second header 50. The first header 40 and the second header 50 are arranged with their longitudinal directions facing the arrangement direction of the heat exchange members 10, i.e., the first direction D1. That is, the longitudinal directions of the first header 40 and the second header 50 are parallel to each other. In the following description, the first header 40 and the second header 50 may be simply referred to as headers without any distinction being made between them.

[0036] (header) The first header 40 and the second header 50 are cylindrical bodies with closed ends, and have spaces formed therein through which the refrigerant flows. The first header 40 and the second header 50 extend in a first direction D1, and in the examples shown in Figures 1, 3, and 4, have rectangular parallelepiped outer shapes, and in a cross section perpendicular to the first direction D1, have a rectangular cross-sectional shape with long sides in a third direction D3.

[0037] 1, 3, and 4, the outer shapes of the first header 40 and the second header 50 are rectangular parallelepipeds, but this shape is not limited thereto. The outer shapes of the first header 40 and the second header 50 may be, for example, cylindrical or elliptical, and the cross-sectional shapes of the first header 40 and the second header 50 may be modified as appropriate. Furthermore, the first header 40 and the second header 50 may be configured as a cylindrical body with both ends closed as described above, but may also be configured as a stack of plate-like bodies with slits formed therein. Furthermore, the first header 40 and the second header 50 may have different outer shapes or cross-sectional shapes.

[0038] The first header 40 and the second header 50 also have refrigerant flow ports 41 and 51, respectively, through which the refrigerant can flow in and out. Specifically, the refrigerant flow port 41 is provided in a wall portion constituting one end of the first header 40 in the first direction D1 (the left wall portion of the first header 40 in FIG. 1). The refrigerant flow port 51 is provided in a wall portion constituting one end of the second header 50 in the first direction D1 (the right wall portion of the second header 50 in FIG. 1). When the heat exchanger 101 functions as an evaporator, the refrigerant flow port 41 serves as a refrigerant inlet in the heat exchanger 101, and the refrigerant flow port 51 serves as a refrigerant outlet in the heat exchanger 101. When the heat exchanger 101 functions as a condenser, the refrigerant flow port 51 serves as a refrigerant inlet in the heat exchanger 101, and the refrigerant flow port 41 serves as a refrigerant outlet in the heat exchanger 101. The positions at which the refrigerant flow ports 41 and 51 are provided in the first header 40 and the second header 50 are not limited to the positions described above, and can be changed as appropriate.

[0039] Furthermore, a plurality of insertion holes (not shown) are formed in the header upper wall portion of the first header 40 located on the lower side in the heat exchanger 101, and the plurality of insertion holes are arranged in parallel in the first direction D1 to correspond to the plurality of heat exchange members 10. The plurality of insertion holes are holes into which the lower ends 13a of the plurality of heat exchange members 10 are inserted, and penetrate the header upper wall portion of the first header 40 in the thickness direction, i.e., in the second direction D2.

[0040] Furthermore, a plurality of insertion holes (not shown) are formed in the header lower wall portion of the second header 50 located on the upper side in the heat exchanger 101, and the plurality of insertion holes are arranged in parallel in the first direction D1 to correspond to the plurality of heat exchange members 10. The plurality of insertion holes are holes into which the upper ends 13b of the plurality of heat exchange members 10 are inserted, and penetrate the header lower wall portion of the second header 50 in the thickness direction, i.e., in the second direction D2.

[0041] The heat exchange members 10 have their ends 13a and 13b inserted into the insertion holes of the first header 40 and the second header 50, respectively, and are joined together by joining means such as brazing or adhesive.

[0042] Next, an example of the operation of the heat exchanger 101 when used as an evaporator will be described. As shown in FIG. 1, low-pressure refrigerant in a two-phase gas-liquid state flows into the heat exchanger 101 from the refrigerant flow port 41. In the heat exchanger 101, the low-pressure refrigerant in a two-phase gas-liquid state first flows into the first header 40 and is distributed to each of the flat tubes 20 of the multiple heat exchange elements 10 by the first header 40. In each flat tube 20, the refrigerant flows in a plurality of refrigerant flow paths 23 (see FIG. 5 described later). In the refrigerant flow paths 23 of each flat tube 20, the low-pressure refrigerant in a two-phase gas-liquid state flows in the second direction D2 toward the second header 50 and passes through the flat tubes 20. At this time, the low-pressure refrigerant in a two-phase gas-liquid state exchanges heat with air flowing through the gaps G between adjacent heat exchange elements 10 via the components that make up the heat exchange elements 10, releasing heat to the air and evaporating, becoming a low-pressure gaseous refrigerant. The low-pressure gaseous refrigerant from the plurality of flat tubes 20 flows into the second header 50 and merges in the second header 50. The low-pressure gaseous refrigerant that has merged in the second header 50 flows out from the refrigerant flow port 41 provided in the second header 50 to the outside of the heat exchanger 101 (for example, the compressor 102 in FIG. 2).

[0043] (heat exchange member 10) As shown in FIG. 5 , the flat tube 20 is a flat, perforated tube having a cross-sectional shape that is flat in one direction, such as an oval shape, and having a plurality of refrigerant flow paths 23 formed by through-holes inside. The flat tube 20 has a pair of flat portions 21 that face the first direction D1 and extend in the third direction D3, and a pair of curved portions 22 that are located at both ends of the flat portions 21 in the third direction D3 and curve outwardly. The flat tubes 20 are arranged in the first direction D1 with gaps G through which air can flow, and extend along a second direction D2 that intersects with the first direction D1. The flat tube 20 is an extruded tube formed by extrusion molding. However, the present invention is not limited to this, and the flat tube 20 may also be a roll-formed tube formed by bending a single rectangular flat plate.

[0044] 5 and 6, the outer fin 30 has a main body portion 31 disposed between adjacent flat tubes 20 in the first direction D1, and a pair of protrusions 32 protruding from the main body portion 31 on both sides in the third direction D3. The main body portion 31 is in contact with the flat portion 21 of the flat tube 20 and has a plurality of base surfaces 31a (hereinafter also referred to as second base surfaces) that are substantially parallel to the flat portion 21 of the flat tube 20, and a plurality of bent portions 31b that are bent in one direction in the first direction D1 relative to the base surface 31a. Note that the number of base surfaces 31a and bent portions 31b is not limited to the above, and there may be only one of each. The base surface 31a is a surface that is brazed to the flat portion 21 of the flat tube 20. The pair of protrusions 32 have a plurality of base surfaces 32a parallel to the flat portion 21 of the flat tube 20, a plurality of bent portions 32b bent in the other direction of the first direction D1 relative to the base surface 32a, and a plurality of ridge portions 32c bent in one direction of the first direction D1 relative to the base surface 32a. The ridge portions 32c are provided at both ends of the bent portions 32b in the second direction D2. The plurality of bent portions 32b are arranged within the width (thickness) of the flat tube 20 in the first direction D1. Here, the other direction of the first direction D1 is the opposite direction to the one direction of the first direction D1.

[0045] The number of base surfaces 32a, bent portions 32b, and peak portions 32c is not limited to the above, and may be singular. The bent portions 32b are bent in the positive direction of the first direction D1 (to the right in FIGS. 5 and 6) relative to the base surface 32a. However, this is not a limitation, and the bent portions 32b may be bent in the negative direction of the first direction D1 (to the left in FIGS. 5 and 6) relative to the base surface 32a. The peak portions 32c are bent in the negative direction of the first direction D1 (to the left in FIGS. 5 and 6) relative to the base surface 32a. However, this is not a limitation, and the peak portions 32c may be bent in the positive direction of the first direction D1 (to the right in FIGS. 5 and 6) relative to the base surface 32a. The outer fin 30 is formed by bending a single rectangular flat plate. However, this is not a limitation, and the outer fin 30 may be formed by connecting multiple rectangular flat plate members.

[0046] Furthermore, the base surface 31a of the main body 31 and the base surface 32a of the protruding portion 32 are connected on the same plane. In this way, the main body 31 and the protruding portion 32 are connected on the same plane, so that the main body 31 and the protruding portion 32 can be firmly connected, and the rigidity of the outer fin 30 can be increased.

[0047] In order to improve the heat exchange performance of the multiple heat exchange elements 10, the gap G (see FIGS. 1 and 5), i.e., the distance between the flat portions 21 of adjacent flat tubes 20, is set narrow. The distance is set, for example, within a range of 1 mm or more and 3 mm or less. In conventional heat exchangers, the structure of the serpentine fins makes it difficult to narrow the distance between the flat portions of adjacent flat tubes, and it is difficult to set the distance within a range of 1 mm or more and 3 mm or less. On the other hand, in the heat exchanger 101 according to the first embodiment, the outer fins 30 have the above structure, so it is possible to set the distance between the flat portions 21 of adjacent flat tubes 20 within a range of 1 mm or more and 3 mm or less.

[0048] Furthermore, the bent portions 32b of the pair of protrusions 32 are bent only in the positive direction of the first direction D1 relative to the base surface 32a. In other words, none of the multiple bent portions 32b are bent in the negative direction of the first direction D1 relative to the base surface 32a. In this way, the bent portions 32b of the pair of protrusions 32 are bent only in the same direction relative to the base surface 32a. Therefore, only one flat tube 20 is arranged between the pair of protrusions 32, and multiple flat tubes 20 are not arranged between the pair of protrusions 32. In other words, flat tubes 20 are arranged only in the bending direction of the protrusions 32 between the pair of protrusions 32, and flat tubes 20 are not arranged in the non-bending direction of the protrusions 32. In this way, by arranging only one flat tube 20 between the pair of protrusions 32, the movement of adjacent flat tubes 20 in the third direction D3 is not affected. In other words, even if adjacent flat tubes 20 move in the third direction D3, they do not come into contact with the bent portions 32b of the outer fins 30, so deformation of the outer fins 30 due to movement of adjacent flat tubes 20 in the third direction D3 can be suppressed.

[0049] FIG. 7 is an enlarged view of the portion indicated by arrow B of the heat exchange element 10 shown in FIG. 6 rotated 90°. FIG. 8 is an enlarged view of the portion indicated by arrow C of the heat exchange element 10 shown in FIG. 7 when uncompressed. FIG. 9 is an enlarged view of the portion indicated by arrow C of the heat exchange element 10 shown in FIG. 7 when compressed. FIG. 10 is a front view illustrating deformation of the heat exchange element of a conventional heat exchanger when compressed. As shown in FIG. 7, the bent portion 31b has a joint surface 31ba and an inclined surface 31bb. The joint surface 31ba is formed longer than the inclined surface 31bb in the second direction D2, is a surface approximately parallel to the flat portion 21 of the flat tube 20, and is a surface to be brazed and joined to the flat portion 21 of the flat tube 20. The inclined surface 31bb is provided between the base surface 31a and the joint surface 31ba and is a surface inclined with respect to the flat portion 21 of the flat tube 20. Furthermore, when the heat exchange member 10 is viewed from the front (viewed in the third direction D3), the base surface 31a and the joining surface 31ba of the main body portion 31 have an arc shape that is convex toward the flat portion 21 of the flat tube 20 to be joined.

[0050] During assembly of the heat exchanger 101, the flat tubes 20 and the outer fins 30 are compressed and pressure is applied to them. When the heat exchanger 101 is viewed from the front, if the base surface 31a and the joint surface 31ba of the main body 31 are planar and parallel to the flat portions 21 of the flat tubes 20, as shown in FIG. 10 , friction occurs between the flat tubes 20 and the outer fins 30 when the heat exchanger 10 is compressed. This causes the contact surface between the flat tubes 20 and the outer fins 30 to deform into an M-shape, creating gaps between the flat tubes 20 and the outer fins 30. This results in unbrazed portions UB, which are not brazed between the flat portions 21 of the flat tubes 20 and the base surface 31a and the joint surface 31ba of the main body 31 of the outer fins 30. This reduces the amount of heat conduction between the flat tubes 20 and the outer fins 30, degrading heat exchange performance. Furthermore, water remaining in the gaps can corrode the flat tubes 20 and the outer fins 30.

[0051] Therefore, when the heat exchanger element 10 is viewed from the front, the base surface 31a and the joint surface 31ba of the main body 31 have an arc shape that convex toward the flat portions 21 of the flat tubes 20 to be joined. This allows the flat tubes 20 and the outer fins 30 to function as leaf springs and absorb pressure when they are compressed during assembly of the heat exchanger 101. The angle of the inclined surface 31bb relative to the flat portions 21 of the flat tubes 20 becomes larger than before compression, and when a specified amount of compression is applied, the base surface 31a and the joint surface 31ba of the main body 31 are in close contact with the flat portions 21 of the flat tubes 20. This prevents gaps from forming between the flat portions 21 of the flat tubes 20 and the base surface 31a and the joint surface 31ba of the main body 31 of the outer fin 30, prevents unbrazed portions UB, and allows them to be brazed. As a result, the amount of heat conduction between the flat tubes 20 and the outer fins 30 increases, improving heat exchange performance, and since the occurrence of gaps can be suppressed, water stagnation can be suppressed, thereby suppressing corrosion.

[0052] In the first embodiment, both the base surface 31a and the joint surface 31ba of the main body 31 have an arc shape, but this is not limiting, and it is sufficient that at least one of the base surface 31a and the joint surface 31ba of the main body 31 has an arc shape. If at least one of the base surface 31a and the joint surface 31ba of the main body 31 has an arc shape, the outer fin 30 can function as a leaf spring.

[0053] As described above, the heat exchanger 101 according to the first embodiment includes a plurality of flat tubes 20 each having a plurality of refrigerant flow paths 23 therein, arranged in a first direction D1 with gaps through which air flows, and extending along a second direction D2 intersecting the first direction D1; a main body portion 31 disposed between adjacent flat tubes 20 and in contact with a flat portion 21 of a first flat tube that is one of the adjacent flat tubes 20; and a plurality of outer fins 30 each having a pair of protruding portions 32 protruding from the main body portion 31 in a third direction D3 that is the air flow direction and intersects the first direction D1 and the second direction D2, the pair of protruding portions 32 having a first base surface parallel to the flat portion 21 of the first flat tube and a third base surface that is in contact with the first base surface. The main body 31 has a second base surface that contacts the flat portion 21 of the first flat tube, and a second bent portion that is bent in one direction D1 relative to the second base surface, and the second bent portion has a joint surface 31ba that contacts the flat portion 21 of the second flat tube, which is the other of the adjacent flat tubes 20, and an inclined surface 31bb provided between the joint surface 31ba and the second base surface, and the pair of protrusions 32 are bent in the first direction D1 relative to the first base surface and have ridge portions 32c provided at both ends of the first bent portion in the second direction D2, and at least one of the joint surface 31ba and the second base surface has an arc shape.

[0054] In the heat exchanger 101 according to the first embodiment, at least one of the joining surface 31ba and the second base surface of the main body 31 of the outer fin 30 has an arc shape. Therefore, when the flat tubes 20 and the outer fins 30 are compressed during assembly of the heat exchanger 101, the outer fins 30 function as leaf springs and absorb pressure. When a predetermined amount of compression is applied, the second base surface and the joining surface 31ba of the main body 31 are fully in contact with the flat portion 21 of the flat tube 20. This prevents gaps from forming between the flat portion 21 of the flat tube 20 and the second base surface and the joining surface 31ba of the main body 31 of the outer fin 30, thereby preventing unbrazed portions UB and allowing them to be brazed. As a result, the amount of heat conduction between the flat tubes 20 and the outer fins 30 is increased, improving heat exchange performance. The reduced gaps prevent water retention, thereby suppressing corrosion.

[0055] Embodiment 2 The second embodiment will be described below, but explanations of parts that overlap with those of the first embodiment will be omitted, and parts that are the same as or equivalent to those of the first embodiment will be given the same reference numerals.

[0056] Fig. 11 is a partially enlarged view of the heat exchange element 10 of the heat exchanger 101 according to the second embodiment. Fig. 11 is an enlarged view of the same portion as the portion indicated by the arrow C in Fig. 7. As shown in Fig. 11, the heat exchange element 10 according to the second embodiment is configured so that the angle α of the inclined surface 31bb relative to the flat portion 21 of the flat tube 20 is 45° or more (α≧45°). When the flat tubes 20 and the outer fins 30 are compressed and pressure is applied to them during assembly of the heat exchanger 101, a force F is generated that tends to deform the base surface 31a and the joint surface 31ba of the main body portion 31, which have an arc shape, in the second direction D2. Therefore, by setting the angle α of the inclined surface 31bb relative to the flat portion 21 of the flat tube 20 to 45° or more, the component force F1 that tries to raise the outer fin 30 becomes larger than the component force F2 along the inclined surface 31bb, so that the outer fin 30 deforms more, that is, it follows the displacement due to compression and easily adheres to the flat tube 20. As a result, heat exchange performance can be further improved and corrosion can be further suppressed.

[0057] As described above, in the heat exchanger 101 according to embodiment 2, the second bent portion has an inclined surface 31bb provided between the joint surface 31ba and the second base surface, and the angle α between the inclined surface 31bb and the flat portion 21 of the flat tube 20 is 45° or more.

[0058] In the heat exchanger 101 according to the second embodiment, the component force F1 that tries to raise the outer fins 30 is larger than the component force F2 along the inclined surfaces 31bb, so the outer fins 30 are more deformed, that is, they are more likely to follow the displacement due to compression and to come into close contact with the flat tubes 20. As a result, the heat exchange performance can be further improved and corrosion can be further suppressed.

[0059] Embodiment 3 Hereinafter, the third embodiment will be described, but explanations of parts that overlap with the first and second embodiments will be omitted, and parts that are the same as or equivalent to the first and second embodiments will be given the same reference numerals.

[0060] Fig. 12 is a partially enlarged view of the heat exchange element 10 of the heat exchanger 101 according to embodiment 3. Fig. 13 is an enlarged view of the portion indicated by arrow D of the heat exchange element 10 shown in Fig. 12. Note that Fig. 12 is an enlarged view of the same portion indicated by arrow C in Fig. 7. The heat exchange element 10 according to embodiment 3 is manufactured by a manufacturing method including a first step of alternately stacking the flat tubes 20 and the outer fins 30 in a first direction D1, and a second step of compressing the flat tubes 20 and the outer fins 30 in the first direction D1 after the first step to set the spacing between adjacent flat tubes 20 to a predetermined specified value. 12, in the first step, the sum (= d1 + d2) of the gap d1 between the joint surface 31ba and the flat portion 21 of the flat tube 20 before compression in the second step and the gap d2 between the base surface 31a and the flat portion 21 of the flat tube 20 is configured to be equal to or greater than the compression amount δ when compressing until the spacing between adjacent flat tubes 20 becomes a predetermined specified value (d1 + d2 ≧ δ). Here, the compression amount when compressing until the spacing between adjacent flat tubes 20 becomes a predetermined specified value is the compression amount necessary to compress until the spacing (pitch) between adjacent flat tubes 20 becomes the spacing (pitch) between adjacent insertion holes in the first header 40 and the second header 50. Note that one of the base surface 31a and the joint surface 31ba of the main body 31 has a flat shape, and one of d1 and d2 may be zero.

[0061] When d1 + d2 = δ, after the flat tubes 20 are compressed in the second step until the spacing between them reaches a predetermined value, both the base surface 31a and the joining surface 31ba of the main body 31 are in close contact with the flat tubes 20, and gaps d1 and d2 do not occur. Furthermore, when d1 + d2 > δ, after the flat tubes 20 are compressed in the second step until the spacing between them reaches a predetermined value, gaps d1 and d2 occur, but the brazing material BR fills gaps d1 and d2 as shown in Fig. 13. Therefore, heat exchange performance between the flat tubes 20 and the outer fins 30 is ensured, and water does not accumulate, suppressing corrosion.

[0062] As described above, the manufacturing method of the heat exchanger 101 according to embodiment 3 comprises a first step of stacking the flat tubes 20 and the outer fins 30 alternately in a first direction D1, and a second step of compressing the flat tubes 20 and the outer fins 30 in the first direction D1 after the first step to set the spacing between adjacent flat tubes 20 to a predetermined specified value. When the gap between the flat portion 21 of the first flat tube and the second base surface before the second step is d1 and the gap between the flat portion 21 of the second flat tube and the joint surface 31ba is d2, and the compression amount required to set the spacing between adjacent flat tubes 20 to a predetermined specified value when the second step is performed is δ, the manufacturing method satisfies d1+d2≧δ.

[0063] According to the method for manufacturing the heat exchanger 101 according to the third embodiment, the heat exchange performance between the flat tubes 20 and the outer fins 30 is ensured, and water does not accumulate, so corrosion can be suppressed.

[0064] Embodiment 4 Hereinafter, the fourth embodiment will be described, but explanations of parts that overlap with those of the first to third embodiments will be omitted, and parts that are the same as or equivalent to those of the first to third embodiments will be given the same reference numerals.

[0065] FIG. 14 is a perspective view of the heat exchange element 10 of the heat exchanger 101 according to the fourth embodiment. FIG. 15 is an enlarged view of the portion indicated by the arrow E in the heat exchange element 10 shown in FIG. 14 , rotated 90 degrees. FIG. 16 is an enlarged view of the portion indicated by the arrow E in the heat exchange element 10 shown in FIG. 14 , rotated 90 degrees, during compression. As shown in FIGS. 14 and 15, the inclined surface 31bb has a planar inclined portion 31bba and a spring portion 31bbb (hereinafter also referred to as a second spring portion) in which a convex portion is formed on one side and a convex portion on the other side in the first direction D1. As shown in FIG. 16, since the outer fins 30 have the spring portion 31bbb, when the flat tubes 20 and the outer fins 30 are compressed during assembly of the heat exchanger 101 and pressure is applied to them, the spring portion 31bbb acts as a leaf spring and absorbs the pressure. Therefore, when the heat exchanger element 10 is compressed, friction occurs between the flat tubes 20 and the outer fins 30, causing the contact surfaces between the flat tubes 20 and the outer fins 30 to deform into an M shape, suppressing the occurrence of gaps between the flat portions 21 of the flat tubes 20 and the base surfaces 31a and joint surfaces 31ba of the main body portions 31 of the outer fins 30. As a result, the occurrence of unbrazed portions UB can be suppressed, and they can be brazed. As a result, the amount of heat conduction between the flat tubes 20 and the outer fins 30 increases, improving heat exchange performance. The suppression of gaps suppresses water retention, thereby suppressing corrosion.

[0066] As described above, the heat exchanger 101 according to the fourth embodiment includes a plurality of flat tubes 20 each having a plurality of refrigerant flow paths 23 therein, arranged in the first direction D1 with gaps through which air flows, and extending along the second direction D2 intersecting the first direction D1; a main body portion 31 disposed between adjacent flat tubes 20 and in contact with the flat portion 21 of a first flat tube that is one of the adjacent flat tubes 20; and a plurality of outer fins 30 each having a pair of protruding portions 32 protruding from the main body portion 31 in the air flow direction and in a third direction D3 intersecting the first direction D1 and the second direction D2. The pair of protruding portions 32 are formed on a first base surface parallel to the flat portion 21 of the first flat tube and a second base surface parallel to the flat portion 21 of the first flat tube. The main body 31 has a second base surface that contacts the flat portion 21 of the first flat tube, and a second bent portion that is bent in one direction in the first direction D1 relative to the second base surface, and the second bent portion has a joint surface 31ba that contacts the flat portion 21 of the second flat tube, which is the other of the adjacent flat tubes 20, and an inclined surface 31bb provided between the joint surface 31ba and the second base surface, and the pair of protrusions 32 are bent in the first direction D1 relative to the first base surface and have ridge portions 32c provided at both ends of the first bent portion in the second direction D2, and the inclined surface 31bb has a second spring portion that is formed by a convexity on one side and a convexity on the other side in the first direction D1.

[0067] According to the heat exchanger 101 of the fourth embodiment, the inclined surface 31bb of the main body 31 of the outer fin 30 has a second spring portion. Therefore, when the flat tubes 20 and the outer fins 30 are compressed during assembly of the heat exchanger 101 and pressure is applied to them, the second spring portion acts as a leaf spring and absorbs the pressure. When a predetermined amount of compression is applied, the entire second base surface and joint surface 31ba of the main body 31 are in close contact with the flat portion 21 of the flat tube 20. This prevents gaps from forming between the flat portion 21 of the flat tube 20 and the second base surface and joint surface 31ba of the main body 31 of the outer fin 30, thereby preventing unbrazed portions UB and allowing them to be brazed. As a result, the amount of heat conduction between the flat tubes 20 and the outer fins 30 is increased, improving heat exchange performance. The reduced gaps prevent water retention, thereby suppressing corrosion.

[0068] Embodiment 5. Hereinafter, the fifth embodiment will be described, but explanations of parts that overlap with those of the first to fourth embodiments will be omitted, and parts that are the same as or equivalent to those of the first to fourth embodiments will be given the same reference numerals.

[0069] FIG. 17 is a perspective view of a heat exchange element 10 of a heat exchanger 101 according to a fifth embodiment. FIG. 18 is an enlarged view of the portion indicated by the arrow F in the heat exchange element 10 shown in FIG. 17, rotated 90 degrees. FIG. 19 is an enlarged view of the portion indicated by the arrow F in the heat exchange element 10 shown in FIG. 17, rotated 90 degrees, during compression. As shown in FIGS. 17 and 18, the inclined surface 31bb of the main body 31 has a flat inclined plane portion 31bba and a spring portion 31bbb formed with a convex portion on one side and a convex portion on the other side in the first direction D1. The pair of protrusions 32 are provided between the base surface 32a and the peak portion 32c and have a spring portion 32bbb (hereinafter also referred to as a first spring portion) formed with a convex portion on one side and a convex portion on the other side in the first direction D1. Furthermore, spring portions 31bbb and 32bbb are formed continuously across the entire width of the outer fin 30 in the third direction D3 and are connected on the same plane. Thus, since the outer fin 30 has spring portions 31bbb and 32bbb, when the flat tubes 20 and the outer fin 30 are compressed and pressure is applied to them during assembly of the heat exchanger 101, spring portions 31bbb and 32bbb function as leaf springs and absorb the pressure. Therefore, when the heat exchanger element 10 is compressed, friction occurs between the flat tubes 20 and the outer fin 30, causing the contact surfaces between the flat tubes 20 and the outer fin 30 to deform into an M-shape. This prevents gaps from forming between the flat portions 21 of the flat tubes 20 and the base surfaces 31a and joint surfaces 31ba of the main body portions 31 of the outer fin 30. As a result, they can be brazed without leaving unbrazed portions UB. As a result, the amount of heat conduction between the flat tubes 20 and the outer fins 30 increases, improving heat exchange performance, and the suppression of gaps prevents water from accumulating, thereby suppressing corrosion. Furthermore, the spring portions 31bbb and 32bbb are formed continuously across the entire width of the outer fins 30 in the third direction D3 and are connected on the same plane. This improves the rigidity of the pair of protrusions 32 in the first direction D1, making it possible to suppress deformation of the outer fins 30 due to external forces.If the outer fin 30 has the spring portion 31bbb and the spring portion 32bbb, the outer fin 30 can function as a plate spring, and therefore the base surface 31a and the joint surface 31ba of the main body portion 31 do not need to have an arc shape.

[0070] As described above, in the heat exchanger 101 according to embodiment 5, the pair of protrusions 32 are provided between the first base surface and the ridge portion 32c, and have a first spring portion having a convex portion formed continuously on one side and a convex portion on the other side in the first direction D1, and the first spring portion and the second spring portion are formed continuously across the entire width of the outer fin 30 in the third direction D3, and are connected on the same plane.

[0071] In the heat exchanger 101 according to the fifth embodiment, the first spring portion and the second spring portion are formed continuously across the entire width of the outer fin 30 in the third direction D3 and are connected on the same plane. This improves the rigidity of the pair of protrusions 32 in the first direction D1, and makes it possible to suppress deformation of the outer fin 30 due to an external force.

[0072] Various aspects of the present disclosure are described below. (Appendix 1) a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube, which is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protrusions protruding from the main body portion in a third direction that is the air flow direction and intersects with the first direction and the second direction, The pair of protruding portions have a first base surface parallel to the flat portion of the first flat tube and a first bent portion bent in the first direction with respect to the first base surface, the main body portion has a second base surface that contacts the flat portion of the first flat tube, and a second bent portion that is bent in one direction of the first direction with respect to the second base surface, The second bent portion has a joint surface that contacts the flat portion of a second flat tube that is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, the pair of protruding portions are bent in the first direction with respect to the first base surface, and have mountain portions provided at both ends of the first bent portion in the second direction, At least one of the joining surface and the second base surface has an arc shape. heat exchanger. (Appendix 2) a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube, which is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protrusions protruding from the main body portion in a third direction that is the air flow direction and intersects with the first direction and the second direction, The pair of protruding portions have a first base surface parallel to the flat portion of the first flat tube and a first bent portion bent in the first direction with respect to the first base surface, the main body portion has a second base surface that contacts the flat portion of the first flat tube, and a second bent portion that is bent in one direction of the first direction with respect to the second base surface, The second bent portion has a joint surface that contacts the flat portion of a second flat tube that is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, the pair of protruding portions are bent in the first direction with respect to the first base surface, and have mountain portions provided at both ends of the first bent portion in the second direction, The inclined surface has a second spring portion formed by continuously forming a convex portion on one side and a convex portion on the other side in the first direction. heat exchanger. (Appendix 3) The inclined surface has a second spring portion formed by continuously forming a convex portion on one side and a convex portion on the other side in the first direction. 10. The heat exchanger of claim 1. (Appendix 4) the pair of protrusions are provided between the first base surface and the mountain portion, and each have a first spring portion formed by a convex portion on one side in the first direction and a convex portion on the other side in the first direction, The first spring portion and the second spring portion are formed continuously across the entire width of the outer fin in the third direction and are connected on the same plane. 4. A heat exchanger according to claim 2 or 3. (Appendix 5) The angle formed between the inclined surface and the flat portion of the flat tube is 45° or more. 5. The heat exchanger according to any one of claims 1 to 4. (Appendix 6) A method for manufacturing a heat exchanger according to any one of appendices 1 to 5, a first step of stacking the flat tubes and the outer fins alternately in the first direction; a second step of compressing the flat tubes and the outer fins in the first direction after the first step to set the interval between adjacent flat tubes to a predetermined specified value, Before performing the second step, a gap between the flat portion of the first flat tube and the second base surface is defined as d1, and a gap between the flat portion of the second flat tube and the joining surface is defined as d2, When performing the second step, when the compression amount required to make the interval between adjacent flat tubes a predetermined specified value is δ, d1+d2≧δ A method for manufacturing a heat exchanger. (Appendix 7) A refrigeration cycle device comprising the heat exchanger according to any one of appendices 1 to 5. [Explanation of symbols]

[0073] 10 heat exchange element, 13a end, 13b end, 20 flat tube, 21 flat portion, 22 curved portion, 23 refrigerant flow path, 30 outer fin, 31 main body, 31a base surface, 31b bent portion, 31ba joint surface, 31bb inclined surface, 31bba flat inclined portion, 31bbb spring portion, 32 protrusion, 32a base surface, 32b bent portion, 32bbb spring portion, 32c ridge portion, 40 first header, 41 refrigerant flow port, 50 second header, 51 refrigerant flow port, 70 flat tube, 80 serpentine fin, 81 main body, 81a base surface, 81b bent portion, 82 protrusion, 82a base surface, 82b bent portion, 82c ridge portion, 100 refrigeration cycle device, 100A outdoor unit, 100B Indoor unit, 100c refrigerant circuit, 101 heat exchanger, 102 compressor, 103 flow path switching device, 104 indoor heat exchanger, 105 throttling device, 106 indoor fan, 107 outdoor fan.

Claims

1. a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube, which is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protrusions protruding from the main body portion in a third direction that is the air flow direction and intersects with the first direction and the second direction, The pair of protruding portions have a first base surface parallel to the flat portion of the first flat tube and a first bent portion bent in the first direction with respect to the first base surface, the main body portion has a second base surface that contacts the flat portion of the first flat tube, and a second bent portion that is bent in one direction of the first direction with respect to the second base surface, The second bent portion has a joint surface that contacts the flat portion of a second flat tube that is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, the pair of protruding portions are bent in the first direction with respect to the first base surface, and each have a mountain portion provided at each end of the first bent portion in the second direction, At least one of the joining surface and the second base surface has an arc shape. heat exchanger.

2. a plurality of flat tubes each having a plurality of refrigerant flow paths therein, arranged in a first direction with gaps through which air flows, and extending along a second direction intersecting the first direction; a main body portion disposed between adjacent flat tubes and in contact with a flat portion of a first flat tube, which is one of the adjacent flat tubes; and a plurality of outer fins each having a pair of protrusions protruding from the main body portion in a third direction that is the air flow direction and intersects with the first direction and the second direction, The pair of protruding portions have a first base surface parallel to the flat portion of the first flat tube and a first bent portion bent in the first direction with respect to the first base surface, the main body portion has a second base surface that contacts the flat portion of the first flat tube, and a second bent portion that is bent in one direction of the first direction with respect to the second base surface, The second bent portion has a joint surface that contacts the flat portion of a second flat tube that is the other of the adjacent flat tubes, and an inclined surface provided between the joint surface and the second base surface, the pair of protruding portions are bent in the first direction with respect to the first base surface, and each have a mountain portion provided at each end of the first bent portion in the second direction, The inclined surface has a second spring portion formed by continuously forming a convex portion on one side and a convex portion on the other side in the first direction. heat exchanger.

3. The inclined surface has a second spring portion formed by continuously forming a convex portion on one side and a convex portion on the other side in the first direction. The heat exchanger of claim 1 .

4. the pair of protruding portions are provided between the first base surface and the mountain portion, and each include a first spring portion having a convex portion formed continuously on one side and a convex portion formed continuously on the other side in the first direction, The first spring portion and the second spring portion are formed continuously across the entire width of the outer fin in the third direction and are connected on the same plane.

4. The heat exchanger according to claim 2 or 3.

5. The angle formed between the inclined surface and the flat portion of the flat tube is 45° or more. The heat exchanger according to any one of claims 1 to 3.

6. A method for manufacturing a heat exchanger according to any one of claims 1 to 3, a first step of stacking the flat tubes and the outer fins alternately in the first direction; a second step of compressing the flat tubes and the outer fins in the first direction after the first step to set the interval between adjacent flat tubes to a predetermined specified value, Before performing the second step, a gap between the flat portion of the first flat tube and the second base surface is defined as d1, and a gap between the flat portion of the second flat tube and the joining surface is defined as d2, When performing the second step, when the compression amount required to make the interval between adjacent flat tubes a predetermined specified value is δ, d1+d2≧δ A method for manufacturing a heat exchanger.

7. A refrigeration cycle device comprising the heat exchanger according to any one of claims 1 to 3.

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