Heat exchanger manufacturing method, heat exchanger, and structure

Abstract

The present invention provides a method for manufacturing a heat exchanger, a heat exchanger, and a structure equipped with the heat exchanger, which suppress the occurrence of steps caused by thermal fusion on the surface of the covering material. [Solution] The heat exchanger is manufactured by placing a covering material 14 on at least one of the two open surfaces of the resin frame 10 or on an open surface of the resin housing, and then heat-sealing the resin frame or resin housing and the covering material with heat rollers 20a and 20b. Since the resin housing has a bottom surface and only one open surface on the top surface, when using a resin housing, only one covering material may be used. The covering material is placed on the top surface of the resin housing and heat-sealed by the upper heat roller, and the bottom surface of the resin housing is not heat-sealed, so the heat roller does not need to be heated, but it may be heated.

Description

[Technical Field]

[0001] This disclosure relates to a method for manufacturing a heat exchanger, a heat exchanger, and a structure. [Background technology]

[0002] In fields such as electronic devices like smartphones and personal computers, and battery modules used in electric vehicles and hybrid vehicles, technologies incorporating water-cooled coolers and heat pipes are known for heat dissipation. Furthermore, in power semiconductor modules made of silicon carbide and other materials, countermeasures using cooling plates and heat sinks have also been proposed to manage heat generation.

[0003] For example, vehicles equipped with motors, such as hybrid vehicles and electric vehicles, are equipped with drive mechanisms to drive the motors. These drive mechanisms consist of a power module containing multiple power semiconductors such as IGBTs (Insulated Gate Bipolar Transistors), electronic components such as capacitors, and busbars that electrically connect these electronic components. When driving a motor, large currents can flow through the power semiconductors, capacitors, and busbars connecting these electronic components. In this case, the drive mechanism generates heat due to switching losses, resistance losses, etc., making efficient cooling of the drive mechanism desirable. Similarly, efficient cooling of heat generated from the battery module mounted on the vehicle is also desirable. Conversely, in cold climates, heating the battery module may be desirable.

[0004] Examples of heat exchangers include structures made of highly thermally conductive metals, such as those with an inner core of aluminum cooling fins. However, because they are made of metal, they are heavy, and because they are attached to the heat exchanger by welding or other means, a certain thickness is required, making it difficult to make them thinner.

[0005] Therefore, from the viewpoint of weight reduction, a cooling structure has been proposed in which the outer and inner core materials are made of laminate material in which a metal heat transfer layer is laminated with a resin layer, and a refrigerant is circulated in a flow path partitioned by the inner core material (see, for example, Patent Document 1). Patent Document 1 describes that the heat exchanger is made by heat-fusing laminate material having a resin layer, and that this allows for sufficient thinning.

[0006] However, although the cooling structure described in Patent Document 1 is lightweight and easy to handle, since the water channels and outer packaging are made of laminate material, the laminate material may deform due to external forces such as the weight of the object to be cooled placed on top of the cooling structure, causing the water channels to be crushed and reducing the cooling capacity.

[0007] Accordingly, Patent Document 2 discloses a heat exchanger comprising a flow channel forming sheet having a hollow heat exchange channel and functioning as a spacer in the thickness direction, a laminate material having a resin sealant layer laminated on the inner surface side of a metal foil layer, and covering sheets on both the front and back surfaces of the flow channel forming sheet, respectively, and an inlet and outlet for allowing a heat exchange medium to flow in and out of the heat exchange channel, and configured to exchange heat between a heat exchange medium flowing through the heat exchange channel and a heat exchange target member arranged on the outer surface of the covering sheet. In the heat exchanger described in Patent Document 2, a covering sheet made of laminate material is bonded to the front and back surfaces of the flow path forming sheet by heat fusion. This eliminates the need for difficult and troublesome metalworking such as brazing, making it easy to manufacture and improving productivity. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2020-3132 [Patent Document 2] Japanese Patent Publication No. 2021-025753 [Overview of the project] [Problems that the invention aims to solve]

[0009] In the heat exchanger described in Patent Document 2, a synthetic resin sheet or the like is used as the flow path forming sheet, which suppresses the collapse of the flow path due to external forces. However, in the heat exchanger described in Patent Document 2, when a covering sheet was bonded to the front and back surfaces of the flow path forming sheet by heat fusion, a step sometimes occurred on the surface of the covering sheet. In particular, a step is more likely to occur on the surface when a large covering sheet is heat-fused.

[0010] In view of the above circumstances, this disclosure relates to a method for manufacturing a heat exchanger in which the occurrence of steps caused by thermal fusion on the surface of a coating material is suppressed, and to a heat exchanger. Furthermore, this disclosure relates to a structure equipped with said heat exchanger. [Means for solving the problem]

[0011] The means for solving the above problems include the following embodiments. <1> A method for manufacturing a heat exchanger, comprising placing a covering material on at least one of the two open surfaces of a resin frame or on an open surface of a resin housing, and heat-sealing the resin frame or resin housing and the covering material using a heat roller. <2> An unwinding coil for unwinding the covering material is placed upstream of the heat roller, and tension is applied to the covering material by biasing the unwinding coil in the opposite direction to the unwinding rotation. <1> A method for manufacturing a heat exchanger as described above. <3> At least one pair of feed rollers are arranged downstream of the heat roller, and the conveying speed of the feed rollers is set to be the same as or greater than the conveying speed of the heat roller. <1> or <2> A method for manufacturing a heat exchanger as described above. <4> The area of ​​the open surface is 25 cm² 2 That's all. <1> ~ <3> A method for manufacturing a heat exchanger as described in any one of the items. <5> The covering material comprises a heat transfer layer and resin layers disposed on both sides of the heat transfer layer. <1> ~ <4> A method for manufacturing a heat exchanger as described in any one of the items. <6> The inner fins are placed inside the resin frame or the resin housing, and the heat fusion is performed. <1> ~ <5> A method for manufacturing a heat exchanger as described in any one of the items. <7> The inner fin comprises a heat transfer layer and resin layers disposed on both sides of the heat transfer layer. <6> A method for manufacturing a heat exchanger as described above. <8> The resin layer of the covering material and the resin layer of the inner fin are made of the same type of resin. <7> A method for manufacturing a heat exchanger as described above. <9> A covering material having resin layers on both sides of the heat transfer layer is placed on at least one of the two open surfaces of the resin frame or on the open surface of the resin housing, the resin frame or resin housing and the covering material are heat-fused together, the step difference on the surface of the covering material is 20 μm or less, and the area of ​​the open surface is 1500 cm². 2 That's all for the heat exchanger. <10> An inner fin is arranged inside the resin frame or the resin housing. <9> The heat exchanger described above. <11> The inner fin is made of a laminate material having resin layers on both sides of the heat transfer layer. <10> The heat exchanger described above. <12> The resin layer of the coating material and the resin layer of the laminate material are composed of the same type of resin. <11> The heat exchanger described above. <13> <9> ~ <12> A structure comprising a heat exchanger as described in any one of the above, and a heat exchanger provided on the heat exchanger. [Effects of the Invention]

[0012] This disclosure provides a method for manufacturing a heat exchanger and a heat exchanger in which the occurrence of steps caused by thermal fusion on the surface of the covering material is suppressed. Furthermore, this disclosure provides a structure equipped with said heat exchanger. [Brief explanation of the drawing]

[0013] [Figure 1] This is a plan view photograph of the surface (surface of the covering material) of a heat exchanger obtained by heat-sealing the covering material using a hot plate press. [Figure 2]It is a perspective photograph of the surface of the heat exchanger (the surface of the coating material) obtained by the manufacturing method of the present disclosure. [Figure 3] It is a diagram for explaining an example of the manufacturing method of the heat exchanger of the present disclosure. [Figure 4] It is a diagram for explaining the members used in the manufacturing method of FIG. 3. [Figure 5] It is a diagram for explaining an example of the arrangement position of the unwinding coil. [Figure 6] It is a schematic perspective view for explaining an example of the flow path forming resin sheet. [Figure 7] It is a schematic perspective view for explaining an example of the resin housing. [Figure 8] It is a diagram for explaining an example of the formation of the inlet and outlet of the cold and heat medium L in the heat exchanger manufactured using the flow path forming resin sheet.

Embodiments for Carrying Out the Invention

[0014] Hereinafter, embodiments of the present disclosure will be described in detail. However, the embodiments of the present disclosure are not limited to the following embodiments. In the following embodiments, the components (including element steps, etc.) are not essential unless otherwise specified. The same applies to numerical values and their ranges, which do not limit the embodiments of the present disclosure.

[0015] When describing the embodiments in the present disclosure with reference to the drawings, the configuration of the embodiment is not limited to the configuration shown in the drawings. Also, the sizes of the members in each figure are conceptual, and the relative relationships of the sizes between the members are not limited to this. Further, in each drawing, members having substantially the same function are given the same reference numerals throughout the drawings, and duplicate descriptions are omitted. In the present disclosure, the up-down direction is not limited to the up-down direction in the vertical direction, and the up and down may be reversed. Also, it may be the left-right direction instead of the up-down direction. In the present disclosure, the term "layer" includes not only the case where it is formed over the entire region when observing the region where the layer exists, but also the case where it is formed only in a part of the region. In this disclosure, the term "lamination" refers to stacking layers, and two or more layers may be bonded together or detachable. In this disclosure, "step" means that when the surface irregularities of the coating material after heat fusion are measured using the method described later, the difference in irregularities is 10 μm or more.

[0016] <Method for manufacturing a heat exchanger> In the method for manufacturing a heat exchanger according to the present disclosure, a covering material is placed on at least one of the two open surfaces of the resin frame or on an open surface of the resin housing, and the resin frame or resin housing and the covering material are heat-fused together using a heat roller.

[0017] Previously, heat fusion between the resin frame or resin housing and the covering material was performed by heat pressing the entire surface of the covering material with a hot plate such as a mold. However, this sometimes resulted in wrinkles causing steps on the surface of the covering material after heat fusion. Heat exchangers with wrinkles causing steps on the surface of the covering material have a reduced contact area with the non-heat exchanger, leading to decreased thermal conductivity. Furthermore, if heat dissipation grease is used in the covering material, the presence of wrinkles can cause areas where the heat dissipation grease is thicker, reducing thermal conductivity in those areas. Furthermore, with conventional manufacturing methods, when producing heat exchangers with different sizes of resin frames or resin housings, it is necessary to create a mold each time to match the size of the resin frame or resin housing, which increases costs. In addition, with conventional manufacturing methods, the equipment is large because the entire surface of the covering material is heat-pressed, which increases the manufacturing cost of the equipment.

[0018] In contrast, this disclosure uses a heat roller to heat-seal a resin frame or resin housing and a coating material. In heat sealing with a heat roller, the heating points between the resin frame or resin housing and the coating material are linear, unlike the heating points with a hot plate which are surface-level. Furthermore, the heat-sealing points move continuously as the heat roller rotates and conveys. This ensures that there is room for the stress generated in the coating material due to thermal swelling and contraction to escape, and prevents the formation of steps due to wrinkles on the surface of the coating material after heat sealing. Therefore, the heat exchanger obtained by the method of this disclosure has excellent heat exchange performance. Also, even when manufacturing heat exchangers with different lengths of resin frames or resin housings, they can be manufactured using the same apparatus without changing the heat roller. Even when manufacturing heat exchangers with different widths of resin frames or resin housings, no strict design changes such as those for molds are required.

[0019] FIG. 1 is a plan photograph of the surface (the surface of the coating material) of a heat exchanger obtained by heat fusion using a hot plate press, and FIG. 2 is a perspective photograph of the surface (the surface of the coating material) of a heat exchanger obtained by the manufacturing method of the present disclosure. The sizes of the heat exchangers in FIGS. 1 and 2 are 50 cm in length and 30 cm in width. In the heat exchanger of FIG. 1, wrinkles are generated and steps are formed at locations derived from the heat fusion portions. In contrast, the heat exchanger of FIG. 2 obtained by the manufacturing method of the present disclosure has no steps on the surface.

[0020] In the manufacturing method of the present disclosure, the area of the coating material applied to one resin frame (when the coating material is arranged above and below the resin frame, it is the area of the coating material on one side. Hereinafter, it is also referred to as the "area of the open surface") is 1500 cm 2 Even if it is larger than or equal to, the generation of steps such as wrinkles on the surface is suppressed, and the area of the open surface may be 6000 cm 2 or more, and may be 12000 cm 2 or more. In the case of a resin frame, there are two open surfaces in the vertical direction, but the area of the open surface referred to here is the area of one open surface. Note that the area of the open surface may be 25 cm 2 or more, may be 100 cm 2 or more, may be 500 cm 2 or more, and may be 1000 cm 2 or more.

[0021] Hereinafter, the manufacturing method of the heat exchanger of the present disclosure will be described with reference to the drawings. FIG. 3 is a diagram for explaining an example of the manufacturing method of the heat exchanger of the present disclosure, and FIG. 4 is a diagram for explaining the members used in the manufacturing method of FIG. 3. In Figures 3 and 4, a resin frame 10, an inner fin 12, and a covering material 14 are used as components. Since the resin frame 10 has two open surfaces in the vertical direction, two pieces of the covering material 14 are used.

[0022] Furthermore, as shown in Figure 4, the heat exchanger may include a header section 18 having an inlet for the cooling medium and a footer section 19 having an outlet for the cooling medium. The shapes of the header section 18 and the footer section 19 may be the same or different. In Figure 4, the header section 18 is on the right and the footer section 19 is on the left, but they may be reversed. The mounting positions of the header section 18 and footer section 19 of the resin frame 10 have a space that serves as a collection channel 11. The cooling medium flowing in from the inlet of the header section 18 first enters this collection channel 11, flows through multiple channels formed by the inner fins 12, is then collected in the collection channel 11 on the header section 19 side, and then flows out from the outlet of the header section 19.

[0023] As shown in Figure 3, unwinding coils 22a and 22b for unwinding the covering material 14 are positioned upstream of the pair of heat rollers 20a and 20b. The heat rollers 20a and 20b can be made of any material that can be heated, such as rubber or metal. In order to arrange the covering material 14 on the two open surfaces in the vertical direction of the resin frame 10, the unwinding coil 22a is positioned corresponding to the upper heat roller 20a, and the unwinding coil 22b is positioned corresponding to the lower heat roller 20b.

[0024] Since the covering material 14 is wound around the unwinding coils 22a and 22b, the covering material 14 is a long piece. The width of the covering material 14 can be appropriately designed to match the width of the resin frame 10, and may be, for example, 10 cm or more, 30 cm or more, or 50 cm or more. Alternatively, the width of the covering material 14 may be 70 cm or less.

[0025] The covering material 14 may have resin layers on both sides of the heat transfer layer. The resin layers on both sides will be heat-fused to the resin frame 10.

[0026] The heat transfer layer is preferably a metal layer from the viewpoint of thermal conductivity and processability. Examples of metal layers include aluminum foil, stainless steel foil, nickel foil, plated copper foil, and clad metal of nickel foil and copper foil. From the viewpoint of thermal conductivity and cost, aluminum foil is preferred. The thickness of the heat transfer layer is preferably 4 μm or more, and more preferably 8 μm or more. Furthermore, the thickness of the heat transfer layer is preferably 300 μm or less, and more preferably 150 μm or less.

[0027] The resin layer is composed of a heat-sealable resin, and examples of such resins include polyolefin resins such as polyethylene and polypropylene, modified resins thereof, fluororesins, polyester resins such as PET resin, and vinyl chloride resin. The thickness of the resin layer is preferably 4 μm or more, and more preferably 8 μm or more. Furthermore, the thickness of the resin layer is preferably 100 μm or less, and more preferably 50 μm or less.

[0028] The heat transfer layer and the resin layer may be laminated together to form a laminate material. Other layers may or may not be provided between the heat transfer layer and the resin layer.

[0029] The total thickness of the coating material 14 is preferably 12 μm or more, preferably 50 μm or more, and more preferably 100 μm or more. Furthermore, the total thickness of the coating material 14 is preferably 900 μm or less, preferably 500 μm or less, and more preferably 200 μm or less.

[0030] The covering material 14 unwound from the unwinding coils 22a and 22b is guided to the heat rollers 20a and 20b by the rotation of the heat rollers 20a and 20b. At this time, it is preferable to bias the unwinding coils 22a and 22b in the opposite direction to the unwinding rotation to apply tension to the covering material 14, so that wrinkles do not form in the covering material 14.

[0031] Downstream of the heat rollers 20a and 20b, a pair of feed rollers 24a and 24b are placed. Multiple pairs of feed rollers 24a and 24b may be arranged.

[0032] Then, the resin frame 10 and inner fins 12 are sandwiched between the pair of heat rollers 20a and 20b from the upstream side. Before sandwiching them between the heat rollers 20a and 20b, the inner fins 12 are positioned inside the resin frame 10.

[0033] When manufacturing a heat exchanger having a header section 18 and a footer section 19, the header section 18 and the footer section 19 may be attached as a separate process after heat fusion with heat rollers 20a and 20b. The method of attaching the header section 18 and the footer section 19 is not particularly limited, and they may be attached by methods such as hot plate welding. When attaching the header section 18 and the footer section 19 as a separate process after heat fusion with heat rollers 20a and 20b, temporary members may be placed in place of the header section 18 and the footer section 19 during heat fusion with heat rollers 20a and 20b. In this case, after heat fusion with heat rollers 20a and 20b, the temporary members are removed and the header section 18 and the footer section 19 are attached.

[0034] The size of the resin frame 10 is not particularly limited. For example, the width of the resin frame 10 may be 10 cm or more, 30 cm or more, or 50 cm or more. Also, the width of the resin frame 10 may be 70 cm or less. The length of the resin frame 10 may be 20 cm or more, 100 cm or more, or 150 cm or more. Also, the width of the resin frame 10 may be 200 cm or less. The height (thickness) of the resin frame 10 may be 2 mm or more, 5 mm or more, or 7 mm or more. The height (thickness) of the resin frame 10 may be 10 mm or less.

[0035] The resin frame 10, on which the inner fins 12 are positioned, is guided between a pair of heat rollers 20a, 20b by the rotation of the heat rollers 20a, 20b and the feed rollers 24a, 24b. When the resin frame 10 is guided between the pair of heat rollers 20a, 20b, the covering material 14 is placed on the upper and lower surfaces (open surfaces) of the resin frame 10. The covering material 14 is pressed against the resin frame 10 by the heat rollers 20a and 20b and heated. As a result, the covering material 14 and the resin frame 10 are heat-fused together.

[0036] The nip pressure applied by the heat rollers 20a and 20b can be appropriately set according to the height of the resin frame 10, the material of the coating material 14 and the resin frame 10, etc. The temperature of the heat rollers 20a and 20b can be appropriately set according to the material of the resin layer of the coating material 14 and the material of the resin frame 10, for example, it may be 180°C to 230°C or 230°C to 280°C.

[0037] If the inner fin 12 has resin layers on both sides of the heat transfer layer, the resin layer of the laminate material is heat-fused to the resin layer of the covering material 14 by pressurized heating by the heat rollers 20a and 20b. For example, as shown in Figure 4, if the inner fin 12 is made of laminate material that has been pleated to form an uneven surface, the peaks of the unevenness of the inner fin 12 are pressed against the covering material 14 and heated, causing it to heat-seal to the covering material 14. This fixes the position of the inner fin 12. The space partitioned by the unevenness of the inner fin 12 becomes a flow path for the cooling medium. Once the peaks of the unevenness are heat-sealed to the covering material 14 and the position of the inner fin 12 is fixed, displacement of the inner fin 12 is suppressed even when flow pressure of the cooling medium is generated.

[0038] The heat transfer layer in the inner fin 12 is similar to the heat transfer layer described in the coating material 14, and the material, thickness, etc. can be applied as appropriate. The resin layer in the inner fin 12 is similar to the resin layer described in the coating material 14, and the material, thickness, etc. can be applied as appropriate. From the viewpoint of effectively heat-fusing the resin layer of the inner fin 12 and the resin layer of the covering material 14, it is preferable that each resin layer is composed of the same type of resin. Also, from the viewpoint of matching thermal conductivity, the heat transfer layer of the inner fin 12 and the heat transfer layer of the covering material 14 may be composed of the same material. From the viewpoint of component procurement, the inner fin 12 and the covering material 14 may be made of the same material.

[0039] The covering material 14 is sequentially pressurized and heated in a linear manner by the heat rollers 20a and 20b and heat-fused to the resin frame 10, and then conveyed by the rotation of the feed rollers 24a and 24b to obtain a heat exchanger. It is preferable to set the conveying speed of the feed rollers 24a and 24b to be the same as or greater than the conveying speed of the heat rollers 20a and 20b. By setting the conveying speed in this way, tension is applied to the heat exchanger after heat fusion, further suppressing the occurrence of steps due to wrinkles. If the conveying speed of the feed rollers 24a and 24b and the conveying speed of the heat rollers 20a and 20b are set to be the same, for example, the setting value of the drive device that drives each roller can be followed.

[0040] In Figures 3 and 4, the inner fin 12 is positioned inside the resin frame 10, but the inner fin 12 does not necessarily have to be used.

[0041] Furthermore, in Figure 3, the upper unwinding coil 22a is positioned to lift the covering material 14 vertically, and the lower unwinding coil 22b is positioned to lower the covering material 14 vertically. However, the positions of the unwinding coils 22a and 22b are not limited. As shown by the arrows in Figure 5, the unwinding coils 22a and 22b may be positioned closer to the resin frame 10. As shown in Figure 3, when the unwinding coils 22a and 22b are arranged, the covering material 14 wraps around the heat rollers 20a and 20b in region A upstream of the nip position of the heat rollers 20a and 20b, and the covering material 14 is preheated. The positions of the unwinding coils 22a and 22b may be set according to the desired degree of preheating.

[0042] Furthermore, the surface of the heat exchanger coating material 14 obtained may be flat, curved, or inclined. In heat fusion using heat rollers 20a and 20b, the heating points between the resin frame or resin housing and the coating material are linear, so the above shapes can be accommodated. As long as linear heat fusion using heat rollers 20a and 20b is possible, the shape of the surface of the heat exchanger coating material 14 obtained is not a concern.

[0043] Furthermore, the resin frame 10 used in Figures 3 and 4 may be replaced with a channel-forming resin sheet 30 as shown in Figure 6. The channel-forming resin sheet 30 has channels 32 formed in it. The channel shape of the channel in the channel-forming resin sheet 30 shown in Figure 6 is U-shaped, but is not limited to this.

[0044] Furthermore, although a resin frame 10 is used in the embodiments described in Figures 3 and 4, this may be replaced with a resin housing 34. As shown in Figure 7, the resin housing 34 has a bottom surface and only one open surface on the top surface, so when using the resin housing 34, only one covering material 14 may be used. The covering material 14 is placed on the top surface of the resin housing 34 and heat-sealed by the upper heat roller 20a, and since the bottom surface of the resin housing 34 is not heat-sealed, the heat roller 20b does not need to be heated, but it may be heated.

[0045] The resin housing 34 in Figure 7 has a partition plate 36 on the inside, but it does not have to have a partition plate. The number and position of the partition plates 36 can also be designed as appropriate. When a resin housing 34 with partition plates 36 is used, the covering material 14 is pressed against the partition plate 36 by the heat roller 20a and heated, causing the covering material 14 and the partition plate 36 to heat-fuse together.

[0046] The heat exchanger obtained by the manufacturing method of this disclosure may have inlets and outlets for the cooling medium provided in advance or provided later. For example, as shown in Figure 7, holes 38 for the inlet and outlet of the cooling medium may be provided in the resin housing 34, and joint pipes or the like may be heat-fused to these holes. Alternatively, holes like those in Figure 7 may be made after the heat exchanger has been manufactured. Furthermore, in a heat exchanger made using the flow channel forming resin sheet 30 shown in Figure 6, holes 16 may be made in the upper covering material 14 as shown in Figure 8 to serve as inlets and outlets for the cooling medium L.

[0047] As shown in the photograph in Figure 2, the heat exchanger obtained by the manufacturing method of this disclosure can have a step on the surface of the coating material reduced to 20 μm or less, and furthermore, the step can be reduced to 15 μm or less, 10 μm or less, and 7 μm or less.

[0048] <Heat exchanger> The heat exchanger of this disclosure has a covering material having resin layers on both sides of the heat transfer layer, which is placed on at least one of the two open surfaces of the resin frame or on the open surface of the resin housing, the resin frame or the resin housing and the covering material are heat-fused together, the step difference on the surface of the covering material is 20 μm or less, and the area of ​​the open surface is 1500 cm². 2 That concludes the disclosure. The heat exchanger of this disclosure may be obtained by the manufacturing method of this disclosure. The heat exchanger of this disclosure has an open surface area of ​​6000 cm². 2 Even with the above conditions, the surface step of the coating material is kept to 20 μm or less.

[0049] The surface step height of the coating material is the average value obtained by measuring 20 arbitrary points using a contour shape measuring device.

[0050] The covering material, resin frame, and resin housing in the heat exchanger of this disclosure may appropriately refer to the covering material, resin frame, and resin housing in the manufacturing method of this disclosure.

[0051] <Structure> The structure of the present disclosure comprises a heat exchanger of the present disclosure and a heat exchanger provided on the heat exchanger. Examples of heat exchangers include heat-generating elements such as electronic devices like smartphones and personal computers, battery modules and power semiconductor modules used in electric vehicles and hybrid vehicles. The heat exchanger is placed on the covering material of the heat exchanger. If two covering materials are heat-fused to a resin frame, the heat exchanger may be placed on both covering materials or on only one of them. [Explanation of symbols]

[0052] 10 Resin frame 11 Collecting channel 12 Inner Fins 14 Covering material 16 holes 18 Header section 19 Footer section 20a, 20b Heat Roller 22a, 22b Unwinding coil 24a, 24b Feed roller 30 Flow channel forming resin sheet 32 channels 34 Resin housing 36 partition plates 38 holes

Claims

1. A method for manufacturing a heat exchanger, comprising placing a covering material on at least one of the two open surfaces of a resin frame or on an open surface of a resin housing, and heat-sealing the resin frame or resin housing and the covering material using a heat roller.

2. A method for manufacturing a heat exchanger according to claim 1, wherein an unwinding coil for unwinding the covering material is placed upstream of the heat roller, and tension is applied to the covering material by biasing the unwinding coil in a direction opposite to the unwinding rotation.

3. A method for manufacturing a heat exchanger according to claim 1 or 2, wherein at least one pair of feed rollers are arranged downstream of the heat roller, and the conveying speed by the feed rollers is set to be the same as or greater than the conveying speed by the heat roller.

4. The area of ​​the open surface is 25 cm² ２ The method for manufacturing a heat exchanger according to claim 1 or claim 2.

5. The method for manufacturing a heat exchanger according to claim 1 or claim 2, wherein the covering material comprises a heat transfer layer and resin layers disposed on both sides of the heat transfer layer.

6. A method for manufacturing a heat exchanger according to claim 1 or claim 2, wherein inner fins are arranged inside the resin frame or the resin housing, and the heat fusion is performed.

7. The method for manufacturing a heat exchanger according to claim 6, wherein the inner fin has a heat transfer layer and resin layers disposed on both sides of the heat transfer layer.

8. The method for manufacturing a heat exchanger according to claim 7, wherein the resin layer of the covering material and the resin layer of the inner fins are composed of the same type of resin.

9. A covering material having resin layers on both sides of the heat transfer layer is placed on at least one of the two open surfaces of the resin frame or on the open surface of the resin housing, the resin frame or resin housing and the covering material are heat-fused together, the step difference on the surface of the covering material is 20 μm or less, and the area of ​​the open surface is 1500 cm². ２ That's all for the heat exchanger.

10. The heat exchanger according to claim 9, wherein inner fins are arranged inside the resin frame or the resin housing.

11. The heat exchanger according to claim 10, wherein the inner fins are made of a laminate material having resin layers on both sides of the heat transfer layer.

12. The heat exchanger according to claim 11, wherein the resin layer of the covering material and the resin layer of the laminate material are composed of the same type of resin.

13. A structure comprising a heat exchanger according to claim 9 or claim 10, and a heat exchanger provided on the heat exchanger.

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