Flow channel forming member, manufacturing method, and manufacturing apparatus

Abstract

In a channel forming member that forms a channel through which a heat transfer medium passes, the number of parts is reduced while ensuring the necessary sealing performance. [Solution] A channel forming member for forming a channel through which a heat transfer medium passes is disclosed, having a first wall portion and a second wall portion, wherein the first wall portion and the second wall portion face each other at a distance from each other at the channel formation position, and have a sealing portion related to the channel outside the channel formation position, the sealing portion being formed by a mechanically deformed portion of the first wall portion and a mechanically deformed portion of the second wall portion which are integrated with each other via a joint surface.

Description

Technical Field

[0001] The present disclosure relates to a flow path forming member, a manufacturing method, and a manufacturing apparatus.

Background Art

[0002] A technique is known in which an end portion of a member forming a flow path through which a heat medium passes is sealed by another member.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the prior art, another member is required to ensure the necessary sealing performance, and reduction of the number of parts cannot be achieved.

[0005] Therefore, on one aspect, an object of the present disclosure is to reduce the number of parts while ensuring the necessary sealing performance in a flow path forming member that forms a flow path through which a heat medium passes.

Means for Solving the Problems

[0006] On one aspect, there is provided a flow path forming member that forms a flow path through which a heat medium passes, having a first wall surface portion and a second wall surface portion, wherein the first wall surface portion and the second wall surface portion face each other with a distance therebetween at a position where the flow path is formed, and have a seal portion related to the flow path outside the position where the flow path is formed, and the seal portion is formed by a mechanically deformed portion of the first wall surface portion and a mechanically deformed portion of the second wall surface portion that are integrated with each other through a joint surface.

Effects of the Invention

[0007] In one aspect, according to this disclosure, it is possible to reduce the number of parts in a channel forming member that forms a channel through which a heat transfer medium passes, while ensuring the necessary sealing performance. [Brief explanation of the drawing]

[0008] [Figure 1] This figure shows an example of an in-vehicle system 1 to which the flow path forming member of this embodiment can be applied. [Figure 2] This is a schematic diagram showing an example of the relationship between the flow path forming member and the battery in this embodiment. [Figure 3] This is a schematic cross-sectional view along line AA in Figure 2. [Figure 4] This is a schematic perspective view of a single channel forming component. [Figure 5] This is an explanatory diagram of the seal structure (seal portion) of the flow path forming member, and is a cross-sectional view along line BB in Figure 4. [Figure 6] This is a flowchart that schematically shows the manufacturing process of the channel forming member 70. [Figure 7] This is a diagram illustrating the workpiece, a perspective view showing a schematic representation of workpiece W. [Figure 8] This is a cross-sectional view along line CC in Figure 7. [Figure 9] This is an explanatory diagram of a mold, a perspective view showing a general overview of the mold. [Figure 10] This is a cross-sectional view showing the main part of the mold before the workpiece is set. [Figure 11] This is a cross-sectional view showing the main part of the mold with the workpiece set inside. [Figure 12] This is a cross-sectional view showing the essential parts of the mold when forming a seal, and it shows the relationship between the workpiece and the mold. [Modes for carrying out the invention]

[0009] Hereinafter, each embodiment will be described in detail with reference to the accompanying drawings. Note that the dimensional ratios in the drawings are merely examples and are not limited thereto. Also, the shapes and the like within the drawings may be exaggerated partially for the sake of explanation. Further, in the drawings, for the sake of clarity, in some cases, only a part of the portions having the same attribute and existing in plural are provided with reference numerals. FIG. 1 is a diagram showing an example of an in-vehicle system 1 to which a flow path forming member 70 (described later) of the present embodiment is applicable.

[0010] The in-vehicle system 1 is mounted on a vehicle. In the present embodiment, the vehicle to be mounted is an electric vehicle or a hybrid vehicle provided with a battery 5, but may also be a vehicle having only an engine as a power source.

[0011] The in-vehicle system 1 includes a refrigerant circuit 11 that circulates through a capacitor 2, an evaporator 3, and a chiller 4 for an air conditioner (not shown), a refrigerant circuit 12 that circulates through the chiller 4 and the battery 5, and a refrigerant circuit 13 that circulates through a radiator 6, a power supply system 7, and an electric motor 8.

[0012] Note that the electric motor 8 is a motor for driving the vehicle, and the power supply system 7 may include an inverter and / or a converter or the like. The battery 5 may be a high-voltage battery that serves as a power source for the electric motor 8. The radiator 6 and the capacitor 2 are disposed at the front of the vehicle and cool the refrigerant by receiving running wind or the like.

[0013] Note that the in-vehicle system 1 shown in FIG. 1 is merely an example, and the in-vehicle system to which the flow path forming member 70 (described later) of the present embodiment is applicable is arbitrary as long as it includes a refrigerant circulation path.

[0014] Hereinafter, as an example, a case where the flow path forming member 70 (described later) of the present embodiment is provided for cooling the battery 5 will be described. However, the flow path forming member 70 (described later) of the present embodiment may be used for cooling any cooling target. For example, the flow path forming member 70 (described later) of the present embodiment may be used in the refrigerant circuit 12 and / or the refrigerant circuit 13.

[0015] Figure 2 is a schematic diagram showing an example of the relationship between the flow path forming member 70 and the battery 5 in this embodiment.

[0016] The flow path forming member 70 is thermally connected to the battery 5. The flow path forming member 70 may be formed of a material with good thermal conductivity such as aluminum. In the example shown in FIG. 2, the two flow path forming members 70 are arranged between the respective cells 52 of the battery 5. The flow path forming member 70 may be in direct contact with the cell 52, or may face the cell 52 via another heat conductive member (for example, a heat conductive sheet). The number of the flow path forming members 70 is arbitrary, and the flow paths in each flow path forming member 70 communicate with each other.

[0017] Figure 3 is a schematic cross-sectional view taken along line A-A of FIG. 2.

[0018] In this embodiment, as an example, the flow path forming member 70 is a so-called multi-hole pipe, and a plurality of holes 72 form the flow path. The flow path forming member 70 is formed of a one-piece member. The flow path formed by the flow path forming member 70 forms a part of the refrigerant path 12 described above.

[0019] By the way, since this type of flow path forming member 70 has a flow path through which the refrigerant passes inside, it is useful to provide a seal structure related to the flow path. That is, it is useful for this type of flow path forming member 70 to have a seal structure that prevents the refrigerant from leaking from the inside.

[0020] In this regard, a method of realizing a seal structure by using a sealing material or joining another lid member can be considered, but in such a method, an increase in the number of parts and an accompanying increase in the manufacturing process become problems.

[0021] Therefore, in this embodiment, as will be described in detail below, a seal structure is realized that improves the manufacturability of the flow path forming member while ensuring the necessary sealing performance.

[0022] Figure 4 is a schematic perspective view of the flow path forming member 70 in its individual state, and Figure 5 is an explanatory diagram of the seal structure 77 (seal portion 78) of the flow path forming member 70, which is a cross-sectional view along line BB in Figure 4. In Figure 4, one end of the flow path forming member 70 is shown in a cross-sectional view.

[0023] Figure 4 shows the three axes (X, Y, and Z) in a right-handed coordinate system. In the following, a cross-sectional view using the XZ plane refers to a cross-sectional view obtained by cutting along the XZ plane (a view in the direction in which the cross-section shown in Figure 4 is visible). The same applies to a cross-sectional view using the YZ plane.

[0024] In this embodiment, as shown in Figure 4, the flow path forming member 70 has a seal structure 77 at its end. The seal structure 77 is provided at the extending end of each flow path (hole 72) of the flow path forming member 70, in a manner that closes each of the holes 72. The multiple holes 72 are arranged in a manner that aligns in the X direction. Each of the multiple holes 72 extends continuously and parallel to each other along the Y direction (the longitudinal direction of the flow path forming member 70). That is, the flow path forming member 70 has multiple holes 72 in a manner that has an equal cross-section. In the absence of the seal structure 77 described later, each of the multiple holes 72 opens at the longitudinal end face of the flow path forming member 70 (see workpiece W shown in Figures 7 and 8 later).

[0025] In this embodiment, the outer shape of the hole 72 in a cross-sectional view using the XZ plane is circular, but it may have other shapes. Furthermore, the holes 72 may be arranged in a manner that multiple holes are lined up in the Z direction, or they may be arranged in a staggered pattern in the Z and Y directions in a cross-sectional view using the XZ plane; the arrangement of the holes 72 is arbitrary. Also, the hole 72 may be a single hole forming a space within the flow path forming member 70.

[0026] In this embodiment, the channel forming member 70 has a flat rectangular shape when viewed in cross-section with respect to the XZ plane. However, the shape of the channel forming member 70 when viewed in cross-section with respect to the XZ plane is arbitrary. Below, the details of the channel forming member 70 will be described via the two wall portions 82 and 84 that form the two long sides of the rectangular shape.

[0027] In this embodiment, the seal structure 77 is formed by mechanically connecting two wall portions 82 and 84. In the region where the hole 72 exists, the wall portions 82 and 84 face each other at a distance. On the other hand, the wall portions 82 and 84 are connected to each other via a partition portion 85 that separates the holes 72.

[0028] Furthermore, the wall portions 82 and 84 are joined to each other in such a manner that the hole 72 is eliminated in the region where the seal structure 77 is formed, thereby forming a seal portion 78. The seal portion 78 is a seal portion relating to the flow path formed by the flow path forming member 70. Therefore, the seal portion 78 is formed outside the position where the flow path is formed.

[0029] The sealing portion 78 is provided in such a manner that all holes 72 are eliminated in the region where the sealing structure 77 is formed. In the example shown in Figure 4, the sealing portion 78 extends continuously in a linear manner from one end to the other in the X direction of the flow path forming member 70 (wall portions 82, 84). In this case, each of the multiple holes 72 is sealed without opening at the longitudinal end face of the flow path forming member 70. As a result, the flow path forming member 70 is continuously sealed by the sealing portion 78 over its entire width in the X direction.

[0030] As shown in Figure 5, the seal portion 78 is formed by a mechanically deformed portion 821 of the wall portion 82 and a mechanically deformed portion 841 of the wall portion 84, which are integrated with each other via a joint surface 90. Mechanically deformed portions such as the mechanically deformed portions 821 and 841 refer to parts that have a mechanical (e.g., irreversible) deformation of shape relative to the original material. Such a seal portion 78 (mechanically deformed portions 821 and 841) is formed by a manufacturing method (manufacturing apparatus 200) described later, and the formation method will be described later.

[0031] The mechanically deformable portion 821 of wall portion 82 and the mechanically deformable portion 841 of wall portion 84 are directly joined and integrated with each other. As a result, the sealing portion 78 can be formed using only the mechanically deformable portions 821 and 841 of the two wall portions 82 and 84, without the need for separate sealing members or lid members.

[0032] As shown in Figure 5, the mechanically deformable portion 821 of the wall portion 82 and the mechanically deformable portion 841 of the wall portion 84 have an S-shaped joint surface 90 in a cross-sectional view in the YZ plane. The method for forming the S-shaped joint surface 90 will be described later. By integrating (joining) the mechanically deformable portions 821 and 841 via such an S-shaped joint surface 90, high sealing performance can be ensured.

[0033] Next, with reference to Figure 6 and subsequent figures, the manufacturing method of the flow path forming member 70, along with the method for forming the seal structure 77 (seal portion 78), will be described. Furthermore, the mold 60 will be described as a component of the manufacturing apparatus 200 for the flow path forming member 70. Although not shown in the figures, the manufacturing apparatus 200 for the flow path forming member 70 also includes a power source and mechanism for generating clamping force in addition to the mold 60.

[0034] Figure 6 is a flowchart schematically showing the manufacturing process of the flow path forming member 70. Figure 7 is an explanatory diagram of the workpiece W, a schematic perspective view of the workpiece W. Figure 8 is a cross-sectional view along line CC in Figure 7. Figure 9 is an explanatory diagram of the mold 60, a schematic perspective view of the mold 60. Figure 10 is a cross-sectional view showing the main part of the mold 60 (the part that forms the seal portion 78) before the workpiece W is set. Figure 11 is a cross-sectional view showing the main part of the mold 60 with the workpiece W set. Figure 12 is a cross-sectional view showing the main part of the mold 60 when the seal portion 78 is formed, and is a cross-sectional view showing the relationship between the workpiece W and the mold 60.

[0035] In the following explanation related to mold 60, the Z direction is defined as the vertical direction, and the positive side of the Z direction is defined as the upper side.

[0036] First, this manufacturing method includes a step (S600) of preparing a workpiece W for forming the flow channel forming member 70. The workpiece W may differ from the flow channel forming member 70 only in that it does not have a sealing portion 78 (see Figures 4 and 5), as shown in Figures 7 and 8. That is, at this stage, as shown in Figures 7 and 8, each hole 72 of the workpiece W has an equal cross-section (cross-sectional view from the XZ plane) and extends along the Y direction.

[0037] Next, this manufacturing method includes a step (S602) of setting the workpiece W in the mold 60. Figure 9 shows the mold 60 with the workpiece W set in place (however, the workpiece W is not visible in Figure 9). The mold 60 includes a die 61, a punch 62, a Y-direction pressing member 63, an X-direction pressing member 64, and a Z-direction pressing member 65.

[0038] When the workpiece W is set in the mold 60, the die 61 supports the workpiece W in a manner that makes surface contact with the lower surface (the negative side in the Z direction) of the workpiece W (see Figure 11). However, as shown in Figure 10, the die 61 has a groove 612 that is recessed downwards from the basic surface 610 that makes surface contact, and a punch receiving portion 613 that receives the punch 62. The punch receiving portion 613 has a receiving surface 6130 that is shallower than the groove 612 but is located below the basic surface 610. In the region where the workpiece W is supported, the die 61 has an equicross-sectional shape in which the cross-section shown in Figure 10 is realized at each position in the X direction.

[0039] The shape of the groove 612 is arbitrary, but preferably, as shown in Figure 10, it is a circular arc (approximately a semicircle) in cross-sectional view along the YZ plane. The wall surface 611 from the base surface 610 to the groove 612 is a straight line perpendicular to the surface 610 in cross-sectional view along the YZ plane, but it may have other shapes. For example, it may be a concave shape that is slightly recessed on the negative side in the Y direction, or a convex shape that is slightly protruding on the positive side in the Y direction.

[0040] The punch 62 is positioned opposite the punch receiving portion 613 in the vertical direction. The punch 62 is vertically movable, and by lowering to the lower position, it is possible to apply a local force (a load for forming) to the workpiece W on the die 61. The lower end face of the punch 62 may be a flat surface that makes surface contact with the workpiece W. The lower end face of the punch 62 is parallel to the receiving surface 6130 and faces the entire receiving surface 6130 in the vertical direction. In addition to the entire receiving surface 6130, the lower end face of the punch 62 may also face a part of the positive Y-direction side of the groove 612 in the vertical direction.

[0041] The Y-direction pressing member 63 presses the Y-direction end of the workpiece W in the Y-direction when the workpiece W is set in the mold 60. The Y-direction pressing member 63 may be in contact with the end face on the positive side in the Y-direction of the workpiece W. The Y-direction pressing member 63 may be in contact with the workpiece W across its entire width in the X-direction.

[0042] The Y-direction retaining member 63 may be movable relative to the die 61 in the Y-direction or the like. Alternatively, the Y-direction retaining member 63 may be fixed relative to the die 61. In this case, the Y-direction retaining member 63 may be formed integrally with the die 61.

[0043] The X-direction pressing member 64 presses the X-direction end of the workpiece W in the X-direction when the workpiece W is set in the mold 60. The X-direction pressing member 64 is provided on both sides of the workpiece W in the X-direction. The X-direction pressing member 64 may be in a configuration that abuts against the X-direction end face of the workpiece W. The X-direction pressing member 64 may abut against the workpiece W over the entire formation range in the Y-direction of the seal structure 77.

[0044] The X-direction pressing member 64 may be movable relative to the die 61 in the X direction or the like. Alternatively, the X-direction pressing member 64 may be fixed relative to the die 61. In this case, the X-direction pressing member 64 may be formed integrally with the die 61.

[0045] The Z-direction pressing member 65 presses downward on the upper surface of the workpiece W, specifically the area near the region where the seal structure 77 is formed, and on the negative side in the Y direction from the region where the punch 62 strikes. The Z-direction pressing member 65 may move downward in the same manner as the punch 62 and may be linked to the punch 62. The Z-direction pressing member 65 has the function of pressing downward to prevent the material from being lifted upward when it is formed by the punch 62. The Z-direction pressing member 65 may be positioned relative to the die 61 after the workpiece W has been set in the mold 60.

[0046] In the modified version, some or all of the Y-direction pressing member 63, the X-direction pressing member 64, and the Z-direction pressing member 65 may be omitted or simplified.

[0047] Next, this manufacturing method includes a step (S604) in which, with the workpiece W set, the punch 62 of the mold 60 is lowered to form a seal portion 78. The seal portion 78 is formed by the deformation of the workpiece W as the punch 62 descends. Specifically, as the punch 62 descends, the mechanical deformation portion 821 of the wall portion 82 and the mechanical deformation portion 841 of the wall portion 84 of the workpiece W are formed according to the principle of the mechanical clinch method. At this time, the material of the wall portion 84 is pushed into the groove 612 and stretches, causing the thickness within the groove 612 to decrease. The material of the wall portion 82 is pushed into the space formed in this way (see arrow R12 in Figure 12), thereby achieving the joining via the S-shaped joining surface 90 described above. In addition, deformation along the groove 612 also forms a joining surface 91 along the groove 612. The joining surface 91 is continuous with the joining surface 90 in such a manner that it shares the lower side of the joining surface 90.

[0048] Furthermore, at each position in the X-direction of the workpiece W corresponding to the hole 72, the wall portions 82 and 84 are directly joined to each other. On the other hand, at each position in the X-direction of the workpiece W corresponding to the partition portion 85, the partition portion 85 itself is crushed in the vertical direction. In this case, the material related to the partition portion 85 can move in the X-direction in a manner that fills the hole 72. That is, the partition portion 85 can deform together with the wall portions 82 and 84 in a manner that fills the hole 72.

[0049] Next, this manufacturing method includes a step (S606) of opening the mold 60 (i.e., raising the punch 62) and removing the processed workpiece W (i.e., the finished product of the flow path forming member 70). The removed workpiece W may be subjected to post-processing such as burr removal to become a finished product.

[0050] According to this embodiment, a flow channel forming member 70 having a sealing portion 78 can be manufactured from a single workpiece W. Furthermore, by utilizing the die 61 and punch 62 described above, the sealing portion 78 that seals the end of the flow channel forming member 70 over the entire X direction can be formed in a single step (S604). That is, the sealing portion 78 can be efficiently manufactured using a die 61 with a groove 612 extending over the entire X direction relative to the workpiece W, and a punch 62 extending over the entire X direction relative to the workpiece W.

[0051] Furthermore, according to this embodiment, by utilizing the Y-direction pressing member 63 and the X-direction pressing member 64, the punch 62 can efficiently push the material of the workpiece W into the groove 612. In other words, the Y-direction pressing member 63 and the X-direction pressing member 64 substantially limit the escape route of the material of the workpiece W to only the groove 612, thereby efficiently forming the seal portion 78. In addition, since the Y-direction pressing member 63 and the X-direction pressing member 64 limit the range of the seal portion 78, it is possible to prevent the range of the seal portion 78 from becoming excessive.

[0052] Although each embodiment has been described in detail above, the invention is not limited to any particular embodiment, and various modifications and changes are possible within the scope described in the claims. Furthermore, it is possible to combine all or more of the components of the embodiments described above.

[0053] For example, in the embodiment described above, the seal portion 78 is formed in a straight line when viewed in the Z direction relative to the end of the workpiece W. However, the seal portion 78 may be formed at a location other than the end of the workpiece W, or it may be formed in another shape, such as an arc shape, when viewed in the Z direction.

[0054] Furthermore, although a multi-hole pipe is used as the workpiece W in the above-described embodiment, other pipe materials that realize other flow path configurations may be used. For example, a pipe material that forms a flow path with many cylindrical fins arranged on it may be used as the workpiece W. Also, the cross-sectional shape of the workpiece W according to the XZ plane is constant over the entire Y direction, but is not limited to this. For example, the cross-sectional shape of the workpiece W according to the XZ plane may differ only in the Y direction range that forms the seal structure 77.

[0055] Furthermore, in the embodiment described above, the cross-sectional shape of the punch 62 according to the YZ plane is constant throughout the entire X direction, but this is not limited to this. For example, the cross-sectional shape of the punch 62 according to the YZ plane may differ at each position in the X direction according to the cross-sectional shape of the workpiece W according to the YZ plane (for example, the difference between the partition portion 85 and the hole 72). The same applies to the punch receiving portion 613.

[0056] Furthermore, in the embodiment described above, the Y-direction pressing member 63 functions to press the workpiece W in the Y direction from the positive Y-direction side (i.e., to prevent the workpiece W from moving towards the positive Y-direction side). In addition, another pressing member may be provided to press the workpiece W in the Y direction from the negative Y-direction side.

[0057] Furthermore, although the above-described embodiment illustrates a channel forming member 70 through which a cooling refrigerant passes, it can also be applied to a channel forming member through which a heat transfer medium passes for heating an object. In other words, the channel forming member 70 according to this embodiment can be realized as a channel forming member that forms a channel through which a heat transfer medium passes. [Explanation of symbols]

[0058] 70 Flow channel forming member, 82 Wall surface (first wall surface), 84 Wall surface (second wall surface), 78 Seal portion, 90 Joining surface, W Workpiece, 60 Mold, 61 Die, 62 Punch

Claims

1. A channel forming member that forms a channel through which a heat transfer medium passes, It has a first wall section and a second wall section, The first wall portion and the second wall portion face each other at a distance from each other at the location where the flow path is formed, and have a sealing portion related to the flow path outside the location where the flow path is formed. The sealing portion is a flow path forming member formed by a mechanically deformed portion of the first wall surface and a mechanically deformed portion of the second wall surface, which are integrated with each other via a joint surface.

2. The flow path forming member according to claim 1, wherein the sealing portion extends continuously from one end to the other end of the first wall portion and the second wall portion.

3. The connecting surface is S-shaped in cross-sectional view, as described in claim 1 or 2.

4. A method for manufacturing a channel forming member that forms a channel through which a heat transfer medium passes, A step of preparing a workpiece having a first wall portion and a second wall portion that are at a distance from each other and facing each other, A setting step of setting the aforementioned workpiece into a mold, The process includes a machining step performed on the workpiece set in the mold, applying a localized force to the workpiece outside the location where the flow path is formed, thereby forming a mechanically deformed portion of the first wall surface and a mechanically deformed portion of the second wall surface that are integrated with each other via a joint surface. A manufacturing method comprising forming a sealing portion related to the flow path between the mechanically deformed portion of the first wall and the mechanically deformed portion of the second wall.

5. The manufacturing method according to claim 4, wherein the processing step includes pressing the workpiece material into grooves of the mold that extend continuously from one end to the other of the first wall portion and the second wall portion, thereby forming a mechanically deformed portion of the first wall portion and a mechanically deformed portion of the second wall portion.

6. The manufacturing method according to claim 4, wherein the joining surface has an S-shape in cross-sectional view.

7. A manufacturing apparatus for a channel forming member that forms a channel through which a heat transfer medium passes, The mold is equipped with a first wall portion and a second wall portion that are separated from each other and face each other, and is capable of setting a workpiece. The aforementioned mold is A die having a groove, The punch includes a mechanism that presses the workpiece material into the groove to form the mechanically deformed portion of the first wall surface and the mechanically deformed portion of the second wall surface, A manufacturing apparatus in which the mechanically deformed portion of the first wall surface and the mechanically deformed portion of the second wall surface form a sealing portion related to the flow path.

Images