Method for manufacturing a flow channel member, flow channel member, and heat exchanger

Abstract

To enable the heat exchanger to have a curved flow path while suppressing a decrease in performance. [Solution] The method for manufacturing a flow channel member includes a forming step of forming a fluid flow channel in a sheet material (J) by pressing the sheet material (J) with a mold (400), wherein the fluid flow channel includes a first flow channel (Z1) extending along a first direction (VA) and a second flow channel (Z2) which is a flow channel leading to the first flow channel (Z1) and extends along a second direction (VB) which is a direction different from the first direction (VA), wherein the flow channel member (111) includes a first projection (11A1) that forms the first flow channel (Z1) and a second projection (11A2) that forms the second flow channel (Z2), and the molding surface (410A, 420A) has a first molding section (413A) and a second molding section (423A), and in the molding process, the first molding end (413A1) and the second molding end (423A1) are spaced apart (M) from each other, and the sheet material (J) is pressed by the mold (400).

Description

Technical Field

[0006] , , , ,

[0001] The present disclosure relates to a method for manufacturing a flow path member, a flow path member, and a heat exchanger.

Background Art

[0002] Patent Document 1 discloses a heat exchanger. The heat exchanger of Patent Document 1 has a structure in which a fluid passage formed using a corrugated flow path member is formed in multiple stages by stacking tube plates (partition members) with a pair of spacer bars (spacer members) interposed therebetween. In each fluid passage, corrugated fins (flow path members) are arranged along the flow direction thereof.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When a plate-like member is press-worked into a corrugated shape to form a corrugated flow path member having a meandering, bent, or otherwise folded flow path (fluid passage), excessive pressure is applied to the bent portions of the flow path compared to the straight portions, resulting in deformation, cracking, and other damage, which may reduce the performance (heat exchange capacity) of the heat exchanger.

[0005] An object of the present disclosure is to provide a flow path member, a heat exchanger, and a method for manufacturing a heat exchanger that can suppress a decrease in the performance of the heat exchanger while having a bent flow path.

Means for Solving the Problems

[0006] A method for manufacturing a flow channel member according to the first embodiment is a method for manufacturing a corrugated flow channel member (111) used in a heat exchanger (1) to form a fluid flow channel, and includes a forming step of forming the fluid flow channel in the plate material (J) by pressing the plate material (J) with a mold (400), wherein the fluid flow channel includes a first flow channel (Z1) extending along a first direction (VA) and a second flow channel that is connected to the first flow channel (Z1) and is in a direction different from the first direction (VA). The flow channel member (111) includes a second flow channel (Z2) extending along (VB), and the flow channel member (111) includes a first projection (11A1) that forms the first flow channel (Z1) and a second projection (11A2) that forms the second flow channel (Z2), the first end (11A11) of the first projection (11A1) being connected to or located around the second end (11A21) of the second projection (11A2), and the molding surface (410A, 420A) has a first molding section (413A) located at a location corresponding to the first protrusion (11A1) and a second molding section (423A) located at a location corresponding to the second protrusion (11A2). In the forming process, the first molding end (413A1) of the first molding section (413A) located at a location corresponding to the first end (11A11) and the second molding end (423A1) of the second molding section (423A) located at a location corresponding to the second end (11A21) are spaced apart (M) from each other, and the sheet material (J) is pressed by the mold (400).

[0007] In the first embodiment, the flow channel member (111) has a bent flow channel, while suppressing a decrease in the performance of the heat exchanger (1).

[0008] In the second embodiment, the first end (11A11) of the first projection (11A1) is located around the second end (11A21) of the second projection (11A2), a first through hole (11C) is formed in the first end (11A11) and a second through hole (12C) is formed in the second end (11A21) and a second through hole (11A21) is formed.

[0009] In the second embodiment, fluid can be delivered from the first channel (Z1) to the second channel (Z2) using through holes (11C, 12C).

[0010] In the third embodiment, in the second embodiment, the forming step is to hold the portion of the plate material (J) corresponding to the portion (11B) located between the first end (11A11) and the second end (11A21) with a holding component (430), and then press the portion of the plate material (J) that will form the first protrusion (11A1) and the portion that will form the second protrusion (11A2) with the mold (400) to form the first through hole (11C) and the second through hole (12C).

[0011] In a third embodiment, through holes (11C, 12C) can be formed using a retaining component (430).

[0012] The flow channel member of the fourth embodiment is a corrugated flow channel member (111) used in a heat exchanger (1) and forming a fluid flow channel, wherein the fluid flow channel includes a first flow channel (Z1) extending along a first direction (VA) and a second flow channel (Z2) that is a flow channel following the first flow channel (Z1) and extending along a second direction (VB) which is a different direction from the first direction (VA), and the flow channel member (111) has a first projection (11A1) that forms the first flow channel (Z1) The first protrusion (11A1) includes a second projection (11A2) that forms the second flow path (Z2), the first end (11A11) of the first projection (11A1) being located around the second end (11A21) of the second projection (11A2), the first end (11A11) having a first through hole (11C) that penetrates the first end (11A11), and the second end (11A21) having a second through hole (12C) that penetrates the second end (11A21).

[0013] In the fourth embodiment, the flow channel member (111) has a bent flow channel while suppressing a decrease in the performance of the heat exchanger (1).

[0014] The heat exchanger of the fifth embodiment includes the flow path member (111) described in the fourth embodiment. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a cross-sectional view of the heat exchanger of this embodiment. [Figure 2] Figure 2 is a plan view of the first layer of the heat exchanger. [Figure 3] Figure 3 is a plan view of the second layer of the heat exchanger. [Figure 4] Figure 4 is a plan view of the partition wall member. [Figure 5] Figure 5 is a perspective view of the heat exchanger. [Figure 6] Figure 6 is a plan view of the first flow channel member. [Figure 7] Figure 7(a) is a cross-section view of the first flow channel member. Figure 7(b) is a cross-section view of Figure 7(a) between IIIb and IIIb. [Figure 8] Figure 8(a) is a plan view of the molding surface of the first lower mold. Figure 8(b) is a plan view of the molding surface of the second lower mold. Figure 8(c) is a plan view of the molding surface of the lower holding section. [Figure 9] Figures 9(a) and 9(b) are schematic diagrams showing the manufacturing process of the first flow channel member by press working. [Figure 10] Figure 10 is a plan view of a modified example of the first flow channel member. [Figure 11] Figure 11 is a plan view showing the molding surface of a mold for manufacturing a modified example of the first flow channel member shown in Figure 10. [Modes for carrying out the invention]

[0016] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. Note that the present disclosure is not limited to the embodiments shown below, and various modifications are possible without departing from the technical idea of the present disclosure. Since each drawing is for conceptually explaining the present disclosure, dimensions, ratios, or numbers may be exaggerated or simplified as necessary for easy understanding. In each embodiment, modification example, and figure, the same or corresponding parts are denoted by the same reference numerals, and detailed descriptions and explanations of their accompanying effects and the like are not repeated.

[0017] (1) Overall configuration The heat exchanger (1) according to the embodiment is a device that performs heat exchange between a plurality of fluids (refrigerants). The heat exchanger (1) is formed of a metal material such as stainless steel or aluminum, for example. As shown in FIGS. 1 and 2, the heat exchanger (1) includes a plurality of fluid layers (100) to be laminated and a partition member (200). The constituent members of the heat exchanger (1) are joined to each other by, for example, brazing.

[0018] As shown in FIG. 1, a fluid flows through each of the plurality of fluid layers (100). The plurality of fluid layers (100) are laminated along the first direction (V1). The first direction (V1) indicates the lamination direction of the plurality of fluid layers (100). The plurality of fluid layers (100) include a first layer (110) and a second layer (120). The first layer (110) and the second layer (120) are alternately laminated along the first direction (V1). The first layer (110) and the second layer (120) are arranged adjacent to each other in the first direction (V1). Different types of fluids flow through the first layer (110) and the second layer (120).

[0019] As shown in Figures 1 and 2, the first layer (110) includes a first flow channel member (111) and a first spacer member (112). The first flow channel member (111) forms a flow channel for the first fluid. In this embodiment, the first flow channel member (111) forms a curved flow channel. The first flow channel member (111) has a corrugated shape. The first flow channel member (111) includes a peak (111a) that is convex in one direction (V11) of the first direction (V1) and a valley (111b) that is convex in the other direction (V12) of the first direction (V1). The valley (111b) and the peak (111a) extend along directions parallel to each other. The direction in which the valley (111b) and the peak (111a) extend indicates the direction in which the first flow channel member (111) extends. The first flow channel member (111) allows the first fluid to flow along the direction in which the valleys (111b) and peaks (111a) extend. The flow channel member (111) has a corrugated shape with alternating peaks (111a) and valleys (111b). The first flow channel space (W1), surrounded by the peaks (111a) and the partition wall member (200), and the second flow channel space (W2), surrounded by the valleys (111b) and the partition wall member (200), form the flow channels for the first fluid. The first spacer member (112) is a member that prevents the first fluid from leaking from the first flow channel member (111) to the outside of the first flow channel member (111). The first spacer member (112) is formed in an annular shape. The first flow channel member (111) is positioned inside the first spacer member (112). The first spacer member (112) is in contact with the partition wall members (200) on both sides in the first direction (V1).

[0020] As shown in Figures 1 and 3, the second layer (120) includes a second flow channel member (121) and a second spacer member (122). The second flow channel member (121) forms a flow channel for the second fluid. In this embodiment, the second flow channel member (121) forms a flow channel extending along the second direction (V2). The second flow channel member (121) has a corrugated shape. The second spacer member (122) is a member for preventing the second fluid from leaking from the second flow channel member (121) to the outside of the second flow channel member (121). The second spacer member (122) includes a first spacer portion (122a) and a second spacer portion (122b). The second flow channel member (121) is positioned between the first spacer portion (122a) and the second spacer portion (122b). The second spacer member (122) is in contact with the partition wall members (200) on both sides in the first direction (V1).

[0021] As shown in Figures 1 and 4, the partition member (200) is a flat plate-shaped member. The partition member (200) is placed between the first layer (110) and the second layer (120) which are adjacent in the first direction (V1).

[0022] As shown in Figures 2 to 4, in each of the first spacer member (112), the second spacer member (122), and the partition wall member (200), a first side surface (1121, 1221, 201) and a first recess (1122, 1222, 202) and a second recess (1123, 1223, 203) are provided on the other side (V32) in the third direction (V3). The first recess (1122, 1222, 202) and the second recess (1123, 1223, 203) are spaced apart in the second direction (V2). Each of the first spacer member (112), the second spacer member (122), and the partition wall member (200) is provided with a second side surface (1124, 1224, 204) and a third recess (1125, 1225, 205) recessed to the second side surface (1124, 1224, 204) on one side (V21) of the second direction (V2). Each of the first spacer member (112), the second spacer member (122), and the partition wall member (200) is provided with a third side surface (1126, 1226, 206) and a fourth recess (1127, 1227, 207) recessed to the third side surface (1126, 1226, 206) on the other side (V22) of the second direction (V2). The spaces formed by the first recesses (1122, 1222, 202) communicate with each other to form the first space (T1). The spaces formed by the second recesses (1123, 1223, 203) communicate with each other to form the second space (T2). The spaces formed by the third recesses (1125, 1225, 205) communicate with each other to form the third space (T3). The spaces formed by the fourth recesses (1127, 1227, 207) communicate with each other to form the fourth space (T4). The first space (T1) communicates with the flow path of the first flow path member (111) through the gap (U1) formed between the first spacer member (112) and the first flow path member (111). The second space (T2) communicates with the flow path of the first flow path member (111) through the gap (U2) formed between the first spacer member (112) and the first flow path member (111). The first space (T1) and the second space (T2) do not communicate with the second flow channel member (121) because they face the second spacer portion (122b). The third space (T3) and the fourth space (T4) do not communicate with the first flow channel member (111) because they face the first spacer member (112).The third space (T3) and the fourth space (T4) face the second flow channel member (121) and communicate with the second flow channel member (121). The first direction (V1), the second direction (V2), and the third direction (V3) are perpendicular to each other.

[0023] As shown in Figures 2 to 5, the first spacer member (112), the second spacer member (122), and the partition wall member (200) are arranged within a space enclosed by plate-shaped members (P13, P22, P32, 300). Plate-shaped members (P13) are fixed to the first sides (1121, 1221, 201) of the first spacer member (112), the second spacer member (122), and the partition wall member (200). A first pipe (P11) and a second pipe (P12) are provided on the plate-shaped member (P13). The first pipe (P11) communicates with the first space (T1). The second pipe (P12) communicates with the second space (T2). Plate-shaped members (P22) are fixed to the first spacer member (112), the second spacer member (122), and the second side surfaces (1124, 1224, 204) of the partition wall member (200). A third pipe (P21) is provided on the plate-shaped member (P22). The third pipe (P21) communicates with the third space (T3). Plate-shaped members (P32) are fixed to the third side surfaces (1126, 1226, 206) of the first spacer member (112), the second spacer member (122), and the partition wall member (200). A fourth pipe (P31) is provided on the plate-shaped member (P32). The fourth pipe (P31) communicates with the fourth space (T4).

[0024] As shown in Figures 2 to 5, the first fluid is sent to the first space (T1) through the first pipe (P11). The first fluid sent to the first space (T1) flows through the channel of the first flow channel member (111) and is then sent to the second space (T2). The first fluid sent to the second space (T2) is discharged through the second pipe (P12). The second fluid is sent to the third space (T3) through the third pipe (P21). The second fluid sent to the third space (T3) flows through the channel of the second flow channel member (121) and is then sent to the fourth space (T4). The first fluid sent to the fourth space (T4) is discharged through the fourth pipe (P31).

[0025] The heat exchanger (1) is used, for example, in a heating appliance such as central heating. In this case, heat exchange occurs between a first fluid flowing through the channel of the first flow channel member (111) and a second fluid flowing through the channel of the second flow channel member (121), so that the first fluid, which is water, is heated by the heat of the second fluid, which is propane or carbon dioxide, and becomes hot water. This hot water is discharged through the second pipe (P2) and circulates through pipes laid inside the wall. As a result, the room is heated. The heat exchanger (1) may also be used in a water heater. The water heater supplies hot water generated by the heat exchanger (1) through heat exchange between the first fluid and the second fluid.

[0026] (2) First flow channel member The first flow channel member (111) will now be described.

[0027] As shown in Figures 6 to 7(b), the fluid channel formed by the first fluid channel member (111) includes a first fluid channel (Z1) and a second fluid channel (Z2). The first fluid channel (Z1) and the second fluid channel (Z2) form a bent fluid channel. The first fluid channel (Z1) extends along the first fluid channel direction (VA), guiding the first fluid to flow in the first fluid channel direction (VA). After flowing through the first fluid channel (Z1), the first fluid flows into the second fluid channel (Z2) and flows through the second fluid channel (Z2). The second fluid channel (Z2) is a continuation of the first fluid channel (Z1). The second fluid channel (Z2) extends along a second fluid channel direction (VB) different from the first fluid channel direction (VA), guiding the first fluid to flow in the second fluid channel direction (VB). In this embodiment, the second flow path direction (VB) is perpendicular to the first flow path direction (VA). Furthermore, both the first flow path direction (VA) and the second flow path direction (VB) are perpendicular to the first direction (V1). After the first fluid finishes flowing through the first flow path (Z1), it then flows through the second flow path (Z2), thereby changing the direction of flow of the first fluid from the first flow path direction (VA) to the second flow path direction (VB).

[0028] The first flow channel member (111) includes a projection (11A). The projection (11A) is the portion of the corrugated first flow channel member (111) between adjacent valleys (111b) (see Figure 1). The projection (11A) has a shape in which the peaks (111a) located between adjacent valleys (111b) protrude in a first direction (V1). The projection (11A) has a shape that protrudes along the projection direction (V1) while curving or bending so as to form a first flow channel space (W1) on its inside. The projection (11A) includes a first projection (11A1) and a second projection (11A2). The first projection (11A1) forms a first flow channel (Z1) and extends along the first flow channel direction (VA). The fact that the first projection (11A1) extends along the first flow direction (VA) indicates that the peak (111a) included in the first projection (11A1) extends along the first flow direction (VA). The second projection (11A2) forms the second flow path (Z2) and extends along the second flow direction (VB). The fact that the second projection (11A2) extends along the second flow direction (VB) indicates that the peak (111a) included in the second projection (11A2) extends along the second flow direction (VB). The first projection (11A1) is positioned at a distance from the second projection (11A2).

[0029] The first projection (11A1) includes a first end (11A11), which is the downstream end of the first projection (11A1). The second projection (11A2) includes a second end (11A21), which is the upstream end of the second projection (11A2). The first end (11A11) of the first projection (11A1) is located around the second end (11A21) of the second projection (11A2), and is spaced apart from the second end (11A21). The intermediate section (11B) of the first flow channel member (111), located between the first end (11A11) of the first projection (11A1) and the second end (11A21) of the second projection (11A2), has a flat shape. Viewed in the first direction (V1), a first virtual line (L1) extending along the first flow direction (VA) while passing through the first end (11A11) of the first protrusion (11A1), and a second virtual line (L2) extending along the second flow direction (VB) while passing through the second end (11A21) of the second protrusion (11A2), intersect at an intermediate point (11B).

[0030] A first through-hole (11C) is formed at the first end (11A11) of the first protrusion (11A1), penetrating the first end (11A11). The first through-hole (11C) communicates with the first flow path space (W1) (see Figure 1) of the first flow path (Z1) and the space above the intermediate section (11B). A second through-hole (12C) is formed at the second end (11A21) of the second protrusion (11A2), penetrating the second end (11A21). The second through-hole (12C) communicates with the first flow path space (W1) of the second flow path (Z2) and the space above the intermediate section (11B).

[0031] In the first flow path (Z1), the first fluid flowing through the first flow path space (W1) flows in the first flow path direction (VA) and, upon reaching the first end (11A11), is sent through the first through hole (11C) to the space above the intermediate section (11B). A portion of the first fluid sent to the space above the intermediate section (11B) is sent through the second through hole (12C) to the first flow path space (W1) of the second flow path (Z2) and flows through the first flow path space (W1) in the second flow path direction (VB). Another portion of the first fluid sent to the space above the intermediate section (11B) is sent to the second flow path space (W2) (see Figure 1) of the second flow path (Z2) and flows through the second flow path space (W2) in the second flow path direction (VB).

[0032] Furthermore, through holes are also formed at the upstream end of the first protrusion (11A1), the downstream end (11A22) of the second protrusion (11A2), and the end (11A31) of the third protrusion (11A3) that forms the third flow path (Z3) following the second flow path (Z2).

[0033] (3) Method for manufacturing the first flow channel member A method for manufacturing the first flow channel member (111) will be described. In this embodiment, the explanation will focus on the first flow channel (Z1), the second flow channel (Z2), and the manufacturing method.

[0034] As shown in Figures 8(a) to 9(b), the first flow channel member (111) is manufactured by pressing a flat plate material (J) with a mold (400). In this embodiment, a holding component (430) is also used when manufacturing the first flow channel member (111). That is, the manufacturing apparatus for the first flow channel member (111) includes a mold (400) for forming a first projection (11A1) and a second projection (11A2) on the plate material (J), and a holding component (430) for forming a first through hole (11C) at the first end (11A11) of the first projection (11A1) and a second through hole (12C) at the second end (11A21) of the second projection (11A2). The mold (400) includes a first mold (410) and a second mold (420).

[0035] The first mold (410) forms a first flow channel (Z1) (see Figure 6) in the sheet material (J). The first mold (410) includes a first upper mold (411) and a first lower mold (412). The molding surface (410A) of the first mold (410) (the molding surface (411A) of the first upper mold (411) and the molding surface (412A) of the first lower mold (412)) has a wave shape that matches the shape of the first protrusion (11A1) that forms the first flow channel (Z1). The molding surface (410A) of the first mold (410) is located in a place corresponding to the first protrusion (11A1) and includes a first molding section (413A) for forming the first protrusion (11A1). The first molded portion (413A) is located in a position corresponding to the first end portion (11A11) and includes a first molded end portion (413A1) for forming the first end portion (11A11). The first molded end portion (413A1) is located at the tip of the first molded portion (413A).

[0036] The second mold (420) forms a second flow channel (Z2) in the sheet material (J). The second mold (420) includes a second upper mold (421) and a second lower mold (422). The molding surface (420A) of the second mold (420) (the molding surface (421A) of the second upper mold (421) and the molding surface (422A) of the second lower mold (422)) has a wave shape that matches the shape of the second protrusion (11A2) that forms the second flow channel (Z2). The molding surface (420A) of the second mold (420) is located in a place corresponding to the second protrusion (11A2) and includes a second molding section (423A) for forming the second protrusion (11A2). The second molded section (423A) is located in a position corresponding to the second end (11A21) and includes a second molded end (423A1) for forming the second end (11A21). The second molded end (423A1) is located at the tip of the second molded section (423A).

[0037] The retaining part (430) forms an intermediate section (11B) in the plate material (J). The retaining part (430) includes an upper retaining part (431) and a lower retaining part (432). The upper retaining part (431) is connected to the press machine (Y1) via an elastic member such as a spring. The forming surface (430A) of the retaining part (430) (the forming surface (431A) of the upper retaining part (431) and the forming surface (432A) of the lower retaining part (432)) is flat. In the first direction (V1), the difference (D) between the height of the molding surface (432A) of the lower holding portion (432) and the respective heights of the molding surface (412A) of the first lower mold (412) and the molding surface (422A) of the second lower mold (422) is approximately the same as the distance between the peak (111a) and the valley (111b) of the first flow channel member (111).

[0038] As shown in Figures 9(a) and 9(b), a holding component (430) is placed between the first mold (410) and the second mold (420), and a sheet material (J) is placed between the molding surfaces (411A, 421A, 431A) and the molding surfaces (412A, 422A, 432A). The first upper mold (411), the second upper mold (421), and the upper holding component (431) are lowered by the press machine (Y1), thereby pressing the sheet material (J) between the molding surfaces (411A, 421A, 431A) and the molding surfaces (412A, 422A, 432A). As a result, a first flow path (Z1) and a second flow path (Z2) are formed in the sheet material (J), and the first flow path member (111) is manufactured.

[0039] By placing a holding component (430) between the first mold (410) and the second mold (420), the sheet material (J) is pressed by the first mold (410) and the second mold (420) with a gap between them, such that in the first mold (410), the first molding end (413A1) located at the position corresponding to the first end (11A11) of the first molding section (413A), and in the second mold (420), the second molding end (423A1) located at the position corresponding to the second end (11A21) of the second molding section (423A), are positioned apart from each other.

[0040] When pressing the sheet metal (J) with the die (400), the sheet metal (J) is held by the holding component (430) by sandwiching the portion (J1) corresponding to the intermediate portion (11B) between the forming surfaces (431A, 432A) of the holding component (430), while the first portion (J2) that forms the first protrusion (11A1) and the second portion (J3) that forms the second protrusion (11A2) of the sheet metal (J) are pressed by the forming surfaces (411A, 421A) and forming surfaces (412A, 422A) of the die (400). At this time, the first portion (J2) and the second portion (J3) of the sheet metal (J) are deformed into a corrugated shape, so that the first portion (11A1) is formed at the first portion (J2) and the second portion (11A2) is formed at the second portion (J3). Furthermore, at this time, the portion (J1) of the plate material (J) corresponding to the intermediate portion (11B) is held by the holding component (430), causing the first end portion (11A11) of the first portion (J2) and the second end portion (11A21) of the second protrusion (11A2) to break off and protrude from the intermediate portion (11B). As a result, a first through hole (11C) is formed at the first end portion (11A11) of the first protrusion (11A1), and a second through hole (12C) is formed at the second end portion (11A21) of the second protrusion (11A2) (see Figures 7 to 7(b)). As a result, a first flow channel member (111) including a first flow channel (Z1) and a second flow channel (Z2) is manufactured. The holding component (430) is used to form the through holes (11C, 12C).

[0041] (4) Effects As described above, the molding surface (400A) of the mold (400) has a first molding section (413A) located in a position corresponding to the first protrusion (11A1) and a second molding section (423A) located in a position corresponding to the second protrusion (11A2). In the molding process of the first flow channel member (111), the mold (400) presses the sheet material (J) with the first molding end (413A1) of the first molding section (413A) located in a position corresponding to the first end (11A11) and the second molding end (423A1) of the second molding section (423A) located in a position corresponding to the second end (11A21) at a distance (M) from each other. As a result, a gap (M) exists between the first molded end (413A1) and the second molded end (423A1), which extend in different directions from each other. This prevents excessive pressure from being applied to the area between the first molded end (413A1) and the second molded end (423A1) in the sheet material (J) during pressing, i.e., the area where the flow path of the first flow path member (111) bends. Consequently, a decrease in the performance of the heat exchanger (1) can be prevented.

[0042] Furthermore, in order to manufacture a mold for forming a single channel having a bent shape, the shape of the molding surface that forms the bend of the channel in the mold is complex (fine), so the tools used to manufacture the mold also become thinner, increasing the manufacturing time and cost of the mold. However, in this embodiment, since a gap (M) is left between the first molding end (413A1) of the first molding section (413A) and the second molding end (423A1) of the second molding section (423A) in the mold (400), it is possible to suppress the molding surface of the mold (400) from becoming a complex shape. As a result, it is possible to suppress an increase in the manufacturing time and cost of the mold (400).

[0043] (5) Variant As shown in Figure 10, the first through hole (11C) (see Figure 7(a)) is not formed in the first end (11A11) of the first projection (11A1), and the second through hole (12C) is not formed in the second end (11A21) of the second projection (11A2). In this case, there is no intermediate section (11B) (see Figure 6) between the first end (11A11) of the first projection (11A1) and the second end (11A21) of the second projection (11A2). In this case, the first end (11A11) of the first protrusion (11A1) and the second end (11A21) of the second protrusion (11A2) are connected via the connecting part (11D), thereby connecting the first flow channel space (W1) formed inside the first protrusion (11A1) with the first flow channel space (W1) formed inside the second protrusion (11A2). The connecting part (11D) has a shape that protrudes along the protrusion direction (V1) while being curved or bent, so as to form a space (W3) on its inside that communicates with the first flow channel spaces (W1, W11) of the first protrusion (11A1) and the first flow channel spaces (W1, W12) of the second protrusion (11A2). In this embodiment, the space (W3) of the connecting portion (11D) is narrower than the first flow path spaces (W1, W11) of the first protrusion (11A1) and the first flow path spaces (W1, W12) of the second protrusion (11A2).

[0044] As shown in Figure 11, in this case, the first flow channel member (111) is manufactured by pressing a flat plate material (J) with a mold (400). The first flow channel member (111) is manufactured using one mold (400) without using a holding part (430). The molding surface (400A) of the mold (400) (upper mold and lower mold) includes a first molding section (413A) located in a place corresponding to the first protrusion (11A1) for forming the first protrusion (11A1), a second molding section (423A) located in a place corresponding to the second protrusion (11A2) for forming the second protrusion (11A2), and a third molding section (433A) located in a place corresponding to the third protrusion (11A3) for forming the third protrusion (11A3). On the molding surface (400A) of the mold (400), a first molding end (413A1) corresponding to the first end (11A11) of the first molding section (413A) and a second molding end (423A1) corresponding to the second end (11A21) of the second molding section (423A) are arranged with a distance (M) between them. The first protrusion (11A1) and the first molding section (413A) extend along the first flow direction (VA). The second protrusion (11A2) and the second molding section (423A) extend along the second flow direction (VB). The first molding section (413A) and the second molding section (423A) extend along different directions. The second molding end (423A1) is located around the first molding end (413A1). The first molded end (413A1) and the second molded end (423A1) are positioned close to each other.

[0045] When the sheet metal (J) is pressed by the die (400), the first location on the sheet metal (J) pressed by the first forming end (413A1) and the second location pressed by the second forming end (423A1) deform slightly larger than the first forming end (413A1) and the second forming end (423A1) due to the force of the pressing and uplift, thereby forming a connecting portion (11D) between the first location and the second location on the sheet metal (J). As a result, the first end (11A11) of the first protrusion (11A1) and the second end (11A21) of the second protrusion (11A2) are connected via the connecting portion (11D).

[0046] In the modified example, the retaining component (430) is not used when manufacturing the first flow channel member (111) shown in Figure 10.

[0047] Furthermore, a connecting portion (11D1) corresponding to the connecting portion (11D) is also formed between the end (11A22) of the second protrusion (11A2) and the end (11A31) of the third protrusion (11A3).

[0048] While embodiments and modifications have been described above, it will be understood that a variety of changes in form and details are possible without departing from the spirit and scope of the claims. Furthermore, the embodiments, modifications, and other embodiments described above may be combined or substituted as appropriate, as long as they do not impair the functions covered by this disclosure.

[0049] The designations "1st," "2nd," "3rd," etc., mentioned above are used to distinguish between the terms to which these designations are attached, and do not limit the number or order of those terms. [Industrial applicability]

[0050] As described above, this disclosure is useful for methods of manufacturing flow channel members, flow channel members, and heat exchangers. [Explanation of Symbols]

[0051] 1 heat exchanger 11A1 1st protrusion 11A11 First end 11A2 Second protrusion 11A21 Second end 11C 1st through hole 12C 2nd through hole 111 First flow channel member (flow channel member) 200 Partition Member 400 molds 410A molding surface 413A 1st molding section 420A molding surface 423A 2nd molding section J Plate material M interval VA First flow path direction (first direction) VB Second flow path direction (second direction) Z1 First channel Z2 Second channel

Claims

1. A method for manufacturing a corrugated flow channel member (111) used in a heat exchanger (1) to form a fluid flow channel, The process includes a forming step of forming a fluid channel in the sheet material (J) by pressing the sheet material (J) with a mold (400), The fluid flow path includes a first flow path (Z1) extending along a first direction (VA), and a second flow path (Z2) that is connected to the first flow path (Z1) and extends along a second direction (VB) which is different from the first direction (VA). The flow channel member (111) includes a first projection (11A1) that forms the first flow channel (Z1) and a second projection (11A2) that forms the second flow channel (Z2). The first end (11A11) of the first projection (11A1) is connected to the second end (11A21) of the second projection (11A2) or is located around the second end (11A21). The molding surface (410A, 420A) of the mold (400) has a first molding section (413A) located in a place corresponding to the first protrusion (11A1) and a second molding section (423A) located in a place corresponding to the second protrusion (11A2). A method for manufacturing a flow channel member, wherein in the forming step, the first molded end (413A1) located in the first molded section (413A) corresponding to the first end (11A11) and the second molded end (423A1) located in the second molded section (423A) corresponding to the second end (11A21) are spaced apart (M) from each other, and the plate material (J) is pressed by the mold (400).

2. The first end (11A11) of the first projection (11A1) is located around the second end (11A21) of the second projection (11A2), A method for manufacturing a flow channel member according to claim 1, wherein a first through hole (11C) is formed in the first end (11A11) and a second through hole (12C) is formed in the second end (11A21) and a second through hole (11A21) is formed

3. The method for manufacturing a flow channel member according to claim 2, wherein in the forming step, the portion of the plate material (J) corresponding to the portion (11B) located between the first end (11A11) and the second end (11A21) is held by a holding component (430), and the portion of the plate material (J) where the first protrusion (11A1) and the portion where the second protrusion (11A2) is formed is pressed by the mold (400) to form the first through hole (11C) and the second through hole (12C).

4. A corrugated flow channel member (111) used in a heat exchanger (1) to form a fluid flow channel, The fluid flow path includes a first flow path (Z1) extending along a first direction (VA), and a second flow path (Z2) that is a continuation of the first flow path (Z1) and extends along a second direction (VB) which is different from the first direction (VA). The flow channel member (111) includes a first projection (11A1) that forms the first flow channel (Z1) and a second projection (11A2) that forms the second flow channel (Z2). The first end (11A11) of the first projection (11A1) is located around the second end (11A21) of the second projection (11A2), A flow channel member having a first through hole (11C) formed in the first end (11A11) and a second through hole (12C) formed in the second end (11A21).

5. A heat exchanger comprising the flow channel member (111) described in claim 4.

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