Cooler and method for manufacturing a cooler

Abstract

The present invention provides a cooler and a method for manufacturing a cooler that can suppress deformation caused by thermal welding between a resin component and a metal component. [Solution] The cooler 1 comprises a resin member 2, a first metal member 3 and a second metal member 4 arranged on both sides of the resin member 2, wherein the resin member 2 has a substantially flat intermediate wall portion 21, a first peripheral wall portion 22 and a second peripheral wall portion 23 rising from the periphery of the intermediate wall portion 21, a first space portion 26 surrounded by a first surface portion and the first peripheral wall portion 22, a second space portion 28 surrounded by a second surface portion and the second peripheral wall portion 23, a first opening 27 through which the first space portion 26 opens to the outside, and a second opening 29 through which the second space portion 28 opens to the outside, and the first peripheral wall portion 22 of the resin member 2 and the first metal member 3 are heat-welded together to form a first cavity, and the second peripheral wall portion 23 of the resin member 2 and the second metal member 4 are heat-welded together to form a second cavity.

Description

Technical Field

[0001] The present invention relates to a cooler and a method for manufacturing the same.

Background Art

[0002] As a method for joining a resin member and a metal member, welding is known in which a heated resin member and a heated metal member are pressed in a contacted state, so that the softened or melted resin is joined to the metal. By this method, a container having an internal space sandwiched between the resin member and the metal member can be manufactured. Such a container can be used, for example, as a cooler.

[0003] For example, Patent Document 1 describes a water-cooled cooler manufactured by joining a hollow metal container (a first aluminum container and a second aluminum container) and a resin member made of a thermoplastic resin. In the resin member, a joining member pre-provided with flow paths for a cooling medium by being arranged with a plurality of flow path walls, and a refrigerant inlet portion and a refrigerant outlet portion made of a thermoplastic resin are integrally formed.

[0004] In manufacturing the cooler of Patent Document 1, first, the resin member is placed on the second aluminum container, and then the first aluminum container is placed on the resin member. The first aluminum container is disposed such that a hollow portion is formed inside when the first aluminum container and the second aluminum container are combined. Then, pressure bonding is performed by heating from both sides of the first aluminum container and the second aluminum container. Thereby, the lower surface of the first aluminum container, the upper surface of the joining member, the upper surface of the refrigerant inlet portion and the upper surface of the refrigerant outlet portion are thermocompression bonded. Similarly, the upper surface of the second aluminum container, the lower surface of the joining member, the lower surface of the refrigerant inlet portion and the lower surface of the refrigerant outlet portion are thermocompression bonded, so that the cooler is assembled.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2014-195068 [Overview of the project] [Problems that the invention aims to solve]

[0006] When joining resin and metal components by welding, both components are heated, and then their temperature drops to room temperature (cools) after joining. Because the coefficients of linear expansion of the resin and metal components are different, deformation (warping, distortion) or cracking (cracks, fissures) may occur in the joined components after cooling due to the expansion and contraction of the materials caused by the temperature change during heating and cooling.

[0007] In the cooler described in Patent Document 1, deformation along the longitudinal direction of the cooler can be suppressed by providing multiple flow path walls along the longitudinal direction of the joining member (the direction connecting the refrigerant inlet and refrigerant outlet). However, in Patent Document 1, deformation of the cooler along the direction intersecting the direction in which the multiple flow path walls are provided (the short direction) could not be suppressed.

[0008] Furthermore, in the cooler described in Patent Document 1, deformation of the central part of the cooler can be suppressed by providing multiple flow channel walls in the central part of the joint member. However, in Patent Document 1, deformation of the peripheral part where multiple flow channel walls are not provided could not be suppressed.

[0009] The present invention aims to provide a cooler and a method for manufacturing a cooler that can suppress deformation caused by thermal welding between a resin member and a metal member. [Means for solving the problem]

[0010] [1] A cooler comprising a resin member and a first metal member and a second metal member arranged on both sides of the resin member, wherein the resin member comprises a substantially flat intermediate wall portion, a first peripheral wall portion rising from the periphery of the intermediate wall portion on the first surface portion of the intermediate wall portion, a second peripheral wall portion rising from the periphery of the intermediate wall portion on the second surface portion of the intermediate wall portion opposite to the first surface portion of the intermediate wall portion, a first space portion surrounded by the first surface portion and the first peripheral wall portion, a second space portion surrounded by the second surface portion and the second peripheral wall portion, and the first space portion opening to the outside surrounded by the first peripheral wall portion. A cooler characterized by having a first opening and a second opening surrounded by the second peripheral wall portion, the first peripheral wall portion of the resin member and the first metal member being heat-welded together to seal the first opening, thereby forming a first cavity between the first surface portion, the first peripheral wall portion, and the first metal member, and the second peripheral wall portion of the resin member and the second metal member being heat-welded together to seal the second opening, thereby forming a second cavity between the second surface portion, the second peripheral wall portion, and the second metal member.

[0011] [2] The cooler according to [1], wherein the first surface side and the second surface side have a substantially symmetrical shape with respect to the intermediate wall.

[0012] [3] The cooler according to [2], wherein the first surface portion and the second surface portion are arranged substantially symmetrically with respect to the intermediate wall portion, and the first peripheral wall portion and the second peripheral wall portion are arranged linearly in a direction perpendicular to the intermediate wall portion.

[0013] [4] The resin member is The cooler according to [1], having a first support portion that rises from the center of the intermediate wall portion in the first surface portion and extends in the in-plane direction of the intermediate wall portion, and a second support portion that rises from the center of the intermediate wall portion in the second surface portion and extends in the in-plane direction of the intermediate wall portion.

[0014] [5] The cooler according to [4], wherein the front first support portion is heat-welded to the first metal member, and the front second support portion is heat-welded to the second metal member.

[0015] [6] The cooler according to [4], wherein the height position of the joint surface of the first peripheral wall portion and the joint surface of the first support portion are the same, and the height position of the joint surface of the second peripheral wall portion and the joint surface of the second support portion are the same.

[0016] [7] The cooler according to [1], wherein the resin member has a first circumferential wall portion having a first stepped side surface extending from the end face of the first circumferential wall portion toward the intermediate wall portion, and a first stepped bottom surface protruding inward from the first stepped side surface, and the second circumferential wall portion having a second stepped side surface extending from the end face of the second circumferential wall portion toward the intermediate wall portion, and a second stepped bottom surface protruding inward from the second stepped side surface, and a first overlapping portion formed by overlapping one surface of the first metal member with the first stepped bottom surface is heat-welded, and a second overlapping portion formed by overlapping one surface of the second metal member with the second stepped bottom surface is heat-welded.

[0017] [8] The cooler according to [7], wherein the resin member has a height greater than the thickness of the first stepped side surface and a height greater than the thickness of the second stepped side surface, the first peripheral wall portion has a first vertical wall portion extending out of plane from the first metal member, and the second peripheral wall portion has a second vertical wall portion extending out of plane from the second metal member.

[0018] [9] The cooler according to [1], wherein the resin member has a first circumferential wall portion and a second circumferential wall portion, and in the circumferential wall portion, there is a first through hole and a second through hole that connect both the first cavity portion and the second cavity portion to the outside, and the resin member has at least one of a first communication hole formed inward from the end where the first through hole is provided and continuous with the first through hole, connecting the first cavity portion and the second cavity portion, and a second communication hole formed inward from the end where the second through hole is provided and continuous with the second through hole, connecting the first cavity portion and the second cavity portion.

[0019]

[10] The cooler according to [1], wherein the first metal member has a plurality of first fins on the side facing the first cavity, and the second metal member has a plurality of second fins on the side facing the second cavity.

[0020]

[11] The cooler according to [9], wherein the resin member has a third communication hole formed at a distance from the first through hole and the second through hole, and the first communication hole and the second communication hole, and connecting the first cavity and the second cavity.

[0021]

[12] The cooler according to

[11] , wherein the resin member has two or more third communication holes.

[0022]

[13] The cooler according to [1], wherein the first metal member has a rough surface on the joint surface with the resin member, the second metal member has a rough surface on the joint surface with the resin member, the first peripheral wall portion of the resin member and the joint surface of the first metal member are heat-welded together, and the second peripheral wall portion of the resin member and the joint surface of the second metal member are heat-welded together.

[0023] 〔14〕A method for manufacturing a cooler comprising a resin member, and a first metal member and a second metal member disposed on both sides of the resin member with the resin member interposed therebetween, wherein the resin member has a substantially flat plate-shaped intermediate wall portion, a first peripheral wall portion rising from a peripheral edge of the intermediate wall portion on a first surface portion of the intermediate wall portion, a second peripheral wall portion rising from a peripheral edge of the intermediate wall portion on a second surface portion of the intermediate wall portion opposite to the first surface portion, a first space portion enclosed by the first surface portion and the first peripheral wall portion, a second space portion enclosed by the second surface portion and the second peripheral wall portion, a first opening portion enclosed by the first peripheral wall portion and allowing the first space portion to open to the outside, and a second opening portion enclosed by the second peripheral wall portion and allowing the second space portion to open to the outside, the method comprising: a heating step of heating a joining surface of the first metal member and a joining surface of the second metal member; and a joining step of causing the joining surface on the first surface portion side of the resin member to face the joining surface of the first metal member, causing the joining surface on the second surface portion side of the resin member to face the joining surface of the second metal member, bringing the joining surface on the first surface portion side of the resin member into contact with the joining surface of the first metal member, and applying pressure in a state where the joining surface on the second surface portion side of the resin member is in contact with the joining surface of the second metal member, to thermally weld and join the resin member to the first metal member and the second metal member, wherein by the joining step, the first peripheral wall portion of the resin member and the first metal member are thermally welded and joined to seal the first opening portion, a first cavity portion is formed between the first surface portion, the first peripheral wall portion and the first metal member, the second peripheral wall portion of the resin member and the second metal member are thermally welded and joined to seal the second opening portion, and a second cavity portion is formed between the second surface portion, the second peripheral wall portion and the second metal member.

[0024] 〔15〕The method for manufacturing a cooler according to 〔14〕, wherein in the heating step, the joining surface of the resin member is heated.

[0025] 〔16〕The method for manufacturing a cooler according to 〔14〕, wherein in the joining step, the thermal welding joining between the first surface portion side of the resin member and the first metal member and the thermal welding joining between the second surface portion side of the resin member and the second metal member are performed simultaneously.

[0026] 〔17〕The method for manufacturing a cooler according to〔14〕, further comprising a roughening step of forming a roughened surface portion on the joint surface of the first metal member and forming a roughened surface portion on the joint surface of the second metal member, wherein in the heating step, the joint surface of the first metal member and the joint surface of the second metal member on which the roughened surface portions are formed are heated.

[0027] 〔18〕The method for manufacturing a cooler according to〔15〕, wherein in the heating step, the joint surface of the resin member, the joint surface of the first metal member, and the joint surface of the second metal member are heated in a non-contact state with a heating device, and in the joining step, the resin member, the first metal member, and the second metal member are thermally welded and joined without additional heating.

Effects of the Invention

[0028] According to the present invention, it is possible to obtain a cooler and a method for manufacturing the cooler that can suppress deformation caused by joining the resin member and the metal member by thermal welding.

Brief Description of the Drawings

[0029] [Figure 1] It is a perspective view of the cooler according to the first embodiment of the present invention as viewed from above. [Figure 2] It is a perspective view of the cooler according to the first embodiment as viewed from below. [Figure 3] It is a split perspective cross-sectional view of the cooler according to the first embodiment. [Figure 4] It is a cross-sectional view taken along line IV-IV of Fig. 1. [Figure 5] It is a perspective view showing the resin member of the first embodiment. [Figure 6] It is a cross-sectional view taken along line VI-VI of Fig. 5. [Figure 7] It is a bottom view of the resin member of the first embodiment. [Figure 8] It is a rear view of the resin member of the first embodiment. [Figure 9] It is a cross-sectional view of the first metal member of the first embodiment. [Figure 10] It is a cross-sectional view of the second metal member of the first embodiment. [Figure 11] This is an enlarged cross-sectional view of the end of the cooler according to the first embodiment. [Figure 12] This is an enlarged cross-sectional view of the central part of the cooler according to the first embodiment. [Figure 13] This is a perspective view showing the preparation steps for the manufacturing method of the cooler according to the first embodiment. [Figure 14] This is a perspective view showing the surface roughening process of the manufacturing method for a cooler according to the first embodiment. [Figure 15] This is a schematic diagram showing the heating step of the manufacturing method for a cooler according to the first embodiment. [Figure 16] This is a cross-sectional view showing the joining process of the manufacturing method for a cooler according to the first embodiment. [Figure 17] This is a perspective view showing a modified example of the cooler according to the first embodiment. [Figure 18] This is a perspective view of a cooler according to the second embodiment of the present invention, viewed from above. [Figure 19] This is a perspective view of the cooler according to the second embodiment, viewed from below. [Figure 20] Figure 17 shows a cross-sectional view along the line XIX-XIX. [Figure 21] This is a perspective view of the resin member according to the second embodiment. [Figure 22] Figure 20 shows a cross-sectional view along the line XXI-XXI. [Figure 23] This is a cross-sectional view of the first metal member of the second embodiment. [Figure 24] This is a cross-sectional view of the second metal member of the second embodiment. [Modes for carrying out the invention]

[0030] Embodiments of the present invention will be described with reference to the drawings as appropriate. The present invention is not limited to the following embodiments. Some or all of the components in each embodiment can be combined as appropriate. Directions in the description follow the arrows in Figure 1. These directions are for convenience only and do not limit the present invention.

[0031] [1. First Embodiment] As shown in Figures 1 to 3, the cooler 1 according to the first embodiment of the present invention comprises a resin member 2, a first metal member 3, and a second metal member 4. The cooler 1 is a device that cools a heating element (not shown) by circulating a fluid inside it and exchanging heat with the heating element. The first metal member 3 is on the upper side of the cooler 1, and the second metal member 4 is on the lower side. The side of the cooler 1 where the inlet 12 and outlet 13 described later are located is the rear side. The side with the inlet 12 is the right side, and the side with the outlet 13 is the left side. First, the detailed configuration of each member will be described.

[0032] [1-1. Resin components] The resin member 2 is a resin member comprising a peripheral wall portion 11, an inlet portion 12, and an outlet portion 13. The peripheral wall portion 11 is frame-shaped and plate-shaped, and is formed in a substantially rectangular shape in plan view. The in-plane direction of the peripheral wall portion 11 is parallel to the vertical direction. The four corners of the peripheral wall portion 11 are rounded. The planar shape of the peripheral wall portion 11 may be a circle, an ellipse, or other angular shape.

[0033] The rear surface of the peripheral wall portion 11 is provided with cylindrical inlet portions 12 and outlet portions 13 perpendicular to the rear surface. The resin member 2 has a first through-hole 14 on the rear surface of the peripheral wall portion 11 at the position where the inlet portion 12 is connected. The first through-hole 14 communicates with the inside of the cooler 1. In other words, the first through-hole 14 communicates with both the first cavity portion 53 and the second cavity portion 54. The resin member 2 has a second through-hole 15 on the rear surface of the peripheral wall portion 11 at the position where the outlet portion 13 is connected. The second through-hole 15 communicates with the inside of the cooler 1. In other words, the second through-hole 15 communicates with both the first cavity portion 53 and the second cavity portion 54. The inlet portion 12 and outlet portion 13 may have other shapes as long as they are cylindrical.

[0034] As shown in Figure 3, the internal structure of the resin member 2 includes an intermediate wall portion 21, a first peripheral wall portion 22, a second peripheral wall portion 23, a first support portion 24, and a second support portion 25. The intermediate wall portion 21 is rectangular in plan view, plate-like, and substantially flat.

[0035] The first circumferential wall portion 22 rises vertically upward from the periphery of the intermediate wall portion 21 relative to the intermediate wall portion 21, and in plan view it is roughly rectangular, forming a frame shape. As shown in Figure 6, the first circumferential wall portion 22 includes a first stepped side surface 22b extending from the end face 22a toward the intermediate wall portion 21, a first stepped bottom surface 22c protruding inward from the first stepped side surface 22b, and a first stepped side surface 22d extending from the first stepped bottom surface 22c toward the intermediate wall portion 21 to the upper surface 21a of the intermediate wall portion 21. The end face 22a, the first stepped side surface 22b, the first stepped bottom surface 22c, the first stepped side surface 22d, and the upper surface 21a of the intermediate wall portion 21 are each vertical (staircase-shaped) and have the same cross-section throughout the entire circumference. The first stepped bottom surface 22c is the part that joins with the first metal member 3.

[0036] The resin member 2 has a first space 26 formed by the upper surface (first surface) 21a of the intermediate wall 21 and the first peripheral wall 22. The resin member 2 also has a first opening 27 formed by the first peripheral wall 22, through which the first space 26 opens to the outside.

[0037] The second circumferential wall portion 23 rises vertically downward from the periphery of the intermediate wall portion 21, and in plan view it is roughly rectangular, forming a frame shape. The first circumferential wall portion 22 and the second circumferential wall portion 23 constitute the circumferential wall portion 11. In other words, the first circumferential wall portion 22 and the second circumferential wall portion 23 are arranged in a straight line perpendicular to the intermediate wall portion 21. As shown in Figure 6, the second circumferential wall portion 23 includes a second stepped side surface 23b extending from the end surface 23a toward the intermediate wall portion 21, a second stepped bottom surface 23c protruding inward from the second stepped side surface 23b, and a second stepped side surface 23d extending from the second stepped bottom surface 23c toward the intermediate wall portion 21 to the bottom surface 21b of the intermediate wall portion 21. The end face 23a, the second stepped side surface 23b, the second stepped bottom surface 23c, the second stepped side surface 23d, and the lower surface 21b of the intermediate wall portion 21 are all vertical (staircase-shaped) and have the same cross-section around the entire circumference. The second stepped bottom surface 23c is the part that joins with the second metal member 4.

[0038] The resin member 2 has a second space 28 formed by the lower surface (second surface portion) 21b of the intermediate wall portion 21 and the second peripheral wall portion 23. The resin member 2 also has a second opening 29 formed by the second peripheral wall portion 23, through which the second space 28 opens to the outside.

[0039] As shown in Figure 5, the first support portion 24 rises vertically from the upper surface 21a of the intermediate wall portion 21 at the center of the intermediate wall portion 21 in the left-right direction, and has a plate-like shape. In other words, the first support portion 24 rises from the center of the intermediate wall portion 21 on the upper surface (first surface portion) 21a and extends in the in-plane direction of the intermediate wall portion 21. The rear end of the first support portion 24 is continuous with the first circumferential wall portion 22 (first stepped side surface 22d), and the front end is spaced apart from the first circumferential wall portion 22 (first stepped side surface 22d). A flow path R1 is formed between the first support portion 24 and the first circumferential wall portion 22. The end face 24a of the first support portion 24 is at the same height as the first stepped bottom surface 22c. The end face 24a of the first support portion 24 is the part that is joined to the first metal member 3.

[0040] As shown in Figure 7, the second support portion 25 is plate-shaped, rising vertically from the lower surface 21b of the intermediate wall portion 21 at the center of the intermediate wall portion 21 in the left-right direction. In other words, the second support portion 25 rises from the center of the intermediate wall portion 21 on the lower surface (second surface portion) 21b and extends in the in-plane direction of the intermediate wall portion 21. The rear end of the second support portion 25 is continuous with the second circumferential wall portion 23 (second stepped side surface 23d), and the front end is spaced apart from the second circumferential wall portion 23 (second stepped side surface 23d). A flow path R2 is formed between the second support portion 25 and the second circumferential wall portion 23. As shown in Figure 6, the end face 25a of the second support portion 25 is at the same height as the second stepped bottom surface 23c. The end face 25a of the second support portion 25 is the part that joins with the second metal member 4.

[0041] Furthermore, as shown in Figure 7, a first communication hole 18 and a second communication hole 19 are formed on the rear side of the intermediate wall portion 21. The first communication hole 18 communicates with the intermediate wall portion 21 in the thickness direction and is formed so that a portion of it contacts the first stepped side surface 22d and the second stepped side surface 23d at a position corresponding to the inlet portion 12. The second communication hole 19 communicates with the intermediate wall portion 21 in the thickness direction and is formed so that a portion of it contacts the first stepped side surface 22d and the second stepped side surface 23d at a position corresponding to the outlet portion 13.

[0042] As shown in Figure 8, when the first through-hole 14 of the inlet 12 is viewed from the rear side, the first communication hole 18 (intermediate wall portion 21) is located in the center of the first through-hole 14. In other words, the first communication hole 18 is formed in the peripheral wall portion 11 from the end of the intermediate wall portion 21 inward, corresponding to the position where the first through-hole 14 is provided. The first communication hole 18 connects the first cavity portion 53 and the second cavity portion 54. Furthermore, when the second through-hole 15 of the outflow section 13 is viewed from the rear side, the second communication hole 19 (intermediate wall section 21) is located in the center of the second through-hole 15. In other words, the second communication hole 19 is formed continuously with the second through-hole 15 from the end of the intermediate wall section 21 inward, corresponding to the position where the second through-hole 15 is provided in the peripheral wall section 11. The second communication hole 19 connects the first cavity section 53 and the second cavity section 54.

[0043] As shown in Figures 5-7, the resin member 2 has a shape that is substantially symmetrical with respect to the intermediate wall portion 21. In other words, the resin member 2 has a configuration in which each component is arranged substantially symmetrically with respect to the intermediate wall portion 21.

[0044] The resin member 2 can be made of any resin, and its manufacturing method and material are not particularly limited, but in this embodiment it is made of PPS (Polyphenylene sulfide) and formed by injection molding. The resin member 2 may be, for example, a thermoplastic resin, such as polyethylene, polypropylene, ABS resin, acrylic resin, polyamide, or polycarbonate. In this embodiment the resin member 2 is integrally formed as a single component, but it may be formed by combining multiple components.

[0045] [1-2. First Metal Component] As shown in Figure 9, the first metal member 3 is made of metal and is the part that exchanges heat with the heating element. The first metal member 3 comprises a first substrate 31, a plurality of first fins 32, a peripheral portion 33, and a central portion 34. The first substrate 31 is rectangular in plan view and has a plate-like shape. The first substrate 31 is sized to be placed on the first stepped bottom surface 22c. The thickness of the first substrate 31 is smaller than the height dimension of the first stepped side surface 22b.

[0046] The first fin 32 is a plate-shaped member that falls perpendicularly to the lower surface 31b of the first substrate 31. In other words, the first metal member 3 has multiple first fins 32 on the side facing the first cavity 53, which will be described later. Multiple first fins 32 are arranged side by side with gaps between them, and their in-plane direction is parallel to the front-rear direction. The height dimension of the first fins 32 is approximately the same as the height dimension of the first support portion 24 and the first stepped side surface 22d. As shown in Figure 14, the peripheral portion 33 and the central portion 34 are spaces on the first substrate 31 where the first fins 32 are not arranged. The peripheral portion 33 is provided around the entire circumference of the periphery of the first substrate 31. The central portion 34 is provided linearly in the center in the left-right direction, parallel to the front-rear direction. The upper surface 31a, which is the surface opposite to the lower surface 31b of the first substrate 31, functions as the mounting surface for the heat-generating element when assembled as the cooler 1.

[0047] A rough surface portion S1 is formed on the peripheral portion 33, and a rough surface portion S2 is formed on the central portion 34. In Figure 14, the rough surface portions S1 and S2 are represented by dots. Both ends of the rough surface portion S2 are connected to the rough surface portion S1. The rough surface portions S1 and S2 are formed to increase the welding strength with the resin, and are processed to have a rough surface. The peripheral portion 33 and the central portion 34 (rough surface portions S1 and S2) are the parts that form the joint surface with the resin member 2. In other words, the first metal member 3 has rough surface portions S1 and S2 formed on the joint surface with the resin member 2.

[0048] The first metal member 3 can be any metal that can be heat-welded, and in this embodiment, an aluminum alloy is used. Aluminum alloys are preferred because they are lightweight, easy to process, and have high thermal conductivity. The first metal member 3 may be, for example, a copper alloy, stainless steel, or iron. From the viewpoint of thermal conductivity, a copper alloy is preferred. From the viewpoint of strength and chemical resistance, stainless steel is preferred.

[0049] [1-3. Second Metal Component] As shown in Figure 10, the second metal member 4 is made of metal and is the part that exchanges heat with the heating element. The second metal member 4 comprises a second substrate 41, a plurality of second fins 42, a peripheral portion 43, and a central portion 44. The second substrate 41 is rectangular in plan view and has a plate-like shape. The second substrate 41 is sized to be placed on the bottom surface 23c of the second step. The thickness of the second substrate 41 is smaller than the height dimension of the side surface 23b of the second step.

[0050] The second fin 42 is a plate-shaped member that rises perpendicularly to the upper surface 41a of the second substrate 41. In other words, the second metal member 4 has multiple second fins 42 on the side facing the second cavity 54, which will be described later. Multiple second fins 42 are arranged side by side with gaps between them, and their in-plane direction is parallel to the front-rear direction. The height dimension of the second fins 42 is approximately the same as the height dimension of the second support portion 25 and the second stepped side surface 23d. The peripheral portion 43 and the central portion 44 are spaces on the second substrate 41 where the second fins 42 are not arranged. The peripheral portion 43 is provided around the entire circumference of the periphery of the second substrate 41. The central portion 44 is provided in a straight line parallel to the front-rear direction at the center in the left-right direction. The lower surface 41b of the second substrate 41, which is the surface opposite to the upper surface 41a, functions as the mounting surface for the heat-generating element when assembled as the cooler 1.

[0051] A roughened surface portion S1 is formed on the peripheral portion 43, and a roughened surface portion S2 is formed on the central portion 44. It is preferable that the shapes of the roughened surfaces S1 and S2 of the first metal member 3 and the second metal member 4 are substantially the same. The peripheral portion 43 and the central portion 44 (roughened surfaces S1 and S2) are the parts that form the bonding surface with the resin member 2. In other words, the second metal member 4 has roughened surfaces S1 and S2 formed on the bonding surface with the resin member 2.

[0052] The second metal member 4 can be any metal that can be heat-welded, and in this embodiment, an aluminum alloy is used. Aluminum alloys are preferred because they are lightweight, easy to process, and have high thermal conductivity. The second metal member 4 may be, for example, a copper alloy, stainless steel, or iron. From the viewpoint of thermal conductivity, a copper alloy is preferred. From the viewpoint of strength and chemical resistance, stainless steel is preferred.

[0053] The first metal member 3 and the second metal member 4 are the same size and shape and are positioned opposite each other. In other words, as shown in Figure 4, the first metal member 3 and the second metal member 4 are substantially symmetrical in shape with respect to the intermediate wall 21. To put it another way, the first metal member 3 and the second metal member 4 have their constituent parts arranged substantially symmetrically with respect to the intermediate wall 21.

[0054] As described above, the resin member 2 has a shape that is substantially symmetrical with respect to the intermediate wall portion 21, and the first metal member 3 and the second metal member 4 have shapes that are substantially symmetrical with respect to the intermediate wall portion 21. As a result, the cooler 1 has a shape that is substantially symmetrical with respect to the intermediate wall portion 21 on both the upper surface (first surface portion) 21a side and the lower surface (second surface portion) 21b side. Furthermore, the cooler 1 has an arrangement that is substantially symmetrical with respect to the intermediate wall portion 21 on both the upper surface (first surface portion) 21a side and the lower surface (second surface portion) 21b side, and the first peripheral wall portion 22 and the second peripheral wall portion 23 are arranged in a straight line perpendicular to the intermediate wall portion 21.

[0055] [1-4.Joining form] Figure 11 is an enlarged cross-sectional view of the end of the cooler according to the first embodiment. As shown in Figure 11, the first stepped bottom surface 22c of the resin member 2 and the peripheral edge 33 of the first metal member 3 are joined by welding around the entire circumference. In other words, the first overlapping portion 55, formed by overlapping one surface (peripheral edge 33) of the first metal member 3 with the first stepped bottom surface 22c, is heat-welded. Furthermore, the first peripheral wall portion 22 of the resin member 2 and the first metal member 3 are heat-welded to seal the first opening 27, and the first cavity portion 53 is formed between the upper surface (first surface portion) 21a, the first peripheral wall portion 22, and the first metal member 3. The side surface 31c of the first substrate 31 and the first stepped side surface 22b may be welded together, but in this embodiment they are either in contact or facing each other with a small gap between them. Also, the end surface 32a of the first fin 32 may be welded together with the upper surface 21a of the intermediate wall portion 21, but in this embodiment they are either in contact or facing each other with a small gap between them.

[0056] Furthermore, a first vertical wall portion 51 is formed on the first stepped side surface 22b, extending out of plane from the upper surface 31a of the first substrate 31. In other words, the first vertical wall portion 51 is formed when the height dimension of the first stepped side surface 22b is greater than the thickness dimension of the first substrate 31 of the first metal member 3. A heating element may be placed in the upper space enclosed by the upper surface 31a of the first substrate 31 and the first vertical wall portion 51 extending in the circumferential direction. Alternatively, as shown in Figure 1, a cover member (not shown) may be installed on the end face 22a of the peripheral wall portion 11 to cover the entire surface, thereby covering the upper space while arranging the heating element.

[0057] On the other hand, as shown in Figure 11, the second stepped bottom surface 23c of the resin member 2 and the peripheral edge 43 of the second metal member 4 are joined by welding around their entire circumference. In other words, the second overlapping portion 56, formed by overlapping one surface (peripheral edge 43) of the second metal member 4 with the second stepped bottom surface 23c, is heat-welded. Furthermore, the second peripheral wall portion 23 of the resin member 2 and the second metal member 4 are heat-welded to seal the second opening 29, and a second cavity portion 54 is formed between the bottom surface (second surface portion) 21b, the second peripheral wall portion 23, and the second metal member 4. The side surface 41c of the second substrate 41 and the second stepped side surface 23b may be welded together, but in this embodiment they are either in contact or facing each other with a small gap between them. Also, the end surface 42a of the second fin 42 may be welded together with the lower surface 21b of the intermediate wall portion 21, but in this embodiment they are either in contact or facing each other with a small gap between them.

[0058] Furthermore, a second vertical wall portion 52 is formed on the second stepped side surface 23b, extending out of plane beyond the lower surface 41b of the second substrate 41. In other words, the second vertical wall portion 52 is formed when the height dimension of the second stepped side surface 23b is greater than the thickness dimension of the second substrate 41 of the second metal member 4. A heating element may be placed in the lower space enclosed by the lower surface 41b of the second substrate 41 and the second vertical wall portion 52 extending in the circumferential direction. Alternatively, as shown in Figure 2, a cover member (not shown) may be installed on the end face 23a of the peripheral wall portion 11 to cover the entire surface, thereby covering the lower space while arranging the heating element.

[0059] Figure 12 is an enlarged cross-sectional view of the central part of the cooler according to the first embodiment. As shown in Figure 12, the end face 24a of the first support portion 24 of the resin member 2 and the central portion 34 of the first metal member 3 are joined by welding along their entire length. In other words, a third overlapping portion 57 is formed when one surface (central portion 34) of the first metal member 3 is superimposed on the end face 24a and is heat-welded. In addition, the end face 25a of the second support portion 25 of the resin member 2 and the central portion 44 of the second metal member 4 are joined by welding along their entire length. In other words, a fourth overlapping portion 58 is formed when one surface (central portion 44) of the second metal member 4 is superimposed on the end face 25a and is heat-welded. Furthermore, the first support portion 24 and the first metal member 3 do not necessarily have to be welded together. Also, the second support portion 25 and the second metal member 4 do not necessarily have to be welded together. In addition, the first support portion 24 and the second support portion 25 may be omitted.

[0060] [1-5. Fluid Flow] Next, the fluid flow in the cooler 1 according to this embodiment will be described. The fluid can be a cooled liquid or gas. The fluid flows in from the inlet 12 through the first through hole 14 and into the interior, and as shown in Figure 8, it branches off at the intermediate wall 21 and flows into the first cavity 53 or the second cavity 54. Because the fluid is separated by the first support 24, it flows from rear to front on the right side of the first cavity 53 or the second cavity 54, and when it reaches the front side of the first cavity 53 or the second cavity 54, it flows into the left side of the first support 24 of the first cavity 53 or the second cavity 54 via the flow paths R1 and R2. After that, it changes direction and flows from front to rear on the left side of the first cavity 53 or the second cavity 54, and finally flows out to the outside from the outlet 13 after passing through the second through hole 15. In other words, the fluid flows in a U-shape when viewed from above inside the cooler 1. Inside the cooler 1, fluid flows between adjacent first fins 32, 32, or between adjacent second fins 42, 42, and exchanges heat with the heat-generating element.

[0061] [1-6. Method for manufacturing a cooler] Next, a method for manufacturing a cooler according to this embodiment will be described. The method for manufacturing a cooler according to this embodiment includes a preparation step, a surface roughening step, a heating step, a joining step, a cooling step, and an opening step.

[0062] As shown in Figure 13, the preparation step is the process of forming the resin member 2, the first metal member 3, and the second metal member 4. The method of forming the resin member 2, the first metal member 3, and the second metal member 4 is not particularly limited. The resin member 2 is integrally formed, for example, by injection molding. The first metal member 3 and the second metal member 4 may be formed, for example, by cutting using a multi-cutter equipped with multiple circular cutting blades, or the substrate and fins may be joined by brazing.

[0063] The surface roughening process, as shown in Figure 14, is a process of forming rough surface portions (rough surface structures) S1 and S2 on the peripheral edge 33 and central portion 34 of the lower surface 31b of the first substrate 31 of the first metal member 3. In other words, in the surface roughening process, rough surface portions S1 and S2 are formed on the bonding surface with the resin member 2 on the first substrate 31 of the first metal member 3. In this embodiment, the rough surface portion S1 is formed in a rectangular frame shape along the periphery of the lower surface 31b. The rough surface portion S2 is formed in a linear shape in the front-to-back direction at the center of the lower surface 31b in the left-to-right direction. The width of the rough surface portions S1 and S2 can be set as appropriate. The rough surface portions S1 and S2 can be formed, for example, by laser processing, mechanical processing (polishing, etc.), chemical processing (etching, etc.), or electrical processing (electropolishing, etc.). The second metal member 4 is also formed with rough surface portions S1 and S2 in the same way as the first metal member 3.

[0064] The heating process, as shown in Figure 15, involves heating the resin member 2, the first metal member 3, and the second metal member 4. In the heating process, the entire resin member 2, the first metal member 3, and the second metal member 4 may be heated, but it is sufficient to heat at least the joint surfaces of each member. In this embodiment, the resin member 2, the first metal member 3, and the second metal member 4 are heated simultaneously using a heating device 61. The heating device 61 comprises a first heating section 62, a second heating section 63, and a connecting section 64 that connects the first heating section 62 and the second heating section 63 in a positional relationship where they are separated and facing each other. The heating device 61 has a U-shaped cross-section or a U-shape with all corners at right angles, and has a space inside that can accommodate the resin member 2. The heating method in the heating device is not limited, but the heating device 61 in this embodiment heats the object using infrared rays.

[0065] The first heating section 62 is equipped with an upper heating section 62a above it for heating the first metal member 3. The first heating section 62 is equipped with a lower heating section 62b below it for heating the resin member 2. The upper heating section 62a and the first metal member 3 may be heated in contact with each other, but in this embodiment they are heated at a distance from each other.

[0066] Below the first heating section 62, there is a lower heating section 62b for heating the resin member 2. The lower heating section 62b and the resin member 2 are heated at a distance from each other to prevent the resin contained in the resin member 2 from adhering to the lower heating section 62b when the resin member 2 melts.

[0067] Above the second heating section 63 is an upper heating section 63a for heating the resin member 2. The upper heating section 63a and the resin member 2 are heated at a distance from each other to prevent the resin contained in the resin member 2 from adhering to it when it melts.

[0068] Below the second heating section 63 is a lower heating section 63b for heating the second metal member 4. The lower heating section 63b and the second metal member 4 may be heated in contact with each other, but in this embodiment they are heated while separated.

[0069] In the heating process, the resin member 2, the first metal member 3, and the second metal member 4 are heated to a temperature at which they can be heat-welded. This temperature is preferably set appropriately, taking into consideration, for example, the melting point of the resin member 2, the materials of the first metal member 3 and the second metal member 4, and the heating method (welding method). The heating temperatures of the resin member 2, the first metal member 3, and the second metal member 4 may be the same or different.

[0070] The heating temperatures of the first metal member 3 and the second metal member 4 can be set based on the melting point temperature of the thermoplastic resin contained in the resin member 2. For example, as in this embodiment, when the resin member 2 is formed from PPS (Polyphenylene sulfide) (melting point: 280°C), and the first metal member 3 and the second metal member 4 are formed from an aluminum alloy (e.g., A6063T5, 150 mm long x 75 mm wide x 2 mm thick), and when heated non-contact by infrared radiation, the temperatures of the first metal member 3 and the second metal member 4 are set to approximately 220°C. It is preferable to set the heating temperatures of the first metal member 3 and the second metal member 4 around the melting point temperature of the resin. The heating temperatures of the first metal member 3 and the second metal member 4 are preferably above the resin melting point -100°C, above the resin melting point -70°C, above the resin melting point -40°C, above the resin melting point -20°C, and preferably below the resin melting point +100°C, below the resin melting point +70°C, below the resin melting point +40°C, below the resin melting point +20°C, and below the resin melting point.

[0071] The heating temperature of the resin member 2 can be set based on the melting point temperature of the thermoplastic resin contained in the resin member 2. Preferably, the heating temperature of the resin member 2 is above the melting point temperature and close to it. Preferably, the heating temperature of the resin member 2 is above the melting point temperature, above 5°C above the melting point temperature, above 10°C above the melting point temperature, above 20°C above the melting point temperature, and preferably below 100°C above the melting point temperature, above 70°C above the melting point temperature, above 50°C above the melting point temperature, and above 30°C above the melting point temperature.

[0072] The joining process, as shown in Figure 16, involves bringing the preheated resin member 2, the first metal member 3, and the second metal member 4 into contact and joining them by welding under pressure using a pressurizing device (not shown). In the joining process, a predetermined pressing force is applied from the upper side of the first metal member 3 and the lower side of the second metal member 4 to cause welding.

[0073] In the joining process, first, the upper surface (first surface portion) 21a of the resin member 2 and the lower surface 31b of the first metal member 3 are brought into opposition, and the lower surface (second surface portion) 21b of the resin member 2 and the upper surface 41a of the second metal member 4 are brought into opposition. Specifically, the first stepped bottom surface 22c and end surface 24a, which will be the joining surface on the upper surface (first surface portion) 21a side of the resin member 2, are brought into opposition with the roughened surfaces S1 and S2 formed on the peripheral edge 33 and central portion 34 of the lower surface 31b of the first metal member 3, which will be the joining surface. Also, the second stepped bottom surface 23c and end surface 25a, which will be the joining surface on the lower surface (second surface portion) 21b side of the resin member 2, are brought into opposition with the roughened surfaces S1 and S2 formed on the peripheral edge 43 and central portion 44 of the upper surface 41a of the second metal member 4, which will be the joining surface. Next, the joining surface on the upper surface (first surface portion) 21a side of the resin member 2 is brought into contact with the joining surface of the first metal member 3, and the joining surface on the lower surface (second surface portion) 21b side of the resin member 2 is brought into contact with the joining surface of the second metal member 4. Specifically, the first stepped bottom surface 22c and end surface 24a, which form the joining surface on the upper surface (first surface portion) 21a side of the resin member 2, are brought into contact with the roughened surfaces S1 and S2 formed on the peripheral edge 33 and central portion 34 of the lower surface 31b, which form the joining surface of the first metal member 3. In addition, the second stepped bottom surface 23c and end surface 25a, which form the joining surface on the lower surface (second surface portion) 21b side of the resin member 2, are brought into contact with the roughened surfaces S1 and S2 formed on the peripheral edge 43 and central portion 44 of the upper surface 41a, which form the joining surface of the second metal member 4. With the resin member 2 sandwiched between the first metal member 3 and the second metal member 4 in this manner, pressure is applied to the first metal member 3 and the second metal member 4, which are in contact with both sides of the resin member 2, from the upper surface (first surface portion) 21a and the lower surface (second surface portion) 21b sides, respectively, thereby joining the resin member 2 to the contact surfaces of the first metal member 3 and the second metal member 4.

[0074] The cooling process is a process of cooling the structure after the joining process. The method of the cooling process is not particularly limited. The cooling process may be, for example, natural cooling or forced cooling. For forced cooling, for example, gas or cooling water may be circulated inside the structure, or airflow may be applied.

[0075] The release process is the process of releasing the pressure on the joined structure after the cooling process. After the temperature of the resin member 2 has decreased and solidified due to the cooling process, the pressure applied to the resin member 2, the first metal member 3, and the second metal member 4 is released, and the joined cooler 1 is removed from the pressurizing device. With this, the cooler 1 is completed.

[0076] Furthermore, the manufacturing method of the cooler can be modified as appropriate. For example, after performing a heating process (preheating process, first heating process), a heating process (main heating process, second heating process) may be performed during the joining process. In other words, each component may be heated and pressurized during the joining process.

[0077] Furthermore, while the aforementioned heat welding method was exemplified as infrared welding (non-contact resin / metal), other methods may also be used. For example, heat welding may be performed using ultrasonic welding, vibration welding, high-frequency induction heating welding, laser welding, hot plate welding, spin welding, etc.

[0078] In ultrasonic thermal welding, the resin member 2 and the first metal member 3 are heated by frictional heat generated by ultrasonic vibrations. In the vibration welding method, the resin member 2 and the first metal member 3 are heated by frictional heat generated by vibration. In the high-frequency induction heating welding method, the first metal member 3 and the second metal member 4 are heated by heat generated by molecular vibration in a high-frequency electric field. In addition, the resin member 2 is heated by heat conduction from the first metal member 3 and the second metal member 4. In the laser welding method, the first metal member 3 and the second metal member 4 are heated by the heat generated from the absorption of laser light. In addition, the resin member 2 is heated by heat conduction from the first metal member 3 and the second metal member 4. In the hot plate welding method, the resin member 2, the first metal member 3, and the second metal member 4 are heated by heat generation through heat conduction from the hot plate or by far-infrared heating. In the spin welding method, the resin member 2, the first metal member 3, and the second metal member 4 are heated by frictional heat generated by high-speed rotation.

[0079] For example, when forming a resin member 2 with PPS and forming the first metal member 3 and the second metal member 4 with an aluminum alloy, and heating them using a general heat welding method, the first metal member 3 and the second metal member 4 are heated to approximately 350°C. The heat welding method is a method in which the resin member 2 is heated by heat conduction from the heated first metal member 3 and the second metal member 4.

[0080] Furthermore, for example, when forming a resin member 2 with PPS and forming the first metal member 3 and the second metal member 4 with an aluminum alloy, and heating them using a resin-contact type hot plate welding method, the first metal member 3 and the second metal member 4 are heated to approximately 280°C. The resin-contact type hot plate welding method is a method in which the first metal member 3 and the second metal member 4 are heated simultaneously with the resin member 2 by bringing them into contact.

[0081] Furthermore, for example, when forming a resin member 2 with PPS, and forming the first metal member 3 and the second metal member 4 with an aluminum alloy, and heating them using a non-contact resin hot plate welding method, the first metal member 3 and the second metal member 4 are heated to approximately 240°C. The non-contact resin hot plate welding method is a method in which the first metal member 3 and the second metal member 4 are heated, and at the same time, the resin member 2 is heated by radiant heat through contact with them.

[0082] [1-7. Effects and Benefits] As described above, the cooler 1 according to this embodiment has a first peripheral wall portion 22 and a second peripheral wall portion 23 rising from the periphery on both sides of the intermediate wall portion 21, the upper surface (first surface portion) 21a side and the lower surface (second surface portion) 21b side, respectively, and the first metal member 3 and the second metal member 4 are joined to the first peripheral wall portion 22 and the second peripheral wall portion 23, respectively. As a result, the cooler 1 has a first opening 27 surrounded by the first peripheral wall portion 22 on the upper surface (first surface portion) 21a side, which is sealed to form a first cavity portion 53, and a second opening 29 surrounded by the second peripheral wall portion 23 on the lower surface (second surface portion) 21b side, which is sealed to form a second cavity portion 54. Thus, in the cooler 1, the first metal member 3 and the second metal member 4 are arranged on both sides of the resin member 2, allowing cooling surfaces (heat receiving surfaces) on which the heating element is placed to be provided on both sides of the cooler 1. This makes it possible to cool the heating element from both sides with a single cooler 1. In conventional coolers, where a peripheral wall is provided on only one side of the resin component and only one side is joined to the metal component, the deformation caused by the difference in the coefficients of thermal expansion between the resin component and the metal component during heat welding is biased toward one side, which can lead to deformation or cracking of the resin component. In contrast, in the cooler 1 according to this embodiment, a first peripheral wall portion 22 and a second peripheral wall portion 23 are provided on both sides of the intermediate wall portion 21. As a result, compared to the case where a peripheral wall portion is provided on only one side and the metal member is joined on only one side, the stress caused by the first peripheral wall portion 22 and the second peripheral wall portion 23 is relieved (canceled), making it easier to suppress deformation caused toward one side. Furthermore, in conventional coolers, if a wall is provided in the resin member along the longitudinal direction of the cooler, deformation along the longitudinal direction of the cooler can be suppressed, but it is difficult to suppress deformation along the direction intersecting the direction in which the wall is provided. In contrast, the cooler 1 according to this embodiment has a first peripheral wall portion 22 and a second peripheral wall portion 23 that rise from the periphery of the intermediate wall portion 21. As a result, the cooler 1 can more easily suppress deformation not only in one direction, but also in two or more intersecting directions along the direction of the periphery where the first peripheral wall portion 22 and the second peripheral wall portion 23 are provided. Furthermore, in conventional coolers, if a wall is provided in the center of the resin component, deformation of the central part of the cooler can be suppressed, but it is difficult to suppress deformation of the peripheral part where no wall is provided. In contrast, the cooler 1 according to this embodiment has a first peripheral wall portion 22 and a second peripheral wall portion 23 that rise from the periphery of the intermediate wall portion 21. As a result, the cooler 1 makes it easier to suppress deformation of the entire unit, including the periphery, not just the central part. Furthermore, in conventional coolers, when the surface of a substantially flat resin member is used as a joint with a metal member by thermal welding, the entire surface of the resin member is heated, and the deformation caused by the difference in the coefficients of linear expansion between the resin member and the metal member during thermal welding occurs in the thickness direction of the substantially flat resin member. In contrast, in the cooler 1 according to this embodiment, the first circumferential wall portion 22 and the second circumferential wall portion 23, which rise from the intermediate wall portion 21, serve as the joint. As a result, when heat welding is performed in the cooler 1, mainly the ends of the first circumferential wall portion 22 and the second circumferential wall portion 23 are heated, and the heating of the intermediate wall portion 21 is suppressed. Furthermore, since the first circumferential wall portion 22 and the second circumferential wall portion 23 rise from the intermediate wall portion 21, the resin member 2, which is the height of the first circumferential wall portion 22 and the second circumferential wall portion 23 combined with the intermediate wall portion 21, can suppress expansion and contraction due to cooling, making it easier to suppress out-of-plane deformation of the intermediate wall portion 21. For the reasons stated above, the cooler 1 according to this embodiment makes it easier to suppress deformation caused by thermal welding between the resin member 2 and the first metal member 3 and the second metal member 4.

[0083] Furthermore, in this embodiment, the cooler 1 has a symmetrical shape between the upper surface (first surface) 21a and the lower surface (second surface) 21b of the intermediate wall portion 21. As a result of thermal welding, residual stress caused by thermal shrinkage is evenly distributed between the upper surface (first surface) 21a and the lower surface (second surface) 21b, making it easier to suppress warping of the cooler 1. Furthermore, in this embodiment, the shape and size (dimensions) of the resin member 2, the first metal member 3, and the second metal member 4 located on the upper surface (first surface) 21a side and the lower surface (second surface) 21b side, respectively, are the same. Also, the shapes of the resin member 2, the first metal member 3, and the second metal member 4 are symmetrical in terms of plane. As a result, the warping of the cooler 1 can be further suppressed by welding in a balanced manner.

[0084] Furthermore, in this embodiment, the cooler 1 has an symmetrical arrangement of the upper surface (first surface) 21a side and the lower surface (second surface) 21b side of the intermediate wall 21, so that the residual stress caused by thermal contraction between the upper surface (first surface) 21a side and the lower surface (second surface) 21b side becomes uniform through heat welding. This makes it easier to suppress warping of the cooler 1. In addition, since the first peripheral wall 22 and the second peripheral wall 23 are arranged in a straight line (arranged on a cylindrical virtual body that is continuous on both sides in the thickness direction of the resin member 2), the loads that the first peripheral wall 22 and the second peripheral wall 23 receive due to the pressure applied during joining are opposed, making it easier to prevent the shear force from becoming high at positions other than the first peripheral wall 22 and the second peripheral wall 23.

[0085] Furthermore, since the cooler 1 according to this embodiment is equipped with a first support portion 24 and a second support portion 25, the strength of the cooler 1 can be increased. In addition, by providing the first support portion 24 and the second support portion 25, the fluid flow path can be appropriately set. The position and shape of the first support portion 24 and the second support portion 25 can be set as appropriate, but in this embodiment they are arranged symmetrically. This makes it possible to further suppress warping of the cooler 1.

[0086] Furthermore, in this embodiment, the cooler 1 has a first support portion 24 that is heat-welded to the first metal member 3, and a second support portion 25 that is heat-welded to the second metal member 4. This makes it possible to further increase the strength of the cooler 1.

[0087] Furthermore, in the cooler 1 according to this embodiment, the height position of the first stepped bottom surface (joint surface) 22c of the first peripheral wall portion 22 and the end surface (joint surface) 24a of the first support portion 24 are the same, and the height position of the second stepped bottom surface (joint surface) 23c of the second peripheral wall portion 23 and the end surface (joint surface) 25a of the second support portion 25 are the same. This makes it easier to suppress warping on the upper surface (first surface portion) 21a side and the lower surface (second surface portion) 21b side of the cooler 1. In addition, the load applied to the resin member 2 by the pressure applied during joining is distributed between the peripheral wall portion 11, the first support portion 24 and the second support portion 25, making it easier to suppress deformation of the peripheral wall portion 11.

[0088] Furthermore, the presence of stepped sections (first stepped side surface 22b, first stepped bottom surface 22c, and first stepped side surface 22d) in the first circumferential wall 22 and stepped sections (second stepped side surface 23b, second stepped bottom surface 23c, and second stepped side surface 23d) in the second circumferential wall 23 increases the rigidity of the circumferential wall 11, making it easier to suppress deformation on the upper surface (first surface) 21a side and the lower surface (second surface) 21b side of the cooler 1. In addition, the provision of the first stepped bottom surface 22c and the second stepped bottom surface 23c makes it easier to arrange the first metal member 3 and the second metal member 4. Moreover, the heat welding joint between the first overlapping section 55 and the second overlapping section 56 in the circumferential direction increases the joint strength.

[0089] Furthermore, the first circumferential wall portion 22 in this embodiment has a first vertical wall portion 51 that extends out of plane from the first metal member 3, and the second circumferential wall portion 23 has a second vertical wall portion 52 that extends out of plane from the second metal member 4. With the heating element placed in the space above the first metal member 3 due to the first vertical wall portion 51, a lid can be placed to cover the heating element. Also, with the heating element placed in the space below the second metal member 4 due to the second vertical wall portion 52, a lid can be placed to cover the heating element. In addition, the rigidity of the circumferential wall portion 11 is improved by the first vertical wall portion 51 and the second vertical wall portion 52, making it easier to suppress deformation.

[0090] Furthermore, the resin member 2 according to this embodiment has at least one of the following: a first communication hole 18 formed inward from the end where the first through hole 14 is provided, continuous with the first through hole 14, and connecting the first cavity 53 and the second cavity 54; and a second communication hole 19 formed inward from the end where the second through hole 15 is provided, continuous with the second through hole 15, and connecting the first cavity 53 and the second cavity 54. The first communication hole 18 and the second communication hole 19, which are formed inward from the first through hole 14 and the second through hole 15, respectively, make it easier to reduce the pressure loss of fluids that branch into or merge and flow out of the first cavity 53 and the second cavity 54. In addition, according to this embodiment, the reduction in rigidity caused by providing the first communication hole 18 and the second communication hole 19 can be compensated for by providing the peripheral wall portion 11, the first support portion 24 and the second support portion 25. The first communication hole 18 and the second communication hole 19 may be omitted, or only one of them may be included.

[0091] Furthermore, the cooler 1 according to this embodiment has a plurality of first fins 32 on the side of the first metal member 3 facing the first cavity 53, and a plurality of second fins 42 on the side of the second metal member 4 facing the second cavity 54. The first fins 32 and second fins 42 provided on the first metal member 3 and the second metal member 4 promote heat exchange with the fluid, thereby improving cooling performance.

[0092] Furthermore, in cases where the metal member has a case shape with a recess surrounded by a wall, as in Patent Document 1, there are processing limitations in forming fins on the metal member. For example, in structures where fins or pins are erected on the bottom plate (base) of the metal member, the fins or pins are formed on the block-shaped metal member by cutting with a rotary blade. When the metal member is a case member, it becomes difficult to form fins or pins with a rotary blade while avoiding interference with the outer wall of the case. In contrast, the cooler 1 according to this embodiment has a resin member 2 with a peripheral wall portion 11, and the first metal member 3 and the second metal member 4 are joined to this peripheral wall portion 11 to form a cavity inside. This allows the first fin 32 to be provided on the flat plate-shaped first substrate 31 of the first metal member 3 and the second metal member 4, and the second fin 42 to be provided on the second substrate 41, respectively, increasing the degree of freedom in manufacturing. Note that the shape of the fins of the first metal member 3 and the second metal member 4 may be other shapes, such as columnar.

[0093] Furthermore, the first metal member 3 of the cooler 1 according to this embodiment has roughened surfaces S1 and S2 on the joint surface with the resin member 2, and the second metal member 4 also has roughened surfaces S1 and S2 on the joint surface with the resin member 2. In addition, the first peripheral wall portion 22 of the resin member 2 and the joint surface of the first metal member 3 are heat-welded, and the second peripheral wall portion 23 of the resin member 2 and the joint surface of the second metal member 4 are heat-welded. In other words, roughened surfaces S1 are formed on the peripheral edges 33 and 43 of the first metal member 3 and the second metal member 4, respectively, and these peripheral edges 33 and 43 are welded to the first stepped bottom surface 22c and the second stepped bottom surface 23c, respectively. Furthermore, since the roughened surfaces S1 are provided around the entire circumference of the peripheral edges 33 and 43, the strength and leak resistance (airtightness and watertightness) of the heat-welded joint can be improved. Furthermore, in this embodiment, roughened surfaces S2 are formed on the central portions 34 and 44 of the first metal member 3 and the second metal member 4, respectively, and these central portions 34 and 44 are welded to the end faces 24a of the first support portion 24 and 25a of the second support portion 25, respectively. Since the roughened surfaces S2 are provided along the longitudinal direction of the central portions 34 and 44, the strength and leak resistance (airtightness and watertightness) of the heat-welded joint can be further enhanced. In addition, since the shape and size of the roughened surfaces S1 and S2 of the first metal member 3 and the second metal member 4 are the same, the welding strength of the first metal member 3 and the second metal member 4 can be made uniform, and stress concentration can be avoided.

[0094] Furthermore, according to the manufacturing method of the cooler in this embodiment, a cooler 1 can be easily manufactured that can suppress deformation caused by thermal welding between the resin member 2 and the first metal member 3 and the second metal member 4.

[0095] Furthermore, as in this embodiment, in the heating process, the joining surface of the resin member 2 may be heated in addition to the first metal member 3 and the second metal member 4. This allows for a strong bond to be formed in a short amount of time during the joining process.

[0096] Furthermore, as in this embodiment, it is preferable to perform the heat welding bonding between the upper surface (first surface portion) 21a of the resin member 2 and the first metal member 3, and the heat welding bonding between the lower surface (second surface portion) 21b of the resin member 2 and the second metal member 4 simultaneously during the bonding process. By performing heat welding bonding from both sides simultaneously, the thermal and load balance is improved, and deformation of the cooler 1 can be suppressed.

[0097] Furthermore, it is preferable to include a surface roughening step, as in this embodiment. This allows the molten resin to fill the fine grooves of the roughened surfaces S1 and S2, thereby increasing the welding strength between the resin member 2 and the first metal member 3 and the second metal member 4.

[0098] Furthermore, as in this embodiment, it is preferable to heat the joint surface of the resin member 2 and the heating device 61 in a non-contact state during the heating process. This prevents the resin member 2 from welding to the heating device 61. Furthermore, as in this embodiment, it is preferable to heat-weld the resin member 2, the first metal member 3, and the second metal member 4 without heating during the joining process. In other words, since heating is performed during the heating process, there is no need to heat each member again during the joining process. This makes it easier to shorten the time required for the cooling process after the joining process, and thus easier to shorten the cycle time required for manufacturing the cooler. In addition, heating costs can be reduced. Furthermore, although each component may be heated separately, it is preferable to heat the resin component 2, the first metal component 3, and the second metal component 4 simultaneously, as in this embodiment. This increases heating efficiency and shortens the manufacturing cycle. In addition, the heating device 61 allows for easy simultaneous heating of the three components.

[0099] [1-8. Variations] Figure 17 is a perspective view showing a modified example of the cooler according to the first embodiment. As shown in Figure 17, the resin member 2 in the modified example has a third communication hole 71 that communicates with the intermediate wall portion 21 in the thickness direction. In other words, the cooler 1 according to this modified example may be provided with a third communication hole 71 that connects the first cavity portion 53 (see Figure 16) and the second cavity portion 54. As a result, fluid flows between the first cavity 53 and the second cavity 54, creating turbulence in the fluid and directing it towards the first metal member 3 or the second metal member 4. This promotes heat exchange between the fluid and the first metal member 3 or the second metal member 4, thereby increasing cooling efficiency.

[0100] Furthermore, in this modified example, there are four third communication holes 71 connecting the first cavity 53 and the second cavity 54, with two on each side of the first support portion 24 and the second support portion 25, but there is no limit to the number. In other words, there may be one third communication hole 71 or two or more. This makes it easier to create fluid turbulence within the cooler 1, thereby further improving the cooling efficiency.

[0101] [2. Second Embodiment] Next, a cooler according to the second embodiment of the present invention will be described. As shown in Figures 18 to 20, the cooler 1A according to this embodiment differs from that of the first embodiment in its overall shape and fluid flow. In this embodiment, the same reference numerals are used for components that are the same as in the first embodiment and their descriptions are omitted, and the focus will be on the differences from the first embodiment.

[0102] As shown in Figures 18 and 19, the cooler 1A comprises a resin member 2A, a first metal member 3A, and a second metal member 4A. An inlet 12A is formed on the rear surface of the resin member 2A, parallel to the front-rear axis. An outlet 13A is formed on the front surface of the resin member 2A, parallel to the front-rear direction. The peripheral wall 11A has an elongated rectangular frame shape in the front-rear direction.

[0103] [2-1. Resin components] As shown in Figures 21 and 22, the internal structure of the resin member 2A includes an intermediate wall portion 21A, a first circumferential wall portion 22, a second circumferential wall portion 23, a first support portion 24A, and a second support portion 25A. As shown in Figure 21, a first communication hole 18 is formed on the rear side of the intermediate wall portion 21A at a position corresponding to the inlet portion 12A. The first communication hole 18 is formed to communicate in the thickness direction of the intermediate wall portion 21A. Also, a second communication hole 19 is formed on the front side of the intermediate wall portion 21A at a position corresponding to the outlet portion 13A. The second communication hole 19 is formed to communicate in the thickness direction of the intermediate wall portion 21A.

[0104] A first support portion 24A is formed parallel to the front-to-back direction at the center of the upper surface 21a of the intermediate wall portion 21A in the left-to-right direction. The first support portion 24A rises vertically from the upper surface 21a of the intermediate wall portion 21A and has a plate-like shape. Due to the presence of the first communication hole 18 and the second communication hole 19, the front and rear sides of the first support portion 24A are spaced apart from the first peripheral wall portion 22. As shown in Figure 22, the height position of the end face 24Aa of the first support portion 24A is the same as the height position of the first stepped bottom surface 22c.

[0105] Furthermore, as shown in Figure 22, a second support portion 25A is formed parallel to the front-to-back direction at the center of the lower surface 21b of the intermediate wall portion 21A in the left-to-right direction. The second support portion 25A rises vertically from the lower surface 21b of the intermediate wall portion 21A and has a plate-like shape. Due to the presence of the first communication hole 18 and the second communication hole 19, the front and rear sides of the second support portion 25A are spaced apart from the second peripheral wall portion 23. The height position of the end face 25Aa of the second support portion 25A is the same as the height position of the second stepped bottom surface 23c.

[0106] [2-2. First Metal Component] As shown in Figure 23, the first metal member 3A is made of metal and is the part that exchanges heat with the heating element. The first metal member 3A comprises a first substrate 31, a plurality of first fins 32, a peripheral portion 33, and a central portion 34. The peripheral portion 33 and the central portion 34 are the spaces on the first substrate 31 where the first fins 32 are not arranged. The peripheral portion 33 is provided around the entire circumference of the periphery. The central portion 34 is provided in a straight line parallel to the front-to-back direction at the center in the left-to-right direction.

[0107] Roughened surfaces S1 and S2 are formed on the peripheral portion 33 and the central portion 34, respectively. The roughened surfaces S1 and S2 are formed to increase the welding strength with the resin, and are processed to have a rough surface.

[0108] [2-3. Second Metal Component] As shown in Figure 24, the second metal member 4A is made of metal and is the part that exchanges heat with the heating element. The second metal member 4A comprises a second substrate 41, a plurality of second fins 42, a peripheral portion 43, and a central portion 44. The peripheral portion 43 and the central portion 44 are the spaces on the second substrate 41 where the second fins 42 are not arranged. The peripheral portion 43 is provided around the entire circumference of the periphery. The central portion 44 is provided in a straight line parallel to the front-to-back direction at the center in the left-to-right direction.

[0109] Roughened surfaces S1 and S2 are formed on the peripheral portion 43 and the central portion 44, respectively. The roughened surfaces S1 and S2 are formed to increase the welding strength with the resin, and are processed to have a rough surface.

[0110] [2-4.Joining form] The joining configuration of this embodiment is generally the same as that of the first embodiment, so a description will be omitted.

[0111] [2-5. Fluid Flow] Next, the fluid flow in the cooler 1A according to this embodiment will be described. The fluid flows into the interior from the inlet 12A, branches off at the first communication hole 18 and the intermediate wall 21, and flows into the first cavity 53 or the second cavity 54. The fluid flows from rear to front through the first cavity 53 or the second cavity 54, merges at the second communication hole 19, and flows out to the outside from the outlet 13A. In other words, the fluid flows in a straight line inside the cooler 1A. Inside the cooler 1A, the fluid flows between adjacent first fins 32, 32 or between adjacent second fins 42, 42.

[0112] [2-6. Method for manufacturing a cooler] The method for manufacturing the cooler in this embodiment is generally the same as that of the first embodiment, so a description will be omitted.

[0113] [2-7. Effects] In this embodiment described above, substantially the same effects as in the first embodiment can be achieved. Furthermore, since this embodiment has a more elongated shape compared to the first embodiment, it can be applied to devices and heating elements with elongated installation spaces. Also, as in this embodiment, the inlet 12A and outlet 13A may be provided at any part of the peripheral wall 11A depending on the shape of the device or heating element to be installed.

[0114] [3. Others] While embodiments of the present invention have been described above, the design can be modified as appropriate within the scope of the spirit of the present invention. For example, although the first support parts 24, 24A and the second support parts 25, 25A are straight, they may be curved, or other shapes may be used to control the fluid flow by causing it to meander. Furthermore, the first support parts 24, 24A and the second support parts 25, 25A may be omitted.

[0115] Furthermore, the first communication hole 18 and the second communication hole 19 may be provided in other positions, or both or one of them may be omitted. Also, the shape and number of the first communication hole 18 and the second communication hole 19 may be set as appropriate. In addition, one or more third communication holes 71 may be provided in the intermediate wall portions 21, 21A that communicate in the thickness direction with other parts. The third communication holes 71 may be provided depending on the strength of the resin members 2, 2A and the position of the heating element.

[0116] Furthermore, the orientation of the inlet sections 12, 12A and outlet sections 13, 13A is not limited to being parallel to the front-to-back direction, but may also be parallel to the left-to-right direction. One of the inlet sections 12, 12A and outlet sections 13, 13A may be parallel to the left-to-right direction, so that the flow directions of the inlet sections 12, 12A and the outlet sections 13, 13A are different.

[0117] Furthermore, in the heating step, the heating device 61 was separated from the first metal member 3 and the second metal member 4, but they may be heated in contact. Also, in the heating step, the resin member 2, the first metal member 3, and the second metal member 4 were heated simultaneously, but they may be heated separately. In the joining step, the first metal member 3 and the second metal member 4 may be heated while being pressurized. Also, in the heating step, the first metal member 3 and the second metal member 4 may be heated, but the resin member 2 may not be heated. Furthermore, the surface roughening step may be omitted.

[0118] Furthermore, the roughened portion S1 may be provided only on a part of the circumferential direction of the first metal member 3 and the second metal member 4, or it may be omitted. Similarly, the roughened portion S2 may be provided only on a part of the central portions 34 and 44, or it may be omitted. [Explanation of Symbols]

[0119] 1: Cooler 2: Resin Component 3: First Metal Component 4: Second Metal Component 11: Peripheral Wall 12: Inflow 13: Outflow 14: First Through Hole 15: Second Through Hole 18: First Connecting Hole 19: Second Connecting Hole 21: Intermediate Wall 22: First Peripheral Wall 22a: End Face 22b: First Step Side 22c: First Step Bottom 22d: First Step Side 23: Second Peripheral Wall 23a: End Face 23b: Second Step Side 23c: Second Step Bottom surface 23d: Second side surface 24: First support part 25: Second support part 26: First space part 27: First opening part 28: Second space part 29: Second opening part 31: First base plate 32: First window 33: Peripheral part 34: Central part 41: Second base plate 42: Second window 43: Peripheral part 44: Central part 53: First cavity part 54: Second cavity part 55: First overlapping part 56: Second overlapping part S1: Rough surface S2: Rough surface

Claims

1. A cooler comprising a resin member, and a first metal member and a second metal member arranged on both sides of the resin member, The aforementioned resin member is A roughly flat intermediate wall section, In the first surface portion of the intermediate wall portion, the first peripheral wall portion rises from the periphery of the intermediate wall portion, On the second surface of the intermediate wall portion opposite to the first surface portion, a second peripheral wall portion rises from the periphery of the intermediate wall portion. The first space enclosed by the first surface portion and the first peripheral wall portion, The second space is enclosed by the second surface portion and the second peripheral wall portion. It has a first opening surrounded by the first peripheral wall portion, through which the first space portion opens to the outside, and a second opening surrounded by the second peripheral wall portion, through which the second space portion opens to the outside. The first peripheral wall portion of the resin member and the first metal member are heat-welded together to seal the first opening, thereby forming a first cavity between the first surface portion, the first peripheral wall portion, and the first metal member. The second peripheral wall portion of the resin member and the second metal member are heat-welded together to seal the second opening, thereby forming a second cavity between the second surface portion, the second peripheral wall portion, and the second metal member. A cooler characterized by the following features.

2. The cooler has a shape that is substantially symmetrical with respect to the intermediate wall, with the first surface and the second surface separated by the intermediate wall. The cooler according to claim 1.

3. The cooler is arranged such that the first surface and the second surface are substantially symmetrical with respect to the intermediate wall, and the first peripheral wall and the second peripheral wall are arranged in a straight line perpendicular to the intermediate wall. The cooler according to claim 2.

4. The aforementioned resin member is In the first surface portion, a first support portion rises from the center of the intermediate wall portion and extends in the in-plane direction of the intermediate wall portion, and The second surface portion has a second support portion that rises from the center of the intermediate wall portion and extends in the in-plane direction of the intermediate wall portion, The cooler according to claim 1.

5. The front first support portion is heat-welded to the first metal member. The front second support portion is heat-welded to the second metal member. The cooler according to claim 4.

6. The height positions of the joint surface of the first peripheral wall and the joint surface of the first support are the same. The height position of the joint surface of the second peripheral wall and the joint surface of the second support are the same. The cooler according to claim 4.

7. The aforementioned resin member is The first peripheral wall portion has a first stepped side surface extending from the end face of the first peripheral wall portion toward the intermediate wall portion, and a first stepped bottom surface protruding inward from the first stepped side surface. The second peripheral wall portion has a second stepped side surface extending from the end face of the second peripheral wall portion toward the intermediate wall portion, and a second stepped bottom surface protruding inward from the second stepped side surface. The first overlapping portion, formed by overlapping one surface of the first metal member with the first stepped bottom surface, is heat-welded and joined. The second overlapping portion, formed by overlapping one surface of the second metal member with the second stepped bottom surface, is heat-welded. The cooler according to claim 1.

8. The aforementioned resin member is The height of the first stepped side surface is greater than the thickness of the first metal member. The height of the second stepped side surface is greater than the thickness of the second metal member. The first peripheral wall portion has a first vertical wall portion that extends out of plane from the first metal member, The second peripheral wall portion has a second vertical wall portion that extends out of plane from the second metal member. The cooler according to claim 7.

9. The resin member has a first through hole and a second through hole in the circumferential wall portion, which is composed of the first circumferential wall portion and the second circumferential wall portion, and which connects both the first cavity portion and the second cavity portion to the outside. The aforementioned resin member is A first communication hole is formed inward from the end where the first through hole is provided, and is continuous with the first through hole, connecting the first cavity and the second cavity, and A second communication hole is formed inward from the end where the second through hole is provided, and is continuous with the second through hole, and has at least one of the second communication holes that connects the first cavity and the second cavity. The cooler according to claim 1.

10. The first metal member has a plurality of first fins on the side facing the first cavity, The second metal member has a plurality of second fins on the side facing the second cavity. The cooler according to claim 1.

11. The aforementioned resin member is A third communication hole is formed at a distance from the first through hole and the second through hole, and the first and second communication holes, and connects the first cavity and the second cavity. The cooler according to claim 9.

12. The resin member has two or more of the third communication holes. The cooler according to claim 11.

13. The first metal member has a roughened surface on the bonding surface with the resin member. The second metal member has a roughened surface on the joint surface with the resin member. The first peripheral wall portion of the resin member and the joining surface of the first metal member are heat-welded together. The second peripheral wall portion of the resin member and the joining surface of the second metal member are heat-welded together. The cooler according to claim 1.

14. A method for manufacturing a cooler comprising a resin member, and a first metal member and a second metal member arranged on both sides of the resin member, The aforementioned resin member is A roughly flat intermediate wall section, In the first surface portion of the intermediate wall portion, the first peripheral wall portion rises from the periphery of the intermediate wall portion, On the second surface of the intermediate wall portion opposite to the first surface portion, a second peripheral wall portion rises from the periphery of the intermediate wall portion. The first space enclosed by the first surface portion and the first peripheral wall portion, The second space is enclosed by the second surface portion and the second peripheral wall portion. It has a first opening surrounded by the first peripheral wall portion, through which the first space portion opens to the outside, and a second opening surrounded by the second peripheral wall portion, through which the second space portion opens to the outside. A heating step of heating the joint surface of the first metal member and the joint surface of the second metal member, The joining process includes a step in which the joining surface on the first surface side of the resin member is placed opposite the joining surface of the first metal member, the joining surface on the second surface side of the resin member is placed opposite the joining surface of the second metal member, the joining surface on the first surface side of the resin member is brought into contact with the joining surface of the first metal member, and pressure is applied while the joining surface on the second surface side of the resin member is in contact with the joining surface of the second metal member, thereby heat-welding the resin member, the first metal member, and the second metal member. By the aforementioned joining process, The first peripheral wall portion of the resin member and the first metal member are heat-welded together to seal the first opening, thereby forming a first cavity between the first surface portion, the first peripheral wall portion, and the first metal member. The second peripheral wall portion of the resin member and the second metal member are heat-welded together to seal the second opening, thereby forming a second cavity between the second surface portion, the second peripheral wall portion, and the second metal member. A method for manufacturing a cooler, characterized by the following:

15. In the heating step, the bonding surface of the resin member is heated. A method for manufacturing a cooler according to claim 14.

16. In the joining process, the heat welding of the first surface of the resin member and the first metal member, and the heat welding of the second surface of the resin member and the second metal member are performed simultaneously. A method for manufacturing a cooler according to claim 14.

17. The process further comprises a surface roughening step of forming a rough surface on the joint surface of the first metal member and forming a rough surface on the joint surface of the second metal member, In the heating step, the joint surface of the first metal member and the joint surface of the second metal member, which have the roughened surface formed thereon, are heated. A method for manufacturing a cooler according to claim 14.

18. In the heating step, the joining surfaces of the resin member, the joining surfaces of the first metal member, and the joining surfaces of the second metal member are heated in a non-contact state with respect to each other. In the joining process, the resin member, the first metal member, and the second metal member are heat-welded together without heating. A method for manufacturing a cooler according to claim 15.

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