Cooler and method for manufacturing a cooler

Abstract

The objective is to provide a cooler and a method for manufacturing the cooler that can prevent an increase in height when heat-generating elements are placed on both sides of the cooler. [Solution] A cooler comprising a metal member 1 and a first resin member 4 and a second resin member 5 arranged on both sides of the metal member 1, wherein the metal member 1 has a main body portion 10 that is substantially flat and a communication hole 11 that penetrates in the thickness direction of the main body portion, and the main body portion 10 has a first open portion 22 on the first surface portion 2 of the main body portion 10 where the first surface portion 2 and the first resin member 4 are joined and open to the outside, and a second open portion 32 on the second surface portion 3 of the main body portion 10 opposite to the first surface portion 2 where the second surface portion 3 and the second resin member 5 are joined and open to the outside, characterized in that a first cavity portion 6 is formed when the first surface portion 2 and the first resin member 4 are joined, and a second cavity portion 7 is formed when the second surface portion 3 and the second resin member 5 are joined.

Description

Technical Field

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

Background Art

[0002] As a joining method for 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 contact state, so that the softened or molten 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 cooling plate for cooling a battery block. In this cooling plate, a metal plate on which the battery block is arranged and a resin plate in which a plurality of grooves are formed are joined, and the grooves of the resin plate form flow paths for cooling water. Like the cooling plate described in Patent Document 1, a heating element is arranged on one side of the metal member, and a fluid such as cooling water flows through the flow path formed by the resin member provided on the other side of the metal member, whereby the heating element can be cooled via heat exchange between the metal member and the fluid. From the viewpoints of reducing the weight of electronic devices, in-vehicle components and the like, and reducing the number of components, there is a demand for a cooler that can cool heating elements provided on both sides of one cooler by arranging the heating elements on both sides of the cooler.

[0004] For example, Patent Document 2 describes a cooler for cooling a heating element. This cooler includes a resin member in which a flow path is formed, a first metal member with one surface in contact with the resin member, and a second metal member with one surface in contact with the resin member. The other surface of the first metal member is in contact with the first heating element, and the other surface of the second metal member is in contact with the second heating element.

[0005] The cooler described in Patent Document 2 has metal members on both sides of a resin member in which a flow path is formed, and heat-generating elements are placed on the outside of the upper and lower metal members, thereby enabling the cooling of heat-generating elements placed on both the upper and lower sides of the cooler. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] WО2020 / 027299 publication [Patent Document 2] Japanese Patent Publication No. 2016-09776 [Overview of the project] [Problems that the invention aims to solve]

[0007] However, in the cooler described in Patent Document 2, the total height when heat-generating elements are placed in the cooler is the sum of the height of the cooler and the heights of the two heat-generating elements placed on both the upper and lower surfaces. Therefore, there is a problem in that the overall height dimension of the cooler becomes excessively large.

[0008] From this perspective, the objective is to provide a cooler that can prevent excessive height increase when heat-generating elements are placed on both sides of the cooler, and a method for manufacturing the cooler. [Means for solving the problem]

[0009] In other words, the above-mentioned problems of the present invention are solved by the following configuration.

[0010] (1) A cooler comprising a metal member and a first resin member and a second resin member arranged on both sides of the metal member, wherein the metal member has a main body portion having a substantially flat plate shape and a communication hole penetrating in the thickness direction of the main body portion, the main body portion has a first open portion on the first surface portion of the main body portion where the first surface portion and the first resin member are joined and open to the outside, and a second open portion on the second surface portion of the main body portion opposite to the first surface portion where the second surface portion and the second resin member are joined and open to the outside, and the joining of the first surface portion and the first resin member provides A cooler characterized in that a first cavity is formed between the second surface and the second resin member, and the second surface and the second resin member are joined together, thereby forming a second cavity between the second surface and the second resin member, the first cavity having a first main cavity located opposite the second open portion with the metal member in between, and a first sub-cavity located at a position corresponding to the communication hole, and the second cavity having a second main cavity located opposite the first open portion with the metal member in between, and a second sub-cavity located at a position corresponding to the communication hole, with the second cavity having a second main cavity located at a position corresponding to the communication hole.

[0011] (2) The cooler according to (1), characterized in that the first resin member has a first through hole that connects the first main cavity to the outside, and the second resin member has a second through hole that connects the second main cavity to the outside, and the first through hole, the first main cavity, the first secondary cavity, the connecting hole, the second secondary cavity, the second main cavity, and the second through hole are in communication to form a flow path through which fluid flows.

[0012] (3) The first resin member has a first bottom, a first peripheral wall rising from the peripheral edge of the first bottom, a first space surrounded by the first bottom and the first peripheral wall, and a first opening surrounded by the end face of the first peripheral wall, which opens the first space to the outside; the second resin member has a second bottom, a second peripheral wall rising from the peripheral edge of the second bottom, a second space surrounded by the second bottom and the second peripheral wall, and a second opening surrounded by the end face of the second peripheral wall, which opens the second space to the outside; the first surface of the metal member and the end face of the first peripheral wall are joined to seal the first opening, The cooler according to (1), characterized in that a first cavity is formed surrounded by a first surface, a first peripheral wall, and a first bottom, the end faces of the second surface and the second peripheral wall of the metal member are joined to seal the second opening, a second cavity is formed surrounded by the second surface, the second peripheral wall, and the second bottom, the first sub-cavity and the first opening and the first main cavity are arranged in parallel on the first surface side of the metal member, and the second main cavity and the second sub-cavity are arranged in parallel on the second surface side of the metal member.

[0013] (4) The cooler according to (3), characterized in that the first resin member has a first through hole that connects the first main cavity to the outside, the second resin member has a second through hole that connects the second main cavity to the outside, the first through hole is provided in the first bottom or the first peripheral wall, and the second through hole is provided in the second bottom or the second peripheral wall.

[0014] (5) The cooler according to (1), characterized in that the first resin member has a first frame-shaped wall portion surrounding the first opening, the second resin member has a second frame-shaped wall portion surrounding the second opening, and the outer peripheral shape of the first resin member and the outer peripheral shape of the second resin member are symmetrical with respect to the metal member.

[0015] (6) The cooler according to (5), characterized by comprising a third resin member that seals the first opening and / or a fourth resin member that seals the second opening.

[0016] (7) The cooler according to (1), characterized in that the first surface of the metal member has a rough surface on the bonding surface with the first resin member, and the second surface of the metal member has a rough surface on the bonding surface with the second resin member.

[0017] (8) A method for manufacturing a cooler comprising a metal member and a first resin member and a second resin member arranged on both sides of the metal member, wherein the metal member has a main body portion having a substantially flat plate shape and a communication hole penetrating in the thickness direction of the main body portion, the main body portion has a first open portion on the first surface portion of the main body portion where the first surface portion and the first resin member are joined and open to the outside, and a second open portion on the second surface portion of the main body portion opposite to the first surface portion where the second surface portion and the second resin member are joined and open to the outside, a heating step of heating the joining surface of the first surface portion and the joining surface of the second surface portion of the metal member, and bringing the joining surface of the metal member and the joining surface of the first resin member, which have been heated in the heating step, into contact with each other, and the metal member A method for manufacturing a cooler, comprising: a joining step of applying pressure while the second surface portion and the joining surface of the second resin member are in contact, thereby joining the metal member, the first resin member and the second resin member, wherein the joining step results in the joining of the first surface portion of the metal member and the first resin member to form a first cavity between the metal member and the first resin member; the joining of the second surface portion of the metal member and the second resin member to form a second cavity between the metal member and the second resin member; the first cavity having a first main cavity portion located opposite the second open portion with the metal member in between, and a first sub-cavity portion continuous with the first main cavity portion and located at a position corresponding to the communication hole; and the second cavity having a second main cavity portion located opposite the first open portion with the metal member in between, and a second sub-cavity portion continuous with the second main cavity portion and located at a position corresponding to the communication hole.

[0018] (9) The method for manufacturing a cooler according to (8), characterized in that, in the heating step, the joining surface of the first resin member and the joining surface of the second resin member are heated.

[0019] (10) The method for manufacturing a cooler according to (8), wherein in the joining step, the joining between the first surface portion side of the metal member and the first resin member and the joining between the second surface portion side of the metal member and the second resin member are performed simultaneously.

[0020] (11) The method for manufacturing a cooler according to (8), further comprising a roughening step of forming a roughened surface portion on the joining surface of the metal member.

[0021] (12) The method for manufacturing a cooler according to (8), wherein in the heating step, the joining surface of the metal member and a heating device are heated in a non-contact state with each other, and in the joining step, the metal member is joined to the first resin member and the second resin member without additional heating. Effects of the Invention

[0022] According to the cooler and the method for manufacturing the same of the present invention, when heating elements are arranged on both surfaces of the cooler, enlargement in the height direction can be prevented, and space saving in the height direction can be achieved. Brief Description of the Drawings

[0023] [Figure 1] It is a perspective view of the cooler according to the first embodiment of the present invention, viewed from above. [Figure 2] It is a perspective view of the cooler according to the first embodiment, viewed from below. [Figure 3] It is an exploded perspective view of the cooler according to the first embodiment. [Figure 4] It is a perspective view showing a metal member according to the first embodiment. [Figure 5] It is a cross-sectional view taken along line V-V in Figure 4. [Figure 6] It is a plan view showing the upper surface of the first resin member according to the first embodiment. [Figure 7] It is a plan view showing the lower surface of the first resin member according to the first embodiment. [Figure 8] It is a plan view showing the upper surface of the second resin member according to the first embodiment. [Figure 9]This is a plan view showing the lower surface of the second resin member according to the first embodiment. [Figure 10] This is a cross-sectional view along line XX in Figure 1. [Figure 11] This is a cross-sectional view taken along the line XI-XI in Figure 1. [Figure 12] This is a cross-sectional view taken along line XII-XII in Figure 1. [Figure 13] This is a plan view of the first surface of a metal member showing the surface roughening process in the manufacturing method of a cooler according to the first embodiment. [Figure 14] This is a plan view of the second surface of a metal member showing the rough surface formation process in the manufacturing method of 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 rear view showing the joining process of the manufacturing method of the cooler according to the first embodiment. [Figure 17] This is a perspective view of a cooler according to the second embodiment of the present invention, viewed from above. [Figure 18] This is a perspective view of a cooler according to a second embodiment of the present invention, viewed from below. [Modes for carrying out the invention]

[0024] 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.

[0025] [1. First Embodiment] [1-1. Cooler Configuration] As shown in Figures 1 to 3, the cooler 100 according to the first embodiment of the present invention comprises a metal member 1, a first resin member 4, and a second resin member 5. The cooler 100 is a device that cools the heating elements by arranging heating elements (not shown) on both sides of the metal member 1 and circulating fluid inside the first resin member 4 and the second resin member 5 to exchange heat with the heating elements. In the cooler 100, the metal member 1, the first resin member 4, and the second resin member 5 are joined together by thermal welding. However, the joining of the metal member 1 and the first resin member 4 and the second resin member 5 is not limited to thermal welding. For example, they may be joined using solid-state diffusion welding by FSW, fusion welding by laser welding, adhesive bonding, etc., or a combination of multiple joining methods may be used. In the cooler 100, the first resin member 4 side is at the top and the second resin member 5 side is at the bottom. Furthermore, the side of the cooler 100 with the inlet 43 and outlet 53 (described later) is the rear side, and the side where the communication hole 11 is located is the front side. Also, the side of the cooler 100 where the first main cavity 61 of the first cavity 6 (described later) is located is the left side, and the side where the first opening 22 is located is the right side. First, the detailed configuration of each component will be explained.

[0026] [1-2. Metal Components] As shown in Figures 4 and 5, the metal member 1 is made of metal and is the part that exchanges heat with the heating element by coming into contact with the fluid. The metal member 1 has a main body 10 and a communication hole 11. The main body 10 is rectangular in plan view, plate-like, and substantially flat. The corners of the main body 10 may be right angles, but in this embodiment, they are rounded. The main body 10 has a first surface 2, which is the upper surface to which the first resin member 4 is joined, and a second surface 3, which is the opposite surface of the first surface 2 and is the lower surface to which the second resin member 5 is joined. The communication hole 11 is a hole that penetrates the main body 10 in the thickness direction. The communication hole 11 is formed in a rectangular shape that is long in the left-right direction.

[0027] As shown in Figures 1, 4, and 5, the main body 10 has a first opening 22, a plurality of first fins 23, a first peripheral edge 24, and a second peripheral edge 25 on the first surface 2 side. The first opening 22 is an area where the first fins 23 are not formed, and the first resin member 4 is exposed to the outside while positioned on the first surface 2, and where the heating element is placed. Note that the first fins 23 are not shown in Figure 1.

[0028] The first fin 23 is a plate-shaped member that rises perpendicularly to the first surface portion 2. In other words, the first surface portion 2 of the metal member 1 has multiple first fins 23 on the side facing the first cavity portion 6, which will be described later. Multiple first fins 23 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 23 is approximately the same as the height dimension of the first peripheral wall portion 42, which will be described later.

[0029] As shown in Figure 13, the first peripheral edge 24 is a space that surrounds a roughly L-shaped frame region arranged around the multiple first fins 23 and the communication holes 11. The first peripheral edge 24 is composed of edge 24A, edge 24B, edge 24C, edge 24D, edge 24E, and edge 24F. Edge 24A is located on the rear side and extends in the left-right direction. Edge 24B is located on the front side and is opposite to edge 24A, and is longer in the left-right direction than edge 24A. Edge 24C is the part that connects the left ends of edge 24A and edge 24B. Edge 24D is opposite to edge 24C, connects to the right end of edge 24A, and extends forward in the in-plane direction. Edge 24D is formed with a gap between its front side and edge 24B. Edge 24E is the portion that faces edge 24B, connects to the front end of edge 24D, and extends to the right. Edge 24F is the portion that faces edge 24C and connects the right ends of edge 24B and edge 24E.

[0030] The second peripheral edge 25 is a roughly L-shaped space positioned along a part of the first open section 22. The second peripheral edge 25 is composed of edge 25A and edge 25B. Edge 25A is opposite edge 24E, connects to the right end of edge 24A, and extends to the right. Edge 25B is opposite edge 24D, and connects the right ends of edge 25A and edge 24E.

[0031] The first peripheral edge 24 has a roughened surface portion S1 formed over its entire circumference with a predetermined width. The second peripheral edge 25 also has a roughened surface portion S2 formed over its entire length with a predetermined width. The roughened surfaces S1 and S2 are formed to increase the bonding strength with the first resin member 4, and are processed to have a rough surface. The first peripheral edge 24 and the second peripheral edge 25 are the bonding surfaces with the first resin member 4. In other words, the first surface portion 2 of the metal member 1 has roughened surfaces S1 and S2 formed on the bonding surface with the first resin member 4.

[0032] As shown in Figures 2 and 5, the main body 10 has a second opening 32, a plurality of second fins 33, a third peripheral edge 34, and a fourth peripheral edge 35 on the second surface 3 side. The second opening 32 is an area where the second fins 33 are not formed, and the second resin member 5 is exposed to the outside while positioned on the second surface 3, and where the heating element is placed. Note that the second fins 33 are not shown in Figure 2.

[0033] The second fin 33 is a plate-shaped member that extends perpendicularly to the second surface 3. In other words, the second surface 3 of the metal member 1 has multiple second fins 33 on the side facing the second cavity 7, which will be described later. The second fins 33 are arranged in parallel to the front-to-back direction in their in-plane direction, and multiple fins are placed side by side with gaps between them. The height dimension of the second fins 33 is approximately the same as the height dimension of the second peripheral wall 52, which will be described later.

[0034] As shown in Figure 14, the third peripheral edge 34 is a roughly rectangular frame-shaped space arranged around the multiple second fins 33 and the communication holes 11. The third peripheral edge 34 is composed of edge 34A, edge 34B, edge 34C, and edge 34D. Edge 34A is located on the rear side and extends in the left-right direction. Edge 34B is located on the front side and is opposite to edge 34A. The left-right lengths of edge 34A and edge 34B are set to be approximately the same. Edge 34C is the part that connects the right ends of edge 34A and edge 34B. Edge 34D is the part that connects the left ends of edge 34A and 34B and is opposite to edge 34C.

[0035] The fourth peripheral edge 35 is positioned along the second open section 32 and is a space that, in plan view, forms a U-shape with all corners being right angles. The fourth peripheral edge 35 is composed of edge 35A, edge 35B, and edge 35C. Edge 35A is located on the rear side and extends in the left-right direction. The right end of edge 35A connects to the left end of edge 34A and the rear end of edge 34D. Edge 35B is located on the front side and is opposite to edge 35A. The right end of edge 35B connects to the left end of edge 34B and the front end of edge 34D. The left-right lengths of edge 35A and edge 35B are set to be approximately the same. Edge 35C is the part that connects the left ends of edge 35A and edge 35B.

[0036] A roughened surface portion S3 is formed along the entire circumference of the third peripheral edge 34. Similarly, a roughened surface portion S4 is formed along the entire length of the fourth peripheral edge 35. The roughened surfaces S3 and S4 are formed to increase the bonding strength with the second resin member 5, and are processed to have a rough surface. The third peripheral edge 34 and the fourth peripheral edge 35 are the bonding surfaces with the second resin member 5. In other words, the second surface portion 3 of the metal member 1 has roughened surfaces S3 and S4 formed on the bonding surfaces with the second resin member 5.

[0037] The metal member 1 can be any metal that can be joined, 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 metal member 1 may also 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.

[0038] [1-3. First resin component] As shown in Figures 3, 6, and 7, the first resin member 4 is a resin member having a first bottom portion 41, a first peripheral wall portion 42, an inlet portion 43, and a first frame-shaped wall portion 47. The first resin member 4 is sized to be placed on the metal member 1.

[0039] The first bottom portion 41 is plate-shaped and formed in a roughly L-shape when viewed from above. The first circumferential wall portion 42 is frame-shaped and plate-shaped and formed in a roughly L-shaped frame when viewed from above. The first circumferential wall portion 42 is a wall portion that falls down in a roughly L-shaped frame shape around the entire circumference of the periphery of the first bottom portion 41. It can also be said that the first circumferential wall portion 42 rises up from the first bottom portion 41 when the first bottom portion 41 is viewed as the bottom surface. The first circumferential wall portion 42 is composed of wall portions 42A, 42B, 42C, 42D, 42E, and 42F, all of the same plate thickness. Wall portion 42A is located on the rear side and is the part where the inlet portion 43, described later, is provided. Wall portion 42B is located on the front side and is the part opposite to wall portion 42A, and is longer in the left-right direction than wall portion 42A. Wall section 42C is the part that connects the left ends of wall section 42A and wall section 42B. Wall section 42D is opposite wall section 42C, connects to the right end of wall section 42A, and extends forward in the in-plane direction. The front side of wall section 42D is spaced apart from wall section 42B. Wall section 42E is opposite wall section 42B, connects to the front end of wall section 42D, and extends to the right. Wall section 42F is opposite wall section 42C, and connects the right ends of wall section 42B and wall section 42E. The four corners of the first circumferential wall section 42 are rounded. The planar shape of the first bottom section 41 and the first circumferential wall section 42 may be a circle, an ellipse, or other angular shape.

[0040] A cylindrical inlet 43 is provided perpendicular to the rear surface (wall portion 42A) of the first circumferential wall portion 42. The first resin member 4 has a first through hole 44 at the position where the inlet 43 is connected on the rear surface (wall portion 42A) of the first circumferential wall portion 42. The first through hole 44 connects the inside and outside of the first resin member 4. In other words, the first through hole 44 connects the first main cavity portion 61 to the outside. The inlet 43 may have any shape other than cylindrical.

[0041] The first frame-shaped wall section 47 is plate-like and formed in a roughly L-shape in plan view. The first frame-shaped wall section 47 is composed of wall sections 47A and 47B, which are made of the same plate thickness. Wall section 47A faces wall section 42E, connects to the right end of wall section 42A, and extends to the right. Wall section 47B faces wall section 42D and connects the right ends of wall sections 47A and 42E. The height dimension of the first frame-shaped wall section 47 is the same as the sum of the plate thickness dimension of the first base section 41 and the height dimension of the first perimeter wall section 42. As a result, as shown in Figure 10, the upper surface 41a of the first base section 41 and the upper surface 47a of the first frame-shaped wall section 47 are flush. Furthermore, as shown in Figure 3, the wall portion 47A of the first frame-shaped wall portion 47 is connected to the wall portion 42A of the first circumferential wall portion 42, and the wall portion 47B of the first frame-shaped wall portion 47 is connected to the wall portion 42E of the first circumferential wall portion 42, so that the outer periphery of the first resin member 4 is substantially rectangular in plan view. A rectangular opening is formed by the wall portions 42D and 42E of the first circumferential wall portion 42 and the wall portions 47A and 47B of the first frame-shaped wall portion 47, and the first open portion 22 of the metal member 1 is exposed through this opening. In this embodiment, the first frame-shaped wall portion 47 is integrally formed with the first circumferential wall portion 42 as a single member, but it may be formed as a separate member from the first circumferential wall portion 42. Also, the first frame-shaped wall portion 47 may be omitted.

[0042] As shown in Figure 7, the lower surface structure of the first resin member 4 has a first space 45 and a first opening 46. The first space 45 is the region enclosed by the first bottom 41 and the first circumferential wall 42. The first opening 46 is enclosed by the lower surface 42b (end surface) of the first circumferential wall 42 and is an opening through which the first space 45 opens to the outside. In other words, as shown in Figure 7, the lower surface 42b of the first circumferential wall 42 is composed of the lower surface 42Ab of wall 42A, the lower surface 42Bb of wall 42B, the lower surface 42Cb of wall 42C, the lower surface 42Db of wall 42D, the lower surface 42Eb of wall 42E, and the lower surface 42Fb of wall 42F. Also, the lower surface 47b of the first frame-shaped wall 47 is composed of the lower surface 47Ab of wall 47A and the lower surface 47Bb of wall 47B. As shown in Figure 10, the lower surface 42b of the first peripheral wall portion 42 is the joint surface with the first surface portion 2 of the metal member 1. When the lower surface 42b of the first peripheral wall portion 42 and the first surface portion 2 are joined, the first opening 46 is sealed and the first cavity portion 6 is formed.

[0043] The first resin member 4 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 first resin member 4 may be, for example, a thermoplastic resin, such as polyethylene, polypropylene, ABS resin, acrylic resin, polyamide, or polycarbonate.

[0044] [1-4. Second resin component] As shown in Figures 3, 8, and 9, the second resin member 5 is a resin member having a second bottom portion 51, a second peripheral wall portion 52, an outflow portion 53, and a second frame-shaped wall portion 57. The second resin member 5 is sized to be placed on the metal member 1.

[0045] The second bottom portion 51 is plate-shaped and formed in a roughly rectangular shape in plan view. The second peripheral wall portion 52 is frame-shaped and plate-shaped and formed in a roughly rectangular shape in plan view. The second peripheral wall portion 52 is a wall portion that rises in a roughly rectangular shape from the periphery of the second bottom portion 51. The second peripheral wall portion 52 is composed of wall portions 52A, 52B, 52C, and 52D, all of the same plate thickness. Wall portion 52A is located on the rear side and is the portion where the outflow portion 53, described later, is provided. Wall portion 52B is located on the front side and is the portion opposite to wall portion 52A. The length of wall portion 52B in the left-right direction is set to be approximately the same as the length of wall portion 52A in the left-right direction. Wall portion 52C is the portion that connects the right ends of wall portion 52A and wall portion 52B. Wall section 52D is the part opposite to wall section 52C and connects the left ends of wall sections 52A and 52B. The four corners of the second perimeter wall section 52 are rounded. The planar shape of the second bottom section 51 and the second perimeter wall section 52 may be a circle, an ellipse, or other angular shape.

[0046] A cylindrical outflow section 53 is provided perpendicular to the rear surface (wall section 52A) of the second circumferential wall section 52. The second resin member 5 has a second through-hole 54 at the position where the outflow section 53 is connected on the rear surface (wall section 52A) of the second circumferential wall section 52. The second through-hole 54 connects the inside and outside of the second resin member 5. In other words, the second through-hole 54 connects the second main cavity section 71 to the outside. The outflow section 53 may have any shape other than cylindrical.

[0047] The second frame-shaped wall section 57 is plate-shaped and, in plan view, is formed in a U-shape or a right-angled U-shape. The second frame-shaped wall section 57 is composed of wall sections 57A, 57B, and 57C, all of the same plate thickness. Wall section 57A is the part that connects to the left end of wall section 52A and extends to the left. Wall section 57B is the part that faces wall section 57A and extends to the left from wall section 52B. Wall section 57C is the part that faces wall section 52D and connects the left ends of wall sections 57A and 57B. The height dimension of the second frame-shaped wall section 57 is the same as the sum of the plate thickness dimension of the second base section 51 and the height dimension of the second peripheral wall section 52. As a result, as shown in Figure 10, the lower surface 51b of the second base section 51 and the lower surface 57b of the second frame-shaped wall section 57 are flush. Furthermore, as shown in Figure 3, the wall portion 57A of the second frame-shaped wall portion 57 is connected to the wall portion 52A of the second circumferential wall portion 52, and the wall portion 57B of the second frame-shaped wall portion 57 is connected to the wall portion 52B of the second circumferential wall portion 52, so that the outer periphery of the second resin member 5 is substantially rectangular in plan view. A rectangular opening is formed by the wall portion 52D of the second circumferential wall portion 52, and the walls 57A, 57B, and 57C of the second frame-shaped wall portion 57, and the second open portion 32 of the metal member 1 is exposed through this opening. In this embodiment, the second frame-shaped wall portion 57 is integrally formed with the second circumferential wall portion 52 as a single member, but it may be formed as a separate member from the second circumferential wall portion 52. Also, the second frame-shaped wall portion 57 may be omitted.

[0048] As shown in Figures 3 and 8, the upper surface structure of the second resin member 5 includes a second space 55 and a second opening 56. The second space 55 is the region enclosed by the second bottom 51 and the second peripheral wall 52. The second opening 56 is enclosed by the upper surface 52a (end face) of the second peripheral wall 52 and is an opening through which the second space 55 opens to the outside. In other words, as shown in Figure 8, the upper surface 52a of the second peripheral wall 52 is composed of the upper surface 52Aa of wall 52A, the upper surface 52Ba of wall 52B, the upper surface 52Ca of wall 52C, and the upper surface 52D of wall 52D. Also, the upper surface 57a of the second frame-shaped wall 57 is composed of the upper surface 57Aa of wall 57A, the upper surface 57Ba of wall 57B, and the upper surface 57Ca of wall 57C. As shown in Figure 10, the upper surface 52a of the second peripheral wall portion 52 is the joint surface with the second surface portion 3 of the metal member 1. When the upper surface 52a and the second surface portion 3 are joined, the second opening 56 is sealed and the second cavity portion 7 is formed.

[0049] The second resin member 5 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 second resin member 5 may be, for example, a thermoplastic resin, such as polyethylene, polypropylene, ABS resin, acrylic resin, polyamide, or polycarbonate.

[0050] The outer periphery shapes of the first resin member 4 and the second resin member 5 are the same size and shape, and they are positioned facing each other. In other words, as shown in Figure 10, the first resin member 4 and the second resin member 5 are substantially symmetrical in plane with respect to the metal member 1 in the cross-section along line XX in Figure 1.

[0051] [1-5.Joining form] As shown in Figure 10, the lower surface 42b of the first peripheral wall portion 42 of the first resin member 4 and the first peripheral edge portion 24 of the metal member 1 are joined together around the entire circumference. In other words, the first periphery of the first resin member 4 is joined to the first peripheral wall portion 42, forming an L-shaped frame in plan view. Specifically, the first overlapping portion 63 is formed by overlapping the lower surface 42Ab of the wall portion 42A to the edge portion 24A, the lower surface 42Bb of the wall portion 42B to the edge portion 24B, the lower surface 42Cb of the wall portion 42C to the edge portion 24C, the lower surface 42Db of the wall portion 42D to the edge portion 24D, the lower surface 42Eb of the wall portion 42E to the edge portion 24E, and the lower surface 42Fb of the wall portion 42F to the edge portion 24F. Furthermore, the end face 23a of the first fin 23 may be joined to the lower surface 41b of the first bottom portion 41, but in this embodiment, they are either in contact or facing each other with a small gap between them.

[0052] As shown in Figure 10, the lower surface 47b of the first frame-shaped wall portion 47 of the first resin member 4 and the second peripheral edge portion 25 of the metal member 1 are joined. In other words, the first frame-shaped wall portion 47 of the first resin member 4 is superimposed on the second peripheral edge portion 25 to form a second overlapping portion 64 that is L-shaped in plan view and is joined. Specifically, the second overlapping portion 64 is formed by superimposing the lower surface 47Ab of the wall portion 47A onto the edge portion 25A, and the lower surface 47Bb of the wall portion 47B onto the edge portion 25B.

[0053] The first cavity 6 is formed between the metal member 1 and the first resin member 4 when the first overlapping portion 63 is joined. The first cavity 6 has an L-shape in plan view. On the first surface portion 2 side, the first cavity 6 is arranged in parallel with the first open portion 22. In other words, in cross-sectional view, the first cavity 6 and the first open portion 22 are located adjacent to each other in the left-right direction. The first open portion 22 is the part of the metal member 1 that is exposed to the outside when the first overlapping portion 63 and the second overlapping portion 64 are joined. That is, the first open portion 22 is a part of the metal member 1 that is exposed from the area surrounded by the wall portions 42D, 42E, 47A, and 47B.

[0054] As shown in Figure 10, the upper surface 52a of the second peripheral wall portion 52 of the second resin member 5 and the third peripheral edge portion 34 of the metal member 1 are joined together around their entire circumference. In other words, a rectangular third overlap portion 73, which is formed in plan view by overlapping the second peripheral wall portion 52 of the second resin member 5 with the third peripheral edge portion 34, is joined together. Specifically, the third overlap portion 73 is formed by overlapping the edge portion 34A on the upper surface 52Aa of the wall portion 52A, the edge portion 34B on the upper surface 52Ba of the wall portion 52B, the edge portion 34C on the upper surface 52Ca of the wall portion 52C, and the edge portion 34D on the upper surface 52Da of the wall portion 52D. Furthermore, the end face 33a of the second fin 33 may be joined to the upper surface 51a of the second bottom portion 51, but in this embodiment, they are either in contact or facing each other with a small gap between them.

[0055] As shown in Figure 10, the upper surface 57a of the second frame-shaped wall portion 57 of the second resin member 5 and the fourth peripheral edge portion 35 of the metal member 1 are joined. In other words, the second frame-shaped wall portion 57 of the second resin member 5 is superimposed on the fourth peripheral edge portion 35 to form a fourth overlapping portion 74 that is U-shaped in plan view or U-shaped with all corners being right angles. Specifically, the fourth overlapping portion 74 is formed by superimposing the edge portion 35A on the upper surface 57Aa of the wall portion 57A, the edge portion 35B on the upper surface 57Ba of the wall portion 57B, and the edge portion 35C on the upper surface 57Ca of the wall portion 57C.

[0056] The second cavity 7 is formed between the metal member 1 and the second resin member 5 when the third overlapping portion 73 is joined. The second cavity 7 has a rectangular shape in plan view. On the second surface portion 3 side, the second cavity 7 is arranged in parallel with the second opening portion 32. In other words, in cross-sectional view, the second cavity 7 and the second opening portion 32 are located adjacent to each other in the left-right direction. The second opening portion 32 is the part of the metal member 1 that is exposed to the outside when the third overlapping portion 73 and the fourth overlapping portion 74 are joined. That is, the second opening portion 32 is a part of the metal member 1 that is exposed from the area surrounded by the wall portion 52D, wall portion 57A, wall portion 57B, and wall portion 57C.

[0057] As shown in Figures 1, 11, and 12, the first cavity 6 comprises a first main cavity 61 and a first sub-cavity 62. The first main cavity 61 faces the second opening 32 across the metal member 1 and is the part in which the first fin 23 is housed. In other words, the first main cavity 61 is the part through which fluid for heat exchange with the heating element located in the second opening 32 flows. As shown in Figures 1 and 12, the first sub-cavity 62 is formed continuously to the right on the front side of the first main cavity 61 and is located at a position corresponding to the communication hole 11. In other words, the first sub-cavity 62 extends to the right (towards the first opening 22) in the left-right direction from the first main cavity 61 and is a space located in a position aligned vertically with the first opening 22.

[0058] As shown in Figures 2 and 12, the second cavity 7 comprises a second main cavity 71 and a second sub-cavity 72. The second main cavity 71 is the part that faces the first open section 22 across the metal member 1 and houses the second fin 33. In other words, the second main cavity 71 is the part through which fluid for heat exchange with the heating element placed in the first open section 22 flows. The second sub-cavity 72 is formed in a forward direction of the second main cavity 71 and is located at a position corresponding to the communication hole 11. In other words, the second sub-cavity 72 is a space located in a position aligned with the second main cavity 71 and facing the first sub-cavity 62 across the metal member 1, and the fluid flowing through the first sub-cavity 62 flows into the second sub-cavity 72 through the communication hole 11.

[0059] [1-6. Fluid Flow] Next, the fluid flow in the cooler 100 according to this embodiment will be described. The fluid can be a cooled liquid or gas. As shown in Figure 11, the fluid flows into the interior from the inlet 43 through the first through hole 44 and proceeds to the first main cavity 61 of the first cavity 6. The fluid flows from rear to front within the first main cavity 61, and once it reaches the front end of the first main cavity 61, it flows to the right and flows into the first sub-cavity 62. The fluid flows between adjacent first fins 23, 23 within the first main cavity 61 and exchanges heat with the heat-generating element located in the second open section 32.

[0060] As the fluid flows into the first sub-cavity 62, as shown in Figure 12, the fluid flows through the communication hole 11 to the second sub-cavity 72 below.

[0061] The fluid that flows into the second sub-cavity 72 flows from front to back and into the second main cavity 71. In the second main cavity 71, the fluid flows between adjacent second fins 33, 33 and exchanges heat with the heat-generating element located in the first open section 22. The fluid that has passed between the second fins 33, 33 passes through the second through-hole 54 and is discharged to the outside from the outlet section 53.

[0062] [1-7. 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.

[0063] As shown in Figure 3, the preparation step involves forming the metal member 1, the first resin member 4, and the second resin member 5. The method for forming the metal member 1, the first resin member 4, and the second resin member 5 is not particularly limited. The metal member 1 may be formed by cutting using a multi-cutter equipped with multiple circular cutting blades, for example, or by joining the substrate and fins by brazing. The first resin member 4 and the second resin member 5 may be integrally formed by injection molding, for example.

[0064] The rough surface formation process, as shown in Figures 13 and 14, involves forming rough surfaces (rough surface structures) on the first peripheral edge 24 and the second peripheral edge 25 of the first surface 2 of the metal member 1, and on the third peripheral edge 34 and the fourth peripheral edge 35 of the second surface 3 of the metal member 1. In other words, rough surfaces are formed on the joint surface with the first resin member 4 on the first surface 2 and on the joint surface with the second resin member 5 on the second surface 3. In this embodiment, a rough surface S1 is formed on the first peripheral edge 24, a rough surface S2 is formed on the second peripheral edge 25, a rough surface S3 is formed on the third peripheral edge 34, and a rough surface S4 is formed on the fourth peripheral edge 35. The rough surface areas S1 to S4 are represented by dots. The width of the rough surface areas S1 to S4 can be set as appropriate. The roughened surfaces S1 to S4 can be formed, for example, by laser processing, mechanical processing (polishing, etc.), chemical processing (etching, etc.), or electrical processing (electropolishing, etc.).

[0065] The heating process, as shown in Figure 15, involves heating the metal member 1, the first resin member 4, and the second resin member 5. In the heating process, the entire metal member 1, the first resin member 4, and the second resin member 5 may be heated, but it is sufficient to heat at least the joint surfaces. In this embodiment, the metal member 1, the first resin member 4, and the second resin member 5 are heated simultaneously using a heating device 81. The heating device 81 comprises a first heating section 82, a second heating section 83, and a connecting section 84 that connects the first heating section 82 and the second heating section 83 in a positional relationship where they are separated and facing each other. The heating device 81 has a U-shaped cross-section or a U-shape with all corners at right angles, and has space inside to accommodate the metal member 1. The heating method in the heating device is not limited, but the heating device 81 in this embodiment heats the object using infrared rays.

[0066] The first heating section 82 is equipped with an upper heating section 82a above it for heating the first resin member 4. The first heating section 82 is equipped with a lower heating section 82b below it for heating the metal member 1. The upper heating section 82a and the first resin member 4 may be heated in contact with each other, but in this embodiment, they are heated at a distance from each other to prevent the resin contained in the first resin member 4 from adhering to the upper heating section 82a when the first resin member 4 melts.

[0067] Below the first heating section 82 is a lower heating section 82b for heating the metal member 1. The lower heating section 82b and the metal member 1 may be heated in contact with each other, but in this embodiment they are heated while separated.

[0068] An upper heating section 83a for heating the metal member 1 is provided above the second heating section 83. The upper heating section 83a and the metal member 1 may be heated in contact with each other, but in this embodiment, they are heated while separated from each other.

[0069] Below the second heating section 83 is a lower heating section 83b for heating the second resin member 5. The lower heating section 83b and the second resin member 5 may be heated in contact with each other, but in this embodiment, they are heated at a distance from each other to prevent the resin contained in the second resin member 5 from adhering to the heating section when the second resin member 5 melts.

[0070] In the heating process, the metal member 1, the first resin member 4, and the second resin member 5 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 points of the first resin member 4 and the second resin member 5, the material of the metal member 1, and the heating method (welding method). The heating temperatures of the metal member 1 and the first resin member 4 and the second resin member 5 may be the same or different.

[0071] The heating temperature of the metal member 1 can be set based on the resin melting point temperature, which is the melting point temperature of the thermoplastic resin contained in the first resin member 4 and the second resin member 5. For example, as in this embodiment, when the first resin member 4 and the second resin member 5 are formed from PPS (Polyphenylene sulfide) (melting point: 280°C), the metal member 1 is formed from an aluminum alloy (e.g., A6063T5), and it is heated non-contact by infrared radiation, the temperature of the metal member 1 is set to approximately 220°C. It is preferable to set the heating temperature of the metal member 1 to around the resin melting point temperature. Preferably, the heating temperature of the metal member 1 is above the resin melting point temperature - 100°C, above the resin melting point temperature - 70°C, above the resin melting point temperature - 40°C, above the resin melting point temperature - 20°C, and preferably below the resin melting point temperature + 100°C, below the resin melting point temperature + 70°C, below the resin melting point temperature + 40°C, below the resin melting point temperature + 20°C, and below the resin melting point temperature.

[0072] The heating temperatures of the first resin member 4 and the second resin member 5 can be set based on the resin melting temperature, which is the melting temperature of the thermoplastic resin contained in the first resin member 4 and the second resin member 5. Preferably, the heating temperatures of the first resin member 4 and the second resin member 5 are above the resin melting temperature and close to the said melting temperature. Preferably, the heating temperatures of the first resin member 4 and the second resin member 5 are above the resin melting temperature, above the resin melting temperature + 5°C, above the resin melting temperature + 10°C, above the resin melting temperature + 20°C, and preferably below the resin melting temperature + 100°C, below the resin melting temperature + 70°C, below the resin melting temperature + 50°C, and below the resin melting temperature + 30°C.

[0073] The joining process, as shown in Figure 16, involves joining the preheated metal member 1, the first resin member 4, and the second resin member 5 by applying pressure with a pressurizing device (not shown) and welding them together. In the joining process, a predetermined pressing force is applied from the upper side of the first resin member 4 and the lower side of the second resin member 5 to cause welding.

[0074] In the joining process, first, the first surface portion 2 of the metal member 1 and the lower surfaces 41b, 42b of the first resin member 4 are brought into opposition, and the second surface portion 3 of the metal member 1 and the upper surfaces 51a, 52a of the second resin member 5 are brought into opposition. Specifically, the lower surface 42b (42Ab, 42Bb, 42Cb, 42Db, 42Eb, 42Fb), which will be the joining surface of the first peripheral wall portion 42, is brought into opposition with the rough surface portion S1 formed on the first peripheral edge portion 24 (24A, 24B, 24C, 24D, 24E, 24F), which will be the joining surface on the first surface portion 2 side of the metal member 1. Also, the lower surface 47b (47Ab, 47Bb), which will be the joining surface of the first frame-shaped wall portion 47, is brought into opposition with the rough surface portion S2 formed on the second peripheral edge portion 25 (25A, 25B). Furthermore, the upper surface 52a (52Aa, 52Ba, 52Ca, 52Da) of the second peripheral wall portion 52, which forms the joining surface, is opposed to the rough surface portion S3 formed on the third peripheral edge portion 34 (34A, 34B, 34C, 34D) of the metal member 1, which forms the joining surface on the second surface portion 3 side. Also, the upper surface 57a (57Aa, 57Ba, 57Ca) of the second frame-shaped wall portion 57, which forms the joining surface, is opposed to the rough surface portion S4 formed on the fourth peripheral edge portion 35 (35A, 35B, 35C) of the metal member 1, which forms the joining surface on the second surface portion 3 side. Next, the joining surface on the first surface portion 2 side of the metal member 1 is brought into contact with the joining surface of the first resin member 4, and the joining surface on the second surface portion 3 side of the metal member 1 is brought into contact with the joining surface of the second resin member 5. Specifically, the lower surface 42b, which is the joining surface of the first peripheral wall portion 42, is brought into contact with the rough surface portion S1 formed on the first peripheral edge portion 24, which is the joining surface on the first surface portion 2 side of the metal member 1. Also, the lower surface 47b, which is the joining surface of the first frame-shaped wall portion 47, is brought into contact with the rough surface portion S2 formed on the second peripheral edge portion 25. Furthermore, the upper surface 52a, which is the joining surface of the second peripheral wall portion 52, is brought into contact with the rough surface portion S3 formed on the third peripheral edge portion 34, which is the joining surface on the second surface portion 3 side of the metal member 1. Furthermore, the upper surface 57a, which is the joining surface of the second frame-shaped wall portion 57, is brought into contact with the rough surface portion S4 formed on the fourth peripheral edge portion 35, which is the joining surface on the second surface portion 3 side of the metal member 1. In this manner, the metal member 1 is sandwiched between the first resin member 4 and the second resin member 5 and in contact with them. By applying pressure to the first resin member 4 and the second resin member 5, which are in contact with both sides of the metal member 1, from the first surface 2 and the second surface 3 sides, the metal member 1 is joined to the contact surfaces of the first resin member 4 and the second resin member 5.

[0075] 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.

[0076] The release process is the process of releasing the pressure on the joined structure after the cooling process. After the temperature of the first resin member 4 and the second resin member 5 has decreased and solidified due to the cooling process, the pressure applied to the metal member 1 and the first resin member 4 and the second resin member 5 is released, and the joined cooler 100 is removed from the pressurizing device. The cooler 100 is then completed.

[0077] 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.

[0078] 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.

[0079] In ultrasonic thermal welding, the first resin member 4, the second resin member 5, and the metal member 1 are heated by frictional heat generated by ultrasonic vibrations. In the vibration welding method, the first resin member 4, the second resin member 5, and the metal member 1 are heated by frictional heat generated by vibration. In the high-frequency induction heating welding method, the metal member 1 is heated by heat generated by molecular vibration in a high-frequency electric field. In addition, the first resin member 4 and the second resin member 5 are heated by heat conduction from the metal member 1. The laser welding method heats the metal member 1 by generating heat through laser light absorption. In addition, the first resin member 4 and the second resin member 5 are heated by heat conduction from the metal member 1. In the hot plate welding method, the metal member 1, the first resin member 4, and the second resin member 5 are heated by heat generation through heat conduction from the hot plate or by far-infrared heating. In the spin welding method, the metal member 1, the first resin member 4, and the second resin member 5 are heated by frictional heat generated by high-speed rotation.

[0080] For example, when forming the first resin member 4 and the second resin member 5 with PPS, and forming the metal member 1 with an aluminum alloy, and heating them using a general heat welding method, the metal member 1 is heated to approximately 350°C. The heat welding method is a method in which the first resin member 4 and the second resin member 5 are heated by heat conduction from the heated metal member 1.

[0081] Furthermore, for example, when forming the first resin member 4 and the second resin member 5 with PPS, forming the metal member 1 with an aluminum alloy, and heating them using a resin-contact type hot plate welding method, the metal member 1 is heated to approximately 280°C. The resin-contact type hot plate welding method is a method in which the metal member 1 is heated while simultaneously being brought into contact with the first resin member 4 and the second resin member 5 to heat them.

[0082] Furthermore, for example, when forming the first resin member 4 and the second resin member 5 with PPS, forming the metal member 1 with an aluminum alloy, and heating them using a non-contact resin hot plate welding method, the metal member 1 is heated to approximately 240°C. The non-contact resin hot plate welding method is a method in which the heated metal member 1 is heated, and at the same time, the first resin member 4 and the second resin member 5 are brought into contact with the heated metal member 1, and the first resin member 4 and the second resin member 5 are heated by radiant heat.

[0083] [1-8. Effects and Benefits] In the cooler 100 according to the embodiment described above, the first resin member 4 and the second resin member 5 are arranged on the first surface portion 2 side and the second surface portion 3 side, respectively, with the metal member 1 in between. In the cooler 100, the first main cavity 61 of the first cavity 6 formed between the first surface portion 2 of the metal member 1 and the first resin member 4 on the first surface portion 2 side is provided at a position facing the second open portion 32 on the second surface portion 3 side, where the second surface portion 3 of the metal member 1 is open to the outside. Also, the second main cavity 71 of the second cavity 7 formed between the second surface portion 3 of the metal member 1 and the second resin member 5 on the second surface portion 3 side is provided at a position facing the first open portion 22 on the first surface portion 2 side, where the first surface portion 2 of the metal member 1 is open to the outside. Furthermore, in the cooler 100, the first main cavity 61 and the second main cavity 71 are connected via the first sub-cavity 62 and the second sub-cavity 72, which are located at positions corresponding to the communication holes 11 provided in the metal member 1. As a result, in the cooler 100, the first opening 22 exchanges heat with the fluid flowing through the opposing second cavity 7, and the second opening 32 exchanges heat with the fluid flowing through the opposing first cavity 6. Thus, with this cooler 100, the outer surfaces of the first opening 22 and the second opening 32, which are provided on both sides of the metal member 1, function as cooling surfaces, thereby enabling cooling of the heat-generating elements located on both sides. In conventional coolers, since the heat-generating elements must be placed on metal components, metal components were placed on both sides of the resin component containing the flow path in order to place the heat-generating elements on both sides of the cooler. In other words, conventional coolers were excessively tall because, in addition to the height of the two metal components and the resin component sandwiched between them, two heat-generating elements were placed on the outside of the metal components. In contrast, the cooler 100 according to this embodiment has a first opening 22 and a second opening 32 on both sides of a single metal member 1 positioned in the middle, each of which has a heating element. Furthermore, a first resin member 4 has a first cavity 6 that is parallel to the first opening 22 and facing the second opening 32, and a second resin member 5 has a second cavity 7 that is parallel to the second opening 32 and facing the first opening 22. As a result, the height of the cooler 100 is the height of the metal member 1 plus the height of the two heating elements, or the height of the metal member 1 plus the height of the first resin member 4 and the second resin member 5. Therefore, the overall height of the cooler 100 does not increase compared to the case where the heating elements are positioned further outside the three members, and space saving can be achieved. For the reasons stated above, the cooler 100 according to this embodiment can prevent the height from increasing (become lower) when heat-generating elements are placed on both sides of the cooler 100.

[0084] Furthermore, in the cooler 100 according to this embodiment, the first resin member 4 has a first through hole 44 (inlet 43) that connects the first main cavity 61 to the outside, and the second resin member 5 has a second through hole 54 (outlet 53) that connects the second main cavity 71 to the outside. In addition, the first through hole 44, the first main cavity 61, the first sub-cavity 62, the communication hole 11, the second sub-cavity 72, the second main cavity 71, and the second through hole 54 are connected to form a fluid flow path. As a result, the cooler 100 can allow fluid to flow into the first main cavity 61 through the first through hole 44 and discharge fluid to the outside from the second main cavity 71 through the second through hole 54. Therefore, the cooler 100 has a fluid flow path from the inlet 43 to the outlet 53, and can efficiently cool the heat-generating elements arranged on both sides of the metal member 1.

[0085] Furthermore, in the cooler 100 according to this embodiment, the first sub-cavity 62 and the first open section 22 are arranged in a vertical line with the first main cavity 61 on the first surface 2 side of the metal member 1, and the second main cavity 71 and the second sub-cavity 72 are arranged in a vertical line with the second open section 32 on the second surface 3 side of the metal member 1. This allows for cooling of heat-generating elements arranged on both sides of the metal member 1 with a simple configuration, and also saves space in the height direction. In addition, by organizing the arrangement of the cavities and open sections, space can also be saved in the planar direction.

[0086] Furthermore, in the cooler 100 according to this embodiment, the first resin member 4 has a first frame-shaped wall portion 47 surrounding the first opening portion 22, and the second resin member 5 has a second frame-shaped wall portion 57 surrounding the second opening portion 32, and the outer circumferential shapes of the first resin member 4 and the second resin member 5 are symmetrical with respect to the metal member 1. In other words, the first circumferential wall portion 42 and the first frame-shaped wall portion 47 combine to form a rectangular outer circumferential shape when viewed from above. Similarly, the second circumferential wall portion 52 and the second frame-shaped wall portion 57 combine to form a rectangular outer circumferential shape when viewed from above. In this way, by combining the first frame-shaped wall portion 47 and the second frame-shaped wall portion 57, the outer circumferential shapes of the first resin member 4 and the second resin member 5 can be made symmetrical with respect to the metal member 1. In this way, by heat-welding the first resin member 4 and the second resin member 5, which are symmetrical with respect to the metal member 1, it becomes easier to prevent deformation caused by heat welding between the first surface 2 side and the second surface 3 side.

[0087] Furthermore, as in this embodiment, the first surface portion 2 of the metal member 1 has roughened surfaces S1 and S2 formed on the joint surface with the first resin member 4. Also, the second surface portion 3 of the metal member 1 has roughened surfaces S3 and S4 formed on the joint surface with the second resin member 5. This makes it possible to improve the strength of the joint and the leak resistance performance (airtightness and watertightness).

[0088] Furthermore, according to the manufacturing method of the cooler according to this embodiment, a cooler 100 can be easily manufactured in which a metal member 1 is joined to a first resin member 4 and a second resin member 5, allowing heat exchange on both sides of the metal member 1 and preventing expansion in the height direction.

[0089] Furthermore, in this embodiment, during the heating process, the joining surface of the first resin member 4 (the lower surface 42b of the first peripheral wall portion 42) and the joining surface of the second resin member 5 (the upper surface 52a of the second peripheral wall portion 52) are heated. This allows the resin near the joining surface that contributes to joining with the metal member 1 to be melted, compared to heating the entire first resin member 4 and the second resin member 5. At this time, heating of the resin other than the joining surfaces of the first resin member 4 and the second resin member 5 can be suppressed, thereby suppressing deformation of the molded body during joining.

[0090] Furthermore, in this embodiment, by simultaneously joining the first surface 2 side of the metal member 1 to the first resin member 4 and the second surface 3 side of the metal member 1 to the second resin member 5 during the joining process, the thermal and load balance is improved, and deformation of the cooler 100 can be suppressed.

[0091] Furthermore, this embodiment further includes a surface roughening step in which roughened surfaces S1, S2, S3, and S4 are formed on the metal member 1. This allows the molten resin to fill the fine grooves of the roughened surfaces S1, S2, S3, and S4, thereby improving the bonding strength and leak resistance (airtightness and watertightness) between the first resin member 4 and the second resin member 5 and the metal member 1.

[0092] Furthermore, in this embodiment, the metal member 1, the first resin member 4, and the second resin member 5 are joined without heating during the joining process. In other words, since the members are preheated in the heating process before the joining 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, heating the metal component 1, the first resin component 4, and the second resin component 5 simultaneously, as in this embodiment, can increase heating efficiency and shorten the manufacturing cycle. In addition, the heating device 81 allows for easy simultaneous heating of all three components.

[0093] [1-9. 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. In the embodiment described above, the case in which the first through-hole 44 is formed in the first peripheral wall portion 42 and the second through-hole 54 is formed in the second peripheral wall portion 52 was explained as an example. The first through-hole 44 may be formed in the first bottom portion 41 or the first peripheral wall portion 42. The second through-hole 54 may also be formed in the second bottom portion 51 or the second peripheral wall portion 52. The first through-hole 44 and the second through-hole 54 can be appropriately changed according to the shape of the component or heating element to which they are applied, thereby improving the degree of design freedom.

[0094] Furthermore, the orientation of the inlet 43 and outlet 53 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 43 and outlet 53 may be parallel to the left-to-right direction, so that the flow directions of the inlet 43 and outlet 53 are different. Furthermore, the communication holes 11 may be provided at other locations. Also, the shape and number of communication holes 11 can be set as appropriate.

[0095] Furthermore, in the heating step, the heating device 81 was separated from the first resin member 4 and the second resin member 5, but they may be heated in contact. Also, in the heating step, the metal member 1, the first resin member 4, and the second resin member 5 were heated simultaneously, but they may be heated separately. In the joining step, the first resin member 4 and the second resin member 5 may be heated while being pressurized. Also, in the heating step, the metal member 1 may be heated, but the first resin member 4 and the second resin member 5 may not be heated. Furthermore, the surface roughening step may be omitted.

[0096] [2. Second Embodiment] Next, a cooler according to the second embodiment of the present invention will be described. As shown in Figures 17 and 18, the cooler 200 according to this embodiment differs from the first embodiment in that it includes a third resin member 201 that seals the first opening 22 and a fourth resin member 202 that seals the second opening 32. 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.

[0097] The cooler 200 comprises a metal member 1, a first resin member 4, a second resin member 5, a third resin member 201, and a fourth resin member 202.

[0098] [2-1. Third resin component] As shown in Figure 17, the third resin member 201 is a substantially flat resin member and is a lid member placed on the first resin member 4. The third resin member 201 is placed on the upper surface 41a of the first bottom portion 41 and the upper surface 47a of the first frame-shaped wall portion 47. In other words, the third resin member 201 seals the opening with a heating element (not shown) placed in the first opening portion 22. The first resin member 4 and the third resin member 201 may be joined in any way, and can be joined by laser welding, heat welding, bolting, adhesive, etc. Also, in this embodiment, the shape is such that only the first opening portion 22 is sealed, but the entire surface of the first resin member 4 may be covered.

[0099] [2-2. Fourth Resin Component] As shown in Figure 18, the fourth resin member 202 is a substantially flat resin member and is a lid member placed on the second resin member 5. The fourth resin member 202 is placed on the lower surface 51b of the second bottom portion 51 and the lower surface 57b of the second frame-shaped wall portion 57. In other words, the fourth resin member 202 seals the opening with a heating element (not shown) placed in the second opening portion 32. The second resin member 5 and the fourth resin member 202 may be joined in any way, and can be joined by laser welding, heat welding, bolting, adhesive, etc. Also, in this embodiment, the shape is such that only the second opening portion 32 is sealed, but the entire surface of the second resin member 5 may be covered.

[0100] Furthermore, either the third resin member 201 or the fourth resin member 202 may be provided. In other words, only the third resin member 201 may be joined, leaving the second open portion 32 exposed. Alternatively, only the fourth resin member 202 may be joined, leaving the first open portion 22 exposed. The joining configuration, fluid flow, and manufacturing method of this embodiment are the same as those of the first embodiment, and therefore will not be described.

[0101] [2-3. Effects and Benefits] The cooler 200 according to the embodiment described above includes a third resin member 201 that seals the first opening 22, and / or a fourth resin member 202 that seals the second opening 32. By arranging the third resin member 201 and the fourth resin member 202 in this way, other components can be placed on the surfaces of the third resin member 201 and the fourth resin member 202, thereby increasing the degree of design freedom and expanding the range of applicability. Furthermore, by forming the third resin member 201 from a resin material, when joining it to the first resin member 4, the joining is done between resins, making the joining process easier compared to joining dissimilar materials. Furthermore, by forming the fourth resin member 202 from a resin material, when joining it to the second resin member 5, the joining is between resins, making the joining process easier compared to joining dissimilar materials.

[0102] [3. Other Embodiments] In the embodiments described above, a cooler formed by joining a metal member with a first resin member and a second resin member was exemplified, but the design can be modified as appropriate without violating the spirit of the invention. Furthermore, although an example was shown in which an inlet is provided in the first resin member to allow fluid to flow in from the first resin member and an outlet is provided on the second resin member side to discharge the fluid from the second resin member side, an inlet may also be provided in the second resin member to allow fluid to flow in from the second resin member and an outlet is provided on the first resin member side to discharge the fluid from the first resin member side. [Explanation of Symbols]

[0103] 100: Cooler 1: Metal Component 2: First Face 3: Second Face 4: First Resin Component 5: Second Resin Component 6: First Cavity 7: Second Cavity 10: Body 11: Connecting Hole 22: First Opening 32: Second Opening 41: First Bottom 42: First Peripheral Wall 43: Inflow 44: First Through Hole 45: First Space 46: First Opening 47: First Strut-like Wall 51: Second Bottom 52: Second Peripheral Wall 53: Outflow 54: Second Through Hole 55: Second Space 56: Second Opening 57: Second Strut-like Wall 61: First Main Cavity 62: First Secondary Cavity 71: Second Main Cavity 72: Secondary Cavity S1: Rough Face S2: Rough Face S3: Rough Face S4: Rough Face

Claims

1. A cooler comprising a metal member, and a first resin member and a second resin member arranged on both sides of the metal member, The metal member has a main body that is substantially flat and a communication hole that penetrates the main body in the thickness direction. The main body portion has a first open portion on the first surface of the main body portion where the first surface portion and the first resin member are joined and open to the outside, and a second open portion on the second surface portion of the main body portion opposite to the first surface portion where the second surface portion and the second resin member are joined and open to the outside. By joining the first surface portion and the first resin member, a first cavity is formed between the first surface portion and the first resin member. By joining the second surface portion and the second resin member, a second cavity is formed between the second surface portion and the second resin member. The first cavity comprises a first main cavity located opposite the second open portion with the metal member in between, and a first sub-cavity located in a position corresponding to the communication hole, which is continuous with the first main cavity. The cooler is characterized in that the second cavity portion has a second main cavity portion located opposite the first open portion with the metal member in between, and a second sub-cavity portion that is continuous with the second main cavity portion and located at a position corresponding to the communication hole.

2. The first resin member has a first through hole that connects the first main cavity to the outside, The second resin member has a second through hole that connects the second main cavity to the outside, The cooler according to claim 1, characterized in that the first through hole, the first main cavity, the first secondary cavity, the communication hole, the second secondary cavity, the second main cavity, and the second through hole are in communication with each other to form a fluid passage.

3. The first resin member has a first bottom, a first peripheral wall rising from the peripheral edge of the first bottom, a first space enclosed by the first bottom and the first peripheral wall, and a first opening surrounded by the end face of the first peripheral wall, through which the first space opens to the outside. The second resin member has a second bottom, a second peripheral wall rising from the peripheral edge of the second bottom, a second space enclosed by the second bottom and the second peripheral wall, and a second opening surrounded by the end face of the second peripheral wall, through which the second space opens to the outside. The first surface portion and the end face of the first peripheral wall portion of the metal member are joined together to seal the first opening, and the first cavity portion is formed, surrounded by the first surface portion, the first peripheral wall portion and the first bottom portion. The second surface portion and the end face of the second peripheral wall portion of the metal member are joined together to seal the second opening, and the second cavity portion is formed, surrounded by the second surface portion, the second peripheral wall portion and the second bottom portion. On the first surface side of the metal member, the first sub-cavity and the first open portion and the first main cavity are arranged in parallel, The cooler according to claim 1, characterized in that the second main cavity and the second sub-cavity, which are arranged vertically, and the second open portion are in parallel on the second surface side of the metal member.

4. The first resin member has a first through hole that connects the first main cavity to the outside, The second resin member has a second through hole that connects the second main cavity to the outside, The first through-hole is provided in the first bottom portion or the first peripheral wall portion, The cooler according to claim 3, characterized in that the second through-hole is provided in the second bottom portion or the second peripheral wall portion.

5. The first resin member has a first frame-shaped wall portion surrounding the first opening, The second resin member has a second frame-shaped wall portion surrounding the second opening, The cooler according to claim 1, characterized in that the outer circumferential shape of the first resin member and the outer circumferential shape of the second resin member are symmetrical with respect to the metal member.

6. The cooler according to claim 5, further comprising a third resin member that seals the first opening and / or a fourth resin member that seals the second opening.

7. The first surface of the metal member has a roughened surface on the bonding surface with the first resin member. The cooler according to claim 1, characterized in that the second surface of the metal member has a rough surface on the bonding surface with the second resin member.

8. A method for manufacturing a cooler comprising a metal member, and a first resin member and a second resin member arranged on both sides of the metal member, The metal member has a main body that is substantially flat and a communication hole that penetrates the main body in the thickness direction. The main body portion has a first open portion on the first surface of the main body portion where the first surface portion and the first resin member are joined and open to the outside, and a second open portion on the second surface portion of the main body portion opposite to the first surface portion where the second surface portion and the second resin member are joined and open to the outside. A heating step of heating the joint surface of the first surface and the joint surface of the second surface of the metal member, The bonding step includes bringing the bonding surface of the metal member heated in the heating step to face the bonding surface of the first resin member, bringing the bonding surface of the metal member heated in the heating step to face the bonding surface of the second resin member, bringing the first surface of the metal member into contact with the bonding surface of the first resin member, and applying pressure while the second surface of the metal member and the bonding surface of the second resin member are in contact, thereby bonding the metal member, the first resin member, and the second resin member. By the aforementioned joining process, The first surface portion of the metal member and the first resin member are joined together to form a first cavity between the metal member and the first resin member. The second surface portion of the metal member and the second resin member are joined together to form a second cavity between the metal member and the second resin member. The first cavity is, A first main cavity is provided in a position opposite the second open portion, with the aforementioned metal member in between, It has a first secondary cavity which is continuous with the first main cavity and is located at a position corresponding to the communication hole, The second cavity is A second main cavity is provided in a position opposite the first open portion, with the aforementioned metal member in between, A method for manufacturing a cooler, characterized by having a second secondary cavity that is continuous with the second main cavity and is located at a position corresponding to the communication hole.

9. The method for manufacturing a cooler according to claim 8, characterized in that, in the heating step, the joining surface of the first resin member and the joining surface of the second resin member are heated.

10. The method for manufacturing a cooler according to claim 8, characterized in that the joining process simultaneously involves joining the first surface side of the metal member to the first resin member and joining the second surface side of the metal member to the second resin member.

11. The method for manufacturing a cooler according to claim 8, further comprising a surface roughening step of forming a rough surface on the joint surface of the metal member.

12. In the heating step, the joining surface of the metal member and the heating device are heated in a non-contact state. The method for manufacturing a cooler according to claim 8, characterized in that the metal member, the first resin member, and the second resin member are joined without heating in the joining step.

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