Heat exchange element and method for manufacturing the same

Abstract

To easily manufacture a heat exchange element having separation flow passages at an inflow side and a discharge side of opposed flow passages, by using a single-sided cardboard with a little man-hour.SOLUTION: Primary-side flow passages 3 and secondary-side flow passages 4 are alternately formed by stacking single-faced corrugated cardboards 2 in multistage, the single-faced corrugated cardboard 2 includes a liner material 21 and a corrugated core material 22 forming a step on the liner material 21, the flow passage formed by the corrugation of the core material 22 has a supply air turning flow passage portion 24 and an exhaust air turning flow passage portion 25, an intermediate flow passage portion 26 is formed between the turning flow passage portions 24, 25 at both sides, the turning flow passage portions 24, 25 adjacent to each other via the liner material 21 turn to directions different from each other, and the whole flow passage from an air supply port 24a of the supply air turning flow passage portion 24 to an air exhaust port 25a of the exhaust air turning flow passage portion 25 is formed with a sheet of the liner material 21.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a heat exchange element made of single-sided corrugated paper and a method for manufacturing the same.

Background Art

[0002] Conventional heat exchange elements include, for example, those described in Patent Document 1. This consists of a liner made of moisture-permeable paper and a corrugated plate made of moisture-permeable crepe paper. Both are joined with an adhesive to form a single-sided corrugated filter, and a large number of these single-sided corrugated filters are laminated and adhered. The step directions of the filters adjacent in the vertical direction are oriented in directions perpendicular to each other.

[0003] Further, the heat exchange element of Patent Document 2 alternately laminates partition plates and partition walls with a corrugated cross-section to form a counter-flow channel portion, a first separated flow channel portion, and a second separated flow channel portion. In the counter-flow channel portion, in the direction along the lamination direction of the partition plates and the partition walls, a first flow channel and a second flow channel are alternately formed with the partition plate interposed therebetween, and adjacent partition walls via the partition plate are arranged with their corrugated step tops parallel to each other.

[0004] The first separated flow channel portion and the second separated flow channel portion separate the air flowing through the first flow channel and the air flowing through the second flow channel in different directions. Each partition plate of the counter-flow channel portion and each partition plate of the first separated flow channel portion are joined with a tape, and each partition plate of the counter-flow channel portion and each partition plate of the second separated flow channel portion are joined with a tape.

[0005] Patent Document 3 is a heat exchanger that forms ventilation channels between a plurality of heat transfer plates laminated at a predetermined interval, and alternately circulates a primary air flow and a secondary air flow every other stage in each ventilation channel to perform heat exchange between the primary air flow and the secondary air flow. Either a convex portion or a concave portion, or a concavo-convex portion is formed in a part of the heat transfer plate.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0007] In a conventional general single-sided corrugated paper, the liner is flat, the core is corrugated to form steps, and the step tops extend linearly.

[0008] When forming a heat exchange element using this single-sided corrugated paper, basically, the primary side flow path and the secondary side flow path are linear in shape.

[0009] As a result, when providing separation flow paths on the inflow side and the discharge side of the counter flow paths in the heat exchange element, the counter flow paths and the separation flow paths cannot be formed as a continuous single member, and after forming the counter flow path portion and the separation flow path portion respectively from separate single-sided corrugated papers, the two are connected to form a continuous flow path.

[0010] Thus, when forming separation flow paths on the inflow side and the discharge side of the counter flow paths in a direction different from the axial direction of the counter flow paths, there is a problem that the manufacturing process is complicated and labor-intensive.

[0011] The present invention solves the above problems, and an object of the present invention is to provide a heat exchange element and a manufacturing method that can easily manufacture a heat exchange element having separation flow paths on the inflow side and the discharge side of a counter flow path with a small number of man-hours using single-sided corrugated paper.

Means for Solving the Problems

[0012] In order to solve the above problems, the heat exchange element of the present invention stacks single-sided corrugated paper in multiple layers to alternately form a primary side flow path and a secondary side flow path. The single-sided corrugated paper includes a liner material and a corrugated core material that forms steps on the liner material. The flow path formed by the corrugation of the core material has turning flow path portions on the air supply side and the exhaust side, and has an intermediate flow path portion between the turning flow path portions on both sides. The turning flow path portions adjacent to each other via the liner material turn in different directions, and the entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is A single core material is corrugated and formed on a single liner material. The intermediate flow path portion is parallel to the opposite two sides of the core material. The turning flow path portions on the air supply side and the exhaust side change their directions at the same angle in different directions with respect to the axis of the intermediate flow path portion, and both the turning flow path portion on the air supply side and the turning flow path portion on the exhaust side extend toward the same side of the core material that is parallel to the intermediate flow path. characterized by this.

[0015] The manufacturing method of the heat exchange element of the present invention arranges a corrugated core material that forms steps on a liner material to form single-sided corrugated paper, provides turning flow path portions on the air supply side and the exhaust side of the flow path formed by the corrugation of the core material, and provides an intermediate flow path portion between the turning flow path portions on both sides. The entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is formed on a single liner material, the single-sided corrugated paper is cut to form single-sheet elements, the single-sheet elements are stacked in multiple layers, and are arranged so that the turning flow path portions adjacent to each other via the liner material turn in different directions, and alternately form a primary side flow path and a secondary side flow path That is, on a single core material, the entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is formed by corrugating with a pair of stepped rolls. Both stepped rolls have teeth that form the core material into a wave shape on the outer periphery of each roll. The teeth have a tooth stripe corresponding to the intermediate flow path portion parallel to the axis of the stepped roll, and the tooth stripes at both side portions of the stepped roll corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the stepped roll. When looking at the pair of stepped rolls from the discharge side of the core material, the tooth stripes at both side portions of the stepped rolls facing each other through the core material extend in a direction approaching the core material toward the outside in the axial direction of the stepped roll. characterized by this.

[0017] In the manufacturing method of the heat exchange element of the present invention, The stepped roll is it consists of a single continuous roll over the entire length in the axial direction, of a single roll the rack corresponding to the intermediate flow path portion is parallel to the axis of the stepped roll, and the of a single roll racks of both side portions corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the stepped roll, the twist directions of the tooth stripes at both side portions facing each other through the core material are opposite, and the twist directions of the tooth stripes at both side portions of each stepped roll are opposite. characterized by this.

[0018] In the manufacturing method of the heat exchange element of the present invention, The stepped roll is it consists of a plurality of rolls that are connected axially and rotate integrally. The rack of the intermediate roll corresponding to the intermediate flow path portion is parallel to the axis of the stepped roll, and the racks of the both side rolls corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the stepped roll, in the side rolls facing each other through the core material, the twist directions of the tooth stripes are opposite, and in the side rolls on both sides of the intermediate roll, the twist directions of the tooth stripes are opposite. characterized by this.

Advantages of the Invention

[0021] In the above configuration, since the flow path formed by the corrugation of the single-sided corrugated paper, that is, the entire flow path from the air supply port of the air supply side turning flow path portion to the exhaust port of the exhaust side turning flow path portion, is formed on a single liner, by cutting the single-sided corrugated paper to form single-sheet elements and simply stacking the single-sheet elements in multiple stages, a heat exchange element having separated flow paths on the inflow side and the discharge side of the counter flow path can be easily manufactured with a small number of man-hours.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Embodiments for Carrying Out the Invention

[0023] Hereinafter, embodiments of the present invention will be described with reference to the drawings. (Example 1) In FIGS. 1 to 4, the heat exchange element 1 according to the present embodiment is for use in a total heat exchanger, and is formed by stacking single-sided corrugated paper 2 in multiple stages to alternately form a primary side flow path 3 and a secondary side flow path 4.

[0024] As shown in FIG. 1, the single-sided corrugated paper 2 is formed by arranging a corrugated core material 22 obtained by corrugating a continuous paper on a liner material 21 of the continuous paper to form steps, and then cutting it into rectangular sheet-like elements 2a. In the present embodiment, it is further cut into elements 2b having a predetermined shape, here a hexagonal shape.

[0025] Then, as shown in FIG. 2, the hexagonal elements 2b arranged in the positive direction and the hexagonal elements 2b rotated 180 degrees on the plane of the drawing as shown in FIG. 3 are alternately stacked in multiple stages to form the heat exchange element 1 shown in FIG. 4.

[0026] The liner material 21 forming the single-sided corrugated paper 2 and the corrugated core material 22 forming steps on the liner material 21 have moisture permeability and heat transfer properties. For the core material 22, a material with high strength, such as a non-woven fabric or paper with a large basis weight, is used.

[0027] The core material 22 forms a flow path 23 in a corrugated shape, and the flow path 23 formed by the corrugation of the core material 22 becomes the primary side flow path 3 or the secondary side flow path 4 of the heat exchange element 1. The flow path 23 of the core material 22 has an air supply turning flow path portion (separation flow path) 24 on the air supply side and an exhaust turning flow path portion (separation flow path) 25 on the exhaust side, and has an intermediate flow path portion (opposing flow path) 26 between the turning flow path portions 24 and 25 on both sides. The entire flow path from the air supply port 24a of the air supply turning flow path portion 24 to the exhaust port 25a of the exhaust turning flow path portion 25 is formed by a single core material 22 on a single liner material 21.

[0028] In the present embodiment, the air supply port 24a of the air supply turning flow path portion 24 and the exhaust port 25a of the exhaust turning flow path portion 25 open toward the same side in the rectangular element 2a before being cut into the hexagonal element 2b.

[0029] The heat exchange element 1, in which the elements 2b of the single-sided corrugated paper 2 are stacked in multiple stages, has the air supply diversion channel portion 24 and the exhaust diversion channel portion 25 of the upper and lower channels 23 adjacent to each other via the liner material 21. The air supply diversion channel portion 24 and the exhaust diversion channel portion 25 are diverted in different directions from each other, and the primary side channel 3 and the secondary side channel 4 of the heat exchange element 1 are alternately formed.

[0030] When the heat exchange element 1 is mounted on the total heat exchanger, the heat exchange element 1 is arranged within a predetermined frame of the total heat exchanger, and silicon resin is filled between the frame and the heat exchange element 1 to bond the frame and the heat exchange element 1 and block air leakage.

[0031] According to the above configuration, since the flow path formed by the corrugated shape of the single-sided corrugated paper stage, that is, the entire flow path from the air supply port 24a of the air supply diversion channel portion 24 to the exhaust port 25a of the exhaust diversion channel portion 25, is formed on a single liner material 21, the single-sided corrugated paper 2 is cut to form the leaf elements 2a and 2b, and by simply stacking the leaf elements 2a and 2b in multiple stages, the heat exchange element 1 having separated flow paths on the inflow side and the discharge side of the counter flow path can be easily manufactured with a small number of man-hours. (Step roll) In the present embodiment, a single step roll 61 shown in FIG. 5 is used for the corrugation process of the core material 22. A pair of step rolls 61 are arranged vertically and used.

[0032] The step roll 61 is composed of a single roll continuous over the entire length in the axial direction, and the outer peripheral surface of the roll has a plurality of teeth 81 forming ridges for forming corrugated steps on the core material 22 and grooves 82 forming concave shapes between adjacent teeth 1. The teeth 81 and the grooves 82 extend over the entire length in the axial direction of the step roll 61.

[0033] For the teeth 81, the tooth bar 81a at the intermediate part corresponding to the intermediate flow path portion 26 is parallel to the axis of the step roll 61, and the tooth bars 81b and 81c at both side parts corresponding to the diversion flow path portions 24 and 25 on the air supply side and the exhaust side have a twist angle with respect to the axis of the step roll 61.

[0034] By corrugating with this stepped roll 61, an entire flow path from the air supply port 24a of the air supply diversion flow path portion 24 to the exhaust port 25a of the exhaust diversion flow path portion 25 is formed in a single sheet material 22.

[0035] In this embodiment, a single stepped roll 61 is used. However, as shown in FIGS. 6 to 9, a pair of stepped rolls 71 and 72 composed of a plurality of rolls can also be used. These stepped rolls 71 and 72 are composed of a plurality of rolls including intermediate rolls 71a and 72a connected in the axial direction and side rolls 71b, 71c, 72b, and 72c on both sides. The intermediate rolls 71a and 72a and the side rolls 71b, 71c, 72b, and 72c are fixed around the axis by keys 73 to their respective shafts 71d and 72d, and the intermediate rolls 71a and 72a and the side rolls 71b, 71c, 72b, and 72c rotate integrally.

[0036] The intermediate rolls 71a and 72a can be single or plural, or it is also possible to eliminate the intermediate rolls 71a and 72a and have only the side rolls 71b, 71c, 72b, and 72c.

[0037] Each of the rolls 71a, 72a, 71b, 71c, 72b, and 72c has teeth 81 that form the sheet material 22 in a wave shape on the outer periphery of the roll.

[0038] The teeth 81 are such that the tooth bars 81a of the intermediate rolls 71a and 72a corresponding to the intermediate flow path portion 26 are in a flat tooth shape parallel to the axis of the stepped rolls 71 and 72, and the tooth bars 81b and 81c of the side rolls 71b, 71c, 72b, and 72c corresponding to the air supply side and exhaust side diversion flow path portions 24 and 25 are in a helical tooth shape having a twist angle with respect to the axis of the stepped roll 71.

[0039] As shown in FIG. 7, a pair of stepped rolls 71 and 72 are arranged vertically, and a pair of rollers 74 for suppressing the lifting of the sheet material 22 are arranged on the supply side of the sheet material 22. It is also possible to adopt a slit structure formed by a plate-like member instead of the rollers 74.

[0040] The racks of all the side rolls 71b, 71c, 72b, and 72c of the double-step rolls 71 and 72 on both sides have the same twist angle. And in the side rolls 71b and 72b facing each other through the strip material 22, and the side rolls 71c and 72c, the twist directions of the racks 81b and 81c are opposite. Also, in the side rolls 71b and 71c on both sides of the intermediate rolls 71a and 72a, and the side rolls 72b and 72c, the twist directions of the racks 81b and 81c are opposite.

[0041] As shown in FIG. 8, when looking at the pair of step rolls 71 and 72 from the supply side of the strip material 22, the racks 81b and 81c of the side rolls 71b and 72b facing each other through the strip material 22, and the side rolls 71c and 72c extend in a direction away from the strip material 22 toward the outside in the axial direction of the step rolls 71 and 72.

[0042] When the strip material 22 enters between the pair of step rolls 71 and 72, a force F acts on the strip material 22 sandwiched between the side rolls 71b and 71c on both sides of the intermediate rolls 71a and 72a, and between the side rolls 72b and 72c, toward the outside in the axial direction of the step rolls 71 and 72. At the same time, the strip material floats up between the rack 81a and the racks 81b and 81c with different angles with respect to the axis of the step rolls 71 and 72, and in this state, it may form steps while becoming wrinkled. Therefore, the occurrence of wrinkles is prevented by suppressing the floating of the strip material 22 with the rollers 74 on the supply side of the pair of rollers 74. As described above, this effect can also be replaced with a slit structure.

[0043] As shown in FIG. 9, when looking at the pair of step rolls 71 and 72 from the discharge side of the strip material 22, the racks 81b and 81c of the side rolls 71b and 72b facing each other through the strip material 22, and the side rolls 71c and 72c extend in a direction approaching the strip material 22 toward the outside in the axial direction of the step rolls 71 and 72.

[0044] When the core material 22 is discharged from between the pair of stepped rolls 71 and 72, a force F acts on the core material 22 discharged between the side rolls 71b and 71c on both sides of the intermediate rolls 71a and 72a, and between the side rolls 72b and 72c, in a direction outward from the axial center direction of the stepped rolls 71 and 72. With this structure, on the discharge side of the core material 22 of the pair of stepped rolls 71 and 72, the racks 81b and 81c act to spread the core material 22 outward in the axial center direction of the stepped rolls 71 and 72, preventing the occurrence of wrinkles in the core material 22.

[0045] By the corrugating process using these stepped rolls 71 and 72, an entire flow path from the air supply port 24a of the air supply diversion flow path portion 24 to the exhaust port 25a of the exhaust diversion flow path portion 25 is formed in a single core material 22. (Example 2) In the above Example 1, the hexagonal element 2b forming the primary side flow path 3 and the secondary side flow path 4 of the heat exchange element 1 has the same flow path shape cut out from a single continuous sheet of single-sided corrugated paper 2. By rotating the rectangular single-sided corrugated paper 2 having the same flow path shape by 180 degrees on the plane of the drawing, the air supply diversion flow path portion 24 and the exhaust diversion flow path portion 25 are directed in different directions. In this case, the air supply port 24a of the air supply diversion flow path portion 24 and the exhaust port 25a of the exhaust diversion flow path portion 25 open toward the same side edge in the single-sided corrugated paper 2 before being cut into the hexagonal element 2b.

[0046] However, as shown in FIG. 9, it is also possible to form two types of single-sided corrugated papers 51 and 52. That is, as shown in FIG. 9, on the liner materials 21 of two continuous sheets, core materials 22a and 22b corrugated in different corrugated shapes are arranged to form steps.

[0047] In this case, for the rectangular single-sheet elements 51a and 52a obtained by cutting each of the single-sided corrugated papers 51 and 52, the air supply port 24a of the air supply diversion flow path portion 24 and the exhaust port 25a of the exhaust diversion flow path portion 25 open toward opposite side edges of the rectangular single-sheet elements 51a and 52a, respectively.

[0048] Then, by cutting the rectangular leaf elements 51a and 52a, two types of elements 51b and 52b, namely the hexagonal element 52b in the positive direction shown in FIG. 10 and the hexagonal element 51b in the reverse direction shown in FIG. 11, are formed.

[0049] Then, as shown in FIG. 12, the two types of elements 51b and 52b are stacked alternately in multiple stages to form the heat exchange element 1. (Example 3) In the above-described Example 1 and Example 2, the core materials 22, 22a, and 22b are corrugated using a single-stage roll.

[0050] However, as shown in FIGS. 13 to 14, the core material 22c forming the air supply diversion channel portion 24, the core material 22d forming the exhaust diversion channel portion 25, and the core material 22e forming the intermediate channel portion 26 are separately pasted onto a single liner material 21 to form a single-sided cardboard 61 and a rectangular element 61a that form the entire flow path from the air supply port 24a of the air supply diversion channel portion 24 to the exhaust port 25a of the exhaust diversion channel portion 25.

[0051] In this case, as shown in FIG. 14, the multi-stage roll 91 has a plurality of rolls 91a, 91b, and 91c for corrugating the respective core materials 22c, 22d, and 22e mounted at intervals on a single shaft 91d for corrugating. (Example 4) In each of the above-described examples, the heat exchange element 1 is formed by the elements 2b, 51b, and 52b cut into a hexagonal shape. However, as shown in FIGS. 16 to 18, it is also possible to form the heat exchange element 1 with the element 2a cut into a rectangular shape and arrange the heat exchange element 1 inside the rectangular frame 8 of the total heat exchanger. Here, the element 2a described in Example 1 is illustrated, but it is also possible to form the heat exchange element 1 with the elements 51a, 52a, and 61a described in Example 2 and Example 3.

[0052] Also, in each of the above-described examples, the intermediate channel portion 26 between the air supply diversion channel portion 24 and the exhaust diversion channel portion 25 has been described as a linear channel, but the intermediate channel portion 26 can also be formed as a curved channel.

[0053] Furthermore, in each of the above embodiments, the core materials 22, 22a to 22e are corrugated processed materials, but it is also possible to use press-formed materials.

Explanation of Signs

[0054] 1 Heat exchange element 2, 51, 52, 61 Single-sided corrugated paper 2a, 51a, 52a, 61a Rectangular sheet-like elements 2b, 51b, 52b Hexagonal elements 3 Primary side flow path 4 Secondary side flow path 8 Frame 21 Liner material 22, 22a, 22b, 22c, 22d, 22e Core materials 23 Flow path 24 Air supply diversion flow path section 24a Air supply port 25 Exhaust diversion flow path section 25a Exhaust port 26 Intermediate flow path section 61, 71, 72 Step rolls 71a, 72a Intermediate part rolls 71b, 71c, 72b, 72c Side rolls 71d, 72d Shafts 73 Key 74 Roll 81 Teeth 82 Grooves 81a, 81b, 81c Rack teeth

Claims

1. Single-sided corrugated paper is stacked in multiple layers to alternately form a primary-side flow path and a secondary-side flow path. The single-sided corrugated paper includes a liner material and a corrugated core material that forms steps on the liner material. The flow path formed by the corrugation of the core material has turning flow path portions on the air supply side and the exhaust side, and has an intermediate flow path portion between the turning flow path portions on both sides. The adjacent turning flow path portions via the liner material turn in different directions from each other. The entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is formed on a single liner material by corrugating a single core material. The intermediate flow path portion is parallel to the opposite sides of the core material, the turning flow path portions on the air supply side and the exhaust side turn in different directions at the same angle with respect to the axis of the intermediate flow path portion, and both the turning flow path portion on the air supply side and the turning flow path portion on the exhaust side extend toward the same side of the core material that is parallel to the intermediate flow path. A heat exchange element characterized by this.

2. A corrugated core material that forms steps is arranged on the liner material to form single-sided corrugated paper. Turning flow path portions are provided on the air supply side and the exhaust side of the flow path formed by the corrugation of the core material, and an intermediate flow path portion is provided between the turning flow path portions on both sides. The entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is formed on a single liner material. The single-sided corrugated paper is cut to form single-sheet elements. The single-sheet elements are stacked in multiple layers, and are arranged such that the adjacent turning flow path portions via the liner material turn in different directions from each other, thereby alternately forming a primary-side flow path and a secondary-side flow path. On a single core material, the entire flow path from the air supply port of the turning flow path portion on the air supply side to the exhaust port of the turning flow path portion on the exhaust side is formed by corrugating with a pair of step rolls. Both step rolls have teeth that form the core material into a corrugation on the outer periphery of each roll. The teeth have a tooth bar corresponding to the intermediate flow path portion parallel to the axis of the step roll, and the tooth bars at both side portions of the step roll corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the step roll. A manufacturing method of a heat exchange element, characterized in that when looking at the pair of step rolls from the discharge side of the core material, the tooth bars at both side portions of the step rolls facing each other via the core material extend in a direction approaching the core material toward the outside in the axial direction of the step roll. **Claim 3**: The stepped roll consists of a single roll that is continuous over the entire length in the axial direction. The rack corresponding to the intermediate flow path portion of the single roll is parallel to the axis of the stepped roll. The racks on both sides of the single roll corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the stepped roll. The twist directions of the racks on both sides facing each other through the core material are opposite, and the twist directions of the racks on both sides of each stepped roll are opposite. A method for manufacturing a heat exchange element according to claim 2, characterized in that. **Claim 4**: The stepped roll consists of a plurality of rolls that are connected axially and rotate integrally. The rack of the intermediate roll corresponding to the intermediate flow path portion is parallel to the axis of the stepped roll. The racks of the side rolls corresponding to the turning flow path portions on the air supply side and the exhaust side have the same twist angle with respect to the axis of the stepped roll. The twist directions of the racks in the side rolls facing each other through the core material are opposite, and the twist directions of the racks in the side rolls on both sides of the intermediate roll are opposite. A method for manufacturing a heat exchange element according to claim 2, characterized in that.

Images