Heat exchanger

Abstract

To provide a heat exchanger capable of simply and reliably preventing corrosion of a metal heat transfer layer.SOLUTION: The present invention relates to a heat exchanger comprising an outer covering body 1 in which a heat exchange medium is circulated, and an inner fin 2 housed in the outer covering body 1 with a part thereof in contact with an inner surface of the outer covering body 1. In the heat exchanger, the outer covering body 1 is composed of an outer covering laminate material L1 in which a resin layer is laminated on at least one side of a metal layer, and an inner core laminate material L2 in which a resin thermal-fusion layer 52 is laminated on both surface sides of the inner fin 2 and a metal heat transfer layer 51. On a side edge 7a of the inner core laminate material L2, a thin edge part 7 is formed, and the thin edge part 7 includes a side edge 6a of the heat transfer layer 51, a resin heat transfer layer side edge lamination part 72 laminated on both surface sides of the side edge 6a, and a resin heat transfer layer end surface covering part 73 covering an end surface 6b of the heat transfer layer 51.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a heat exchanger manufactured using a laminate material in which a resin layer is laminated on a metal layer, and related technologies thereof.

Background Art

[0002] Measures against heat generation around the CPU in electronic devices such as smartphones and personal computers, and measures against heat generation of battery modules mounted on electric vehicles and hybrid vehicles are important. As heat exchangers for these heat generation countermeasures, metal heat exchangers (coolers) manufactured using metals with high heat conductivity such as aluminum are well known (Patent Documents 1 to 3, etc.).

[0003] However, since a metal heat exchanger is manufactured based on metal processing, it is difficult to make it thinner than the current situation. In particular, it is difficult to incorporate it into a thin casing of an electronic device such as a smartphone or a personal computer, or into a narrow space between battery modules for automobiles.

[0004] Therefore, as shown in Patent Document 4, the development of a heat exchanger using a laminate material in which resin layers are laminated on both sides of a metal layer has been promoted.

[0005] This heat exchanger is configured such that an inner core material (inner fin) formed of a laminate material is accommodated inside an outer package formed of the laminate material, and heat exchange is performed between a refrigerant circulating inside the outer package and a cooling target member in contact with the outer surface of the outer package through the inner fin, thereby cooling the cooling target member.

[0006] Such a heat exchanger, for example, the outer package and the inner fin are formed of a laminate material cut to a predetermined size. Therefore, compared with the above-mentioned metal cooler, the degree of freedom in design and versatility are increased, and it is possible to achieve miniaturization, weight reduction, improvement in production efficiency, and cost reduction.

Prior Art Documents

Patent Documents

[0007] Patent Document 1 Japanese Unexamined Patent Application Publication No. 2015-59693 Patent Document 2 Japanese Unexamined Patent Application Publication No. 2015-141002 Patent Document 3 Japanese Unexamined Patent Application Publication No. 2016-189415 Patent Document 4 Japanese Unexamined Patent Application Publication No. 2020-3132 Patent Document 5 Japanese Unexamined Patent Application Publication No. 2020-159667 Patent Document 6 Japanese Unexamined Patent Application Publication No. 2020-161449 Summary of the Invention Problems to be Solved by the Invention

[0008] By the way, in a heat exchanger using the above laminate material, for example, in the laminate material for inner fins, since the heat transfer layer as a metal layer is exposed at the cut end face, the exposed heat transfer layer comes into contact with the refrigerant flowing through the outer package, resulting in corrosion, a decrease in heat transfer performance, and ultimately a possible decrease in heat exchange efficiency.

[0009] On the other hand, Patent Documents 5 and 6 propose a technique in which the cut end face of the laminate material for inner fins is coated with resin to cover the cut end face of the heat transfer layer and prevent the exposure of the heat transfer layer.

[0010] However, there is a problem that the anticorrosion treatment of accurately and appropriately coating the resin on the cut end face of the laminate material requires advanced technology and is a delicate and careful operation, which may lead to a decrease in production efficiency.

[0011] The present invention has been made in view of the above problems, and provides a heat exchanger using a laminate material, which can easily and surely prevent corrosion of a heat transfer layer and maintain excellent heat transfer performance, and related technologies thereof.

Means for Solving the Problems

[0012] To solve the above problems, the present invention comprises the following means.

[0013] [1] A heat exchanger comprising an outer casing through which a heat exchange medium flows inside, and inner fins housed in the outer casing in a state where a part thereof is in contact with the inner surface of the outer casing, wherein the outer casing is composed of an outer laminate material having a resin layer laminated on at least one side of a metal layer, the inner fins are composed of an inner core laminate material having resin-made heat fusion layers laminated on both sides of a metal-made heat transfer layer, a thin edge portion is formed at the side edge of the inner core laminate material, and the thin edge portion includes a side edge of the heat transfer layer, resin-made heat transfer layer side edge laminated portions laminated on both sides of the side edge, and a resin-made heat transfer layer end face covering portion covering the end face of the heat transfer layer. The heat exchanger is characterized by this.

[0014] [2] The heat exchanger according to item 1 above, wherein the heat fusion layer, the heat transfer layer side edge laminated portion, and the heat transfer layer end face covering portion are continuously formed integrally.

[0015] [3] The heat exchanger according to item 1 or 2 above, wherein the heat transfer layer side edge laminated portion and the heat transfer layer end face covering portion are composed of a molten resin molded body of the heat fusion layer.

[0016] [4] Let the thickness of the heat fusion layer be "T1" and the thickness of the heat transfer layer side edge laminated portion be "T2", T1 = 0.02 mm to 0.5 mm T2 = 1 / 6 × T1 to 2 / 3 × T1 The heat exchanger according to any one of items 1 to 3 above is configured such that the relational expression holds.

[0017] [5] Taking the width of the heat transfer layer side edge laminated portion as “W1”, W1 = 2 mm to 15 mm The heat exchanger according to any one of the preceding items 1 to 4, which is configured such that the relational expression holds.

[0018] [6] Taking the width of the heat transfer layer end face covering portion as “W2”, W2 = 0.01 mm to 2 mm The heat exchanger according to any one of the preceding items 1 to 5, which is configured such that the relational expression holds.

[0019] [7] An inner fin for a heat exchanger, which is configured such that a heat exchange medium flows inside, and a part of it is accommodated in a housing formed by an outer wrapping laminate material in which a resin layer is laminated on at least one side of a metal layer in a state of being in contact with the inner surface of the outer wrapping body, It is composed of an inner core laminate material in which heat - fusion layers made of resin are laminated on both sides of a heat transfer layer made of metal, A thin edge portion is formed on the side edge of the inner core laminate material, The thin edge portion includes the side edge of the heat transfer layer, resin - made heat transfer layer side edge laminated portions laminated on both sides of the side edge, and a resin - made heat transfer layer end face covering portion covering the end face of the heat transfer layer. The inner fin for a heat exchanger is characterized by this.

[0020] [8] A manufacturing method of an inner fin for a heat exchanger, which is configured such that a heat exchange medium flows inside, and a part of it is accommodated in a housing formed by an outer wrapping laminate material in which a resin layer is laminated on at least one side of a metal layer in a state of being in contact with the inner surface of the outer wrapping body, An inner core laminate material in which heat - fusion layers made of resin are laminated on both sides of a heat transfer layer made of metal is produced, Heat press forming is performed on the side edge of the inner core laminate material to cover the side edge and the end face of the heat transfer layer, and a thin edge portion made of a molten resin molded body of the heat - fusion layer is molded, A method for manufacturing an inner fin for a heat exchanger, characterized in that an inner fin is manufactured using an inner core laminate material after forming a thin edge portion.

Advantages of the Invention

[0021] According to the heat exchanger of Invention [1], since the side edge of the metal heat transfer layer is covered by the thin edge portion at the edge of the inner fin, the end face of the heat transfer layer is not exposed, preventing the heat exchange medium from contacting the heat transfer layer, and surely preventing the occurrence of corrosion caused by such contact, and maintaining good heat transfer performance. Further, the thin edge portion provided at the side edge of the inner core laminate material can be formed by thinning the side edge, so that the thin edge portion can be easily formed simply by hot pressing the side edge of the inner core laminate material. Therefore, in the heat exchanger of the present invention, in order to cover the end face of the heat transfer layer, delicate and careful operations such as resin coating are unnecessary, the thin edge portion can be easily formed, and the production efficiency can be improved.

[0022] According to the heat exchangers of Inventions [2] to [6], the above effects can be obtained more surely.

[0023] According to the inner fin for a heat exchanger of Invention [7], since it specifies the main part of the above Invention [1], the same effects as above can be obtained.

[0024] According to the manufacturing method of Invention [8], since it specifies the manufacturing process of the above Invention [7], an inner fin having the same effects as above can be manufactured.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

[0026] FIGS. 1 to 3 are views showing a heat exchanger according to an embodiment of the present invention. As shown in these figures, the heat exchanger of the present embodiment is used as a heat transfer panel, a heat transfer tube, etc., and includes an outer casing 1 as a casing (container), an inner fin (inner core material) 2 housed inside the outer casing 1, and a pair (both sides) of headers (joint members) 3, 3 housed at both ends inside the outer casing 1.

[0027] The outer casing 1 is composed of a tray member 10 having a rectangular shape in plan view and a cover member 15 having a rectangular shape in plan view.

[0028] The tray member 10 is formed of a molded product of an outer wrap laminate material L1. Using a cold forming method such as deep drawing or protrusion forming, the entire intermediate region except the outer peripheral edge portion is recessed downward to form a concave portion 11 having a rectangular shape in plan view, and a flange portion 12 protruding outward is integrally formed on the outer periphery of the opening edge portion of the concave portion 11.

[0029] In addition, a pair of entrances and exits 16, 16 are formed in the cover member 15 corresponding to both front and rear end portions of the recess 11 in the tray member 10. Needless to say, in the present embodiment, of the pair of entrances and exits 16, one entrance and exit 16 is configured as an entrance, and the other entrance and exit 16 is configured as an exit.

[0030] The tray member 10 and the cover member 15 are composed of an outer packaging laminate material L1 which is a laminate sheet or film having flexibility and flexibility.

[0031] As shown in FIG. 5, the outer packaging laminate material L1 includes a heat transfer layer 51 made of metal (metal foil), a heat-sealing layer 52 which is a heat-sealing resin laminated on one surface (inner surface) of the heat transfer layer 51, and a heat-resistant resin laminated on the other surface (outer surface) of the heat transfer layer 51. A protective layer 53. In the present embodiment, the term "foil" is used to include films, thin plates, and sheets.

[0032] As the heat transfer layer 51 in the outer packaging laminate material L1, aluminum foil, copper foil, stainless steel (SUS) foil, nickel foil, copper foil processed by nickel plating, clad metal made of nickel and copper, etc. can be preferably used. In the present embodiment, the terms "aluminum", "copper", "nickel", and "titanium" are used to include their alloys.

[0033] The heat transfer layer 51, which is also referred to as a metal foil layer or a heat collection layer, preferably has a thickness of 30 μm to 200 μm, and more preferably 40 μm to 150 μm.

[0034] As the heat-sealing layer 52, those composed of olefin resins or modified resins thereof, resins containing olefin polymers having carboxylic acids can be preferably used.

[0035] Examples of the olefin resin or its modified resin include unstretched polypropylene film (CPP), polyethylene film (LDPE, LLDPE, HDPE), acid-modified polyolefin resin, etc.

[0036] Examples of the resin containing an olefin polymer having a carboxylic acid include ionomer resin, ethylene-methacrylic acid copolymer (EMAA), ethylene-ethyl acrylate copolymer (EEA), ethylene-methyl acrylate copolymer (EMA), etc.

[0037] The heat-sealing layer 52 can be formed by attaching a film or sheet of these resins to the heat-transfer layer 51 or by applying and coating these resins.

[0038] The heat-sealing layer 52, also referred to as a sealant layer, preferably has a thickness of 20 μm to 500 μm, more preferably 30 μm to 80 μm.

[0039] Examples of the protective layer 53 include those composed of a heat-resistant resin such as polyester resin and polyamide resin. The protective layer 53 can be formed by attaching a film or sheet of these resins to the heat-transfer layer 51 or by applying and coating these resins.

[0040] The protective layer 53, also referred to as a coating layer, preferably has a thickness of 6 μm to 100 μm, more preferably 9 μm to 50 μm.

[0041] When laminating the above resin films for the heat-sealing layer 52 and the protective layer 53 to the aluminum foil heat-transfer layer 51 with a two-component curable adhesive, it is preferable to perform degreasing on the aluminum foil by annealing or washing in advance and then perform surface treatment such as chemical conversion treatment, as better adhesiveness can be obtained.

[0042] The outer packaging laminate material L1 with the above configuration is cut into a predetermined size and, if necessary, thermoformed as described above to form the tray member 10 and the cover member 15 as the outer package 1.

[0043] On the other hand, the inner fin 2 is composed of a molded product of the inner core laminate material L2. As shown in FIG. 6, the inner core laminate material L2 includes a heat transfer layer 61 made of metal (metal foil) and a heat-sealing layer 62, which is a heat-sealing resin laminated on both sides (inner surface and outer surface) of the heat transfer layer 61.

[0044] As the heat transfer layer 61 in the inner core laminate material L2, aluminum foil, copper foil, etc. can be preferably used.

[0045] The heat transfer layer 61 is also referred to as a metal foil layer or a heat collection layer, and it is preferably a layer with a thickness of 30 μm to 200 μm, more preferably 40 μm to 150 μm.

[0046] As the heat-sealing layer 52, a resin composed of an olefin resin or its modified resin, or a resin containing an olefin polymer having a carboxylic acid can be preferably used.

[0047] Examples of the olefin resin or its modified resin include unstretched polypropylene film (CPP), polyethylene film (LDPE, LLDPE, HDPE), and acid-modified polyolefin resin.

[0048] Examples of the resin containing an olefin polymer having a carboxylic acid include ionomer resin, ethylene-methacrylic acid copolymer (EMAA), ethylene-ethyl acrylate copolymer (EEA), ethylene-methyl acrylate copolymer (EMA), etc.

[0049] The heat-sealing layer 62 can be formed by attaching a film or sheet of these resins to the heat transfer layer 61 or by coating these resins.

[0050] The heat-sealing layer 62, also referred to as a sealant layer, preferably has a thickness of 20 μm to 500 μm, more preferably 30 μm to 80 μm.

[0051] In addition, it is preferable to perform surface treatment such as chemical conversion treatment on the heat transfer layer 61 for the inner core laminate material L2 as well, if necessary, in the same manner as described above.

[0052] In this embodiment, after cutting the inner core laminate material L2 into a predetermined size, an end corrosion prevention treatment is performed on the cut end of the cut inner core laminate material L2.

[0053] That is, as shown in FIG. 6, when the inner core laminate material L2 is cut, the end face 6b of the metal heat transfer layer 61 is exposed at the cut end. By sandwiching and pressing the side edges (usually the four surrounding side edges) 6a around the cut end of this inner core laminate material L2 while heating with a pair of upper and lower seal molds 4, 4 (by heat press molding), while melting a part of the heat-sealing layer 62 at the side edge 6a of the inner core laminate material L2 before heat press molding and leaving a part behind, the rest is allowed to flow outward and is cooled and solidified in that state.

[0054] As a result, as shown in FIG. 7, a thin edge portion 7 having a thickness thinner than the unpressurized portion is formed on the side edge 6a of the inner core laminate material L2. This thin edge portion 7 is a molded body of the resin remaining in the heat-sealing layer 62 and the side edge 6a of the heat transfer layer 61, and includes a heat transfer layer side edge laminated portion 72 laminated on both sides of the side edge 6a of the heat transfer layer 61, and a heat transfer layer end face covering portion 73 that is a molded body of the resin that has flowed in the heat-sealing layer 62 and covers the end face 6b of the heat transfer layer 61. In other words, the heat transfer layer side edge laminated portion 72 and the heat transfer layer end face covering portion 73 are formed by a molded body of the molten resin of the heat-sealing layer 62 formed by melting a part of the resin of the heat-sealing layer 62. Therefore, the heat transfer layer side edge laminated portion 72 is continuously and integrally formed with the heat-sealing layer 62, and the heat transfer layer end face covering portion 73 is continuously and integrally formed with the heat transfer layer side edge laminated portion 72.

[0055] In this way, an end corrosion prevention treatment is performed on the inner core laminate material L2 by heat press molding, and the cut end face 6b of the heat transfer layer 61 is surely covered by the thin edge portion 7.

[0056] Needless to say, the cavities 41 in the pair of seal molds 4, 4 are formed in a shape corresponding to the thin edge portion 7.

[0057] Here, in this embodiment, the thickness of the heat fusion layer 62 is set as "T1", the thickness of the heat transfer layer side edge laminated portion 72 is set as "T2", the width of the heat transfer layer side edge laminated portion 72 is set as "W1", and the width of the heat transfer layer end face covering portion 73 is set as "W2". It is preferable to satisfy the following relational expressions.

[0058] That is, it is preferable to satisfy T2 = 1 / 6 × T1 to 2 / 3 × T1, and more preferably to satisfy T2 = 1 / 3 × T1 to 1 / 2 × T1. As described above, T1 can be set to 20 μm to 500 μm (0.02 mm to 0.5 mm), and more preferably to 30 μm to 80 μm (0.03 mm to 0.08 mm).

[0059] Furthermore, it is preferable to satisfy W1 = 2 mm to 15 mm, and more preferably to satisfy W1 = 3 mm to 8 mm. Also, it is preferable to satisfy W2 = 0.01 mm to 2 mm, and more preferably to satisfy W2 = 0.05 mm to 1.0 mm. When these relational expressions are satisfied in this embodiment, the cut end face 6b of the heat transfer layer 61 can be surely covered by the thin edge portion 7. As a result, as will be described later, it is possible to surely prevent a heat exchange medium such as a refrigerant from coming into contact with the heat transfer layer 61, and it is possible to surely prevent the corrosion and deterioration of the heat transfer layer 61. In other words, when the thickness "T2" and width "T1" of the heat transfer layer side edge laminated portion 72 and the width "T2" of the heat transfer layer end face covering portion are too small, the corrosion of the heat transfer layer 61 cannot be surely prevented. On the contrary, even if they are made larger than necessary, the corresponding effects cannot be sufficiently obtained, which is not preferable.

[0060] The inner core laminate material L2 that has undergone heat press forming (end corrosion prevention treatment) in this way is subjected to uneven processing to produce the inner fin 2. The processing method of the inner fin 2 is not particularly limited. For example, a method of forming unevenness can be exemplified by sandwiching the inner core laminate material L2 between a pair of embossing rolls or a pair of corrugated rolls and passing it between the pair of rolls. Furthermore, a method of forming uneven portions on the inner core laminate material L2 using a press machine or a press die can be exemplified.

[0061] As shown in FIGS. 2 to 4, the inner fin 2 is formed in a square wave shape (rectangular wave shape) in which the concave portions 25 and the convex portions 26 are alternately and continuously formed, that is, a so-called digital signal waveform. That is, the bottom surface (bottom wall) of the concave portion and the top surface (top wall) of the convex portion of the inner fin 2 in the present embodiment are formed flat and are arranged parallel to the bottom wall (lower wall) of the tray member 10 and the top wall (upper wall) of the cover member 15 in the state where the heat exchanger is assembled. Further, the inner fin 2 has rising walls connecting between adjacent bottom walls of the concave portions and top walls of the convex portions, which are arranged perpendicular to the bottom walls of the concave portions and the top walls of the convex portions, or perpendicular to the upper and lower walls of the outer package 1 in the state where the heat exchanger is assembled.

[0062] In the present embodiment, a square wave-shaped inner fin 2 is used, but it is not limited thereto. In the present invention, a general wave shape (sine wave shape) in which concave and convex portions having a circular arc-shaped cross section are alternately and continuously formed, that is, a so-called analog signal waveform, may be used. However, in the present invention, any shape of inner fin can be used as long as it is provided with concave and convex portions joined to the inner surface of the outer package.

[0063] This inner fin 2 is housed in the middle part of the recess 11 of the tray member 10, excluding both end parts. The housed inner fin 2 is arranged such that its ridge direction and valley direction (left - right direction facing the paper surface of Fig. 3) coincide with the length direction of the tray member 10 (left - right direction of Fig. 3). Thereby, the tunnel part and groove part formed along the ridge part and valley part of the inner fin 2 are arranged along the length direction of the tray member 10, and a heat exchange medium such as a refrigerant can smoothly flow from one end side to the other end side in the length direction of the outer package 1 through the tunnel part and groove part.

[0064] As shown in Figs. 2 and 3, a pair of headers 3, 3 arranged at both end parts of the outer package 1 are constituted by molded products of a heat - fusible resin.

[0065] The header 3 includes a box - shaped mounting box part 31 having an opening 32 on one side surface, and a pipe part 33 provided on the upper wall of the mounting box part 31. The pipe part 33 communicates with the inside of the mounting box part 31, and is configured such that a heat exchange medium can flow back and forth between the inside of the pipe part 33 and the inside of the mounting box part 31.

[0066] The molding method of the header 3 is not particularly limited, but for example, a method of molding using injection molding can be preferably adopted.

[0067] The mounting box part 31 of this header 3 is arranged on both sides of the inner fin 2 in the recess 11 of the tray member 10. Further, the pipe part 33 of the header 3 is arranged upward, and the opening 32 of the mounting box part 31 is arranged inward, that is, facing the inner fin 2.

[0068] In this way, the headers 3, 3 are housed in the tray member 10, and the cover member 15 is arranged on the tray member 10 so as to close its opening. In this case, the upward pipe parts 33, 33 of the headers 3, 3 are inserted and arranged in the entrances and exits 16 of the cover member 15.

[0069] By hot press forming the temporarily assembled heat exchanger assembly in this way, the required parts of the contacting members are heat-fused and joined integrally. This heat-fusing process includes an outer package fusing process (outer package sealing process) of heat-fusing (heat-sealing) between the flange portion 12 of the tray member 10 and the outer peripheral edge portion of the cover member 15, and an interior part fusing process of heat-fusing (heat-sealing) between the outer package 1 (tray member 10 and cover member 15) and the interior parts (inner fins 2 and header 3).

[0070] Also, in this embodiment, the case of performing the outer package fusing process and the interior part fusing process simultaneously is referred to as one-stage sealing (one-stage sealing method), and the case of performing them separately with a time shift is referred to as two-stage sealing (two-stage sealing method).

[0071] In this embodiment, as the conditions (sealing conditions) of the heat-fusing process, it is preferable to set the heat-fusing temperature to 160°C to 200°C, and more preferably to 170°C to 190°C. Further, it is preferable to set the heat-fusing pressure to 0.1 MPa to 0.5 MPa, and more preferably to 0.15 MPa to 0.4 MPa. Further, it is preferable to set the heat-fusing time to 2 seconds to 10 seconds, and more preferably to 3 seconds to 8 seconds.

[0072] The heat exchanger configured as described above is used as a cooler (cooling device) for cooling a battery or the like as a member to be cooled (heat exchange target member). That is, an inflow pipe for flowing a coolant (cooling water, antifreeze, etc.) as a heat exchange medium (refrigerant) is connected to one pipe portion 33 of the heat exchanger, and an outflow pipe for flowing out the coolant is connected to the other pipe portion 33. Further, the battery as a member to be cooled is disposed in contact with the upper wall and the lower wall of the outer casing 1 of the heat exchanger. And in that state, the coolant flows into the inside of the outer casing 1 from one pipe portion 33 through one header 3, the coolant is circulated through the portion of the inner fin 2, and flows out from the other pipe portion 33 through the other header 3. By circulating the coolant through the outer casing 1 in this way, heat exchange is performed between the coolant and the battery through the inner fin 2 and the outer casing 1, thereby cooling the battery.

[0073] According to the heat exchanger of the present embodiment configured as described above, since the cut end face 6b of the heat transfer layer 61 made of metal is covered by the thin edge portion 7 at the edge of the inner fin 2, the heat transfer layer 61 is not exposed, and it is possible to prevent the refrigerant from contacting the heat transfer layer 61. In particular, it is possible to surely prevent corrosion from occurring due to water, chloride ions, copper ions, etc., which are corrosion factors in the refrigerant, acting on the heat transfer layer 61, maintain good heat transfer performance, and improve the heat exchange efficiency.

[0074] Also, in the heat exchanger of the present embodiment, by thickening the side edge 6a of the inner core laminate material L2 and flowing the heat fusion layer 62 of the side edge 7a to the end face 6b side of the heat transfer layer 61 to form the heat transfer layer end face covering portion 73, since the end face 6b of the heat transfer layer 61 is covered, the thin edge portion 7 (heat transfer layer end face covering portion 73) can be easily formed only by heat press forming on the side edge 7a of the inner core laminate material L2. Therefore, in the heat exchanger of the present embodiment, delicate and careful work such as coating with resin is not required to cover the end face of the heat transfer layer, the heat transfer layer end face covering portion 73 can be easily formed, and the production efficiency can be improved.

[0075] Moreover, according to the heat exchanger of the present embodiment, since the outer package 1 and the inner fins 2 are manufactured using the laminate materials L1 and L2, there is no need to use complicated metal processing, and it can be efficiently and easily manufactured to reduce costs. In addition, since the outer package 1 and the inner fins 2, which are the laminate materials L1 and L2, are joined and manufactured, sufficient thinning can be achieved.

[0076] In the above embodiment, the case where the heat exchanger is used as a cooler (cooling device) by circulating a heat medium (refrigerant) for cooling inside thereof has been described as an example. However, the present invention is not limited thereto. In the present invention, it is also possible to use the heat exchanger as a heater (heating device) or a heat generator (heat generating device) by circulating a heat medium (heat medium) for heating inside thereof.

[0077] In the above embodiment, when manufacturing the outer package 1, the three-dimensionally formed tray member 10 and the sheet-like cover member 15 are bonded together. However, in the present invention, three-dimensionally formed members (laminate materials) may be bonded together. Furthermore, it is not necessarily required to three-dimensionally form the constituent members of the outer package 1. For example, when not performing three-dimensional forming, a bag-shaped outer package made of a laminate material may be manufactured by bonding the outer peripheral edge portions of two sheet-like laminate materials to each other by heat fusion or the like.

[0078] Furthermore, in the above embodiment, the case where the outer package 1 is manufactured using two laminate materials has been described as an example. However, the present invention is not limited thereto. In the present invention, a single laminate material may be folded in half and the outer peripheral edge portions of the overlapping laminate materials, excluding the folded-back portion, may be bonded by heat fusion or the like to manufacture a bag-shaped outer package. Needless to say, in the present invention, an outer package may be manufactured using three or more laminate materials.

[0079] In the above-described embodiment, a laminate material L1, L2 having a three-layer structure is used, but the present invention is not limited thereto. In the present invention, as the outer laminate material L1, a laminate material having a two-layer structure or a structure of four or more layers may be used, and as the inner core laminate material L2, a laminate material having a structure of four or more layers may be used.

[0080] In the above-described embodiment, the case where the heat exchanger of the present invention is used as a cooler for a battery pack for an automobile or the like has been described as an example. However, in the present invention, it can also be applied to heat exchangers other than the cooler for the battery pack. For example, a heat exchanger for heating an automotive battery pack, a heat exchanger for cooling a power semiconductor element (power module) for controlling the main power of a power drive device such as an automotive electric motor, an industrial machine, a home appliance, or an information terminal, a heat exchanger for cooling a CPU (central processing unit) of a personal computer, a heat exchanger for cooling / heating a household or industrial battery, a heat exchanger for cooling a battery pack (battery module) of a personal computer, a heat exchanger for cooling a display of a liquid crystal television, an organic EL television, or a plasma television, and a heat exchanger for a floor heating facility, a roof, a passage, a road, etc. in a cold region for snow melting can also be used.

Example

[0081] <Example 1> Based on the heat exchanger of the above-described embodiment, the heat exchanger of Example 1 was manufactured as follows.

[0082] 1. Fabrication of outer laminate material and outer body On one surface (outer surface) of an aluminum foil (thickness: 120 μm) of A8021H-O as the heat transfer layer 51, a polyester resin (PET) with a thickness of 12 μm is laminated as the protective layer 53 via an adhesive.

[0083] On the other side (inner surface) of the aluminum foil, a non-stretched polypropylene film (CPP) with a thickness of 40 μm was laminated as a heat-sealing layer 52 via an adhesive to produce an outer packaging laminate material (PET 12 μm / adhesive / AL (A8021H-O) 120 μm / adhesive / CPP 40 μm) L1.

[0084] By performing deep drawing forming on this outer packaging laminate material L1, a tray member 10 of an outer package 1 was produced, in which a recess 11 with a depth of 4 mm × width of 65 mm × length of 180 and a flange portion 12 with a width of 10 mm were integrally formed around the entire circumference of the opening edge of the recess 11.

[0085] Furthermore, a similar outer packaging laminate material L1 was cut to produce a sheet-shaped cover member 15 with a width of 85 mm × length of 200 mm. Circular entrances and exits 16 with a diameter of 12 mm were formed at predetermined positions at both ends of this cover member 15.

[0086] 2. Production of the inner core laminate material and the inner fin CPP with a thickness of 30 μm was laminated as a heat-sealing layer 62 via an adhesive on both sides of an aluminum foil (thickness 120 μm) of A8021H-O as a heat transfer layer 61 to produce an inner core laminate material (CPP 30 μm / adhesive / AL (A8021H-O) 120 μm / adhesive / CPP 30 μm) L2.

[0087] This inner core laminate material L2 was cut into a size of width 193 mm × length 120 mm to be a blank for the fin. For the four sides around the blank, as shown in FIGS. 6 and 7, by using a heat press forming with a heat seal die 4, a thin edge portion 7 with a width W1 = 2 mm of the side edge laminated portion 72 of the heat transfer layer, a width W2 = 0.2 mm of the heat transfer layer end face covering portion 73, and a thickness (Al thickness + T2 × 2) = 0.16 mm was formed, and the side edge 6a of the heat transfer layer 61 was covered with CPP (the side edge laminated portion 72 of the heat transfer layer and the heat transfer layer end face covering portion 73), and an inner core laminate material L2 (corrosion-proof treated fin material) after heat press forming (after corrosion prevention treatment) was produced.

[0088] For the inner core laminate material L2 (corrosion-treated fin material) after this heat press forming, corrugation processing was performed to form it into a square wave shape with a fin height (Hf) of 4 mm, a fin pitch (Pf) of 4 mm, a fin thickness (Tf) of 0.2 mm, and an outer corner radius (R4) of 0.5 mm as shown in Fig. 4. The square wave sheet was cut into a width of 65 mm × a length of 120 mm to produce the inner fin 2.

[0089] Note that the ridge direction and valley direction of the inner fin 2 are arranged along the length direction (vertical direction).

[0090] 3. Production of the header A PP-made header 3 in which a pipe portion 33 was integrally formed was prepared for a mounting box portion 31 with a length of 65 mm × a width of 30 mm × a height of 4 mm (see Fig. 3). The pipe portion 33 has an inner diameter of φ10 mm, an outer diameter of φ12 mm, and a length of 3 mm.

[0091] 4. Assembly of the heat exchanger The header 3 was accommodated in the longitudinal direction (length direction) at both ends in the recess 11 of the tray member 10 with the pipe portion 33 facing upward. Further, the inner fin 2 was accommodated between the two headers 3, 3 in the recess 11 of the tray member 10. Note that each opening 32 of the header 3 was arranged inward so as to face the end of the inner fin 2.

[0092] Next, the cover member 15 was placed on the flange portion 12 of the tray member 10 with its inner heat fusion layer 52 facing down so as to cover the recess 11 of the tray member 10 from above. At this time, the upward pipe portion 33 of the header 3 in the tray member 10 was inserted through the inlet / outlet 16 of the cover member 15 and arranged to protrude above the cover member 15.

[0093] In this way, a heat exchanger sub-assembly in a non-joined state was fabricated, and heat fusion was performed on the heat exchanger sub-assembly with a two-stage seal. The first-stage seal was performed under the seal conditions of 180°C × 0.3 MPa × 7 seconds to heat-fuse the flange portion 12 of the tray member 10 and the outer peripheral edge portion of the cover member 15. Further, the second-stage seal was performed under the seal conditions of 190°C × 0.3 MPa × 7 seconds to heat-fuse between the outer package 1, the inner fin 2, and the header 3. In this way, the heat exchanger of Example 1 was fabricated.

[0094] <Example 2> An outer package laminate material L1 similar to that in Example 1 above was prepared, except that an ionomer (thickness 50 μm) was used as the heat fusion layer 52 of the outer package laminate material L1 (PET 12 μm / adhesive / AL (A8021H-O) 120 μm / adhesive / ionomer 50 μm).

[0095] Using this outer package laminate material L1, the tray member 10 and the cover member 15 were fabricated in the same manner as in Example 1 above.

[0096] An inner core laminate material L2 similar to that in Example 1 above was prepared, except that an ionomer (thickness 50 μm) was used as the heat fusion layer 62 of the inner core laminate material L2 (ionomer 50 μm / adhesive / AL (A8021H-O) 120 μm / adhesive / ionomer 50 μm).

[0097] This inner core laminate material L2 was cut out into a size of width 193 mm × length 120 mm to form a fin blank, and heat press forming was performed on the four sides around the blank in the same manner as in Example 1 above to form a thin edge portion 7 with a width W1 = 3 mm of the side edge laminated portion 72 of the heat transfer layer, a width W2 = 0.5 mm of the heat transfer layer end face covering portion 73, and a thickness (Al thickness + T2 × 2) = 0.18 mm. The side edge 6a of the heat transfer layer 61 was covered with an ionomer resin (the side edge laminated portion 72 of the heat transfer layer and the heat transfer layer end face covering portion 73), and the inner core laminate material L2 (corrosion-proof treated fin material) after heat press forming was fabricated.

[0098] Using the inner core laminate L2 after heat press forming, an inner fin 2 having the same shape as in Example 1 above was produced.

[0099] A header 3 was produced in the same manner as in Example 1 above, except that it was made of PE.

[0100] Using these tray members 10, cover members 15, and headers 3, a heat exchanger sub-assembly was produced in the same manner as in Example 1 above, and heat fusion bonding was performed on the sub-assembly with a two-stage seal to produce the heat exchanger of Example 2.

[0101] In the two-stage seal of Example 2, the first-stage seal was performed under the seal conditions of 140 °C × 0.3 MPa a × 7 seconds to heat-fuse the tray member 10 and the cover member 15. Further, the second-stage seal was performed under the seal conditions of 150 °C × 0.3 MPa × 7 seconds to heat-fuse between the outer package 1, the inner fin 2, and the header 3.

[0102] <Comparative Example> A heat exchanger of the comparative example was produced in the same manner as in Example 1 above, except that the inner core laminate (fin blank) was not subjected to anticorrosion treatment by heat press forming. Needless to say, in the inner fin 2 of this heat exchanger, the metal heat transfer layer 61 is exposed at the cut end face, and the refrigerant circulating through the heat exchanger can come into contact with the exposed heat transfer layer 61.

[0103] <Corrosion Resistance Test (Accelerated Corrosion Test)> As the corrosive solution, an OY solution (Cl - : 195 ppm, SO4 2- : 60 ppm, Cu 2+ : 1 ppm, Fe 3+ : A corrosive solution having a pH of 3 containing 30 ppm) was prepared.

[0104] The above corrosion liquid was introduced into the heat exchangers of Examples 1 and 2 and the Comparative Example from one pipe portion 33, circulated through the inside, and discharged from the other pipe portion 33. As the test conditions during this circulation, the temperature of the corrosion liquid was set to 60 °C, the flow rate was set to 1 L / min, and the circulation time was set to 250 hours continuously.

[0105] After the test, the appearances of the heat exchangers of Examples 1 and 2 and the Comparative Example were visually observed and evaluated. As a result, those with no change in the appearance of the heat exchanger (outer package) and no corrosion occurring in both the outer package and the inner fins were evaluated as "○ (good)", and those with corrosion occurring on the end faces of the inner fins were evaluated as "× (bad)". The results are shown in Table 1.

[0106]

Table 1

[0107] As is clear from the test results (Table 1) of the above corrosion resistance test, it can be seen that the heat exchangers of Examples 1 and 2 related to the present invention are superior in corrosion resistance compared to the heat exchangers of the Comparative Example that deviate from the gist of the present invention.

Industrial Applicability

[0108] The heat exchanger of this invention can be used as a cooler for heat dissipation countermeasures around the CPU and battery of information terminals such as smartphones, tablet terminals, and personal computers, heat dissipation countermeasures around the displays of liquid crystal TVs, organic ELs, and plasma TVs, and heat dissipation countermeasures around the power modules and batteries of automobiles, and also as a heater used for floor heating and snow removal.

Explanation of Signs

[0109] 1: Outer package 2: Inner fin 61: Heat transfer layer 62: Heat fusion layer 6a: Side edge of the heat transfer layer 6b: End face of the heat transfer layer 7: Thin edge part 7a: Side edge of the inner core laminate material 72: Heat transfer layer side edge laminated part 73: Heat transfer layer end face covering part L1: Outer package laminate material L2: Inner core laminate material

Claims

1. A heat exchanger comprising an outer casing through which a heat exchange medium flows inside, and inner fins accommodated in the outer casing with a part thereof in contact with the inner surface of the outer casing, wherein the outer casing is composed of an outer laminate material in which a resin layer is laminated on at least one side of a metal layer, the inner fins are composed of an inner core laminate material in which resin-made heat fusion layers are laminated on both sides of a heat transfer layer made of metal, a thin edge portion is formed at a side edge of the inner core laminate material, the thin edge portion includes a side edge of the heat transfer layer, a heat transfer layer side edge laminated portion made of resin laminated on both sides of the side edge, and a heat transfer layer end face covering portion made of resin covering an end face of the heat transfer layer, with the thickness of the heat fusion layer being "T1", the thickness of the heat transfer layer side edge laminated portion being "T2", the width of the heat transfer layer side edge laminated portion being "W1", and the width of the heat transfer layer end face covering portion being "W2", T1 = 0.02 mm to 0.5 mm T2 = 1 / 6 × T1 to 2 / 3 × T1 W1 = 2 mm to 15 mm W2 = 0.01 mm to 2 mm configured such that the relational expressions are satisfied, and the inner core laminate material is formed with uneven portions, characterized heat exchanger.

2. The heat exchanger according to claim 1, wherein the heat fusion layer, the heat transfer layer side edge laminated portion, and the heat transfer layer end face covering portion are continuously formed integrally.

3. The heat exchanger according to claim 1 or 2, wherein the heat transfer layer side edge laminated portion and the heat transfer layer end face covering portion are composed of a molten resin molded body of the heat fusion layer.

4. An inner fin for a heat exchanger, which is accommodated in an outer casing through which a heat exchange medium flows inside and is composed of an outer laminate material in which a resin layer is laminated on at least one side of a metal layer, with a part thereof in contact with the inner surface of the outer casing, composed of an inner core laminate material in which resin-made heat fusion layers are laminated on both sides of a heat transfer layer made of metal, a thin edge portion is formed at a side edge of the inner core laminate material, the thin edge portion includes a side edge of the heat transfer layer, a heat transfer layer side edge laminated portion made of resin laminated on both sides of the side edge, and a heat transfer layer end face covering portion made of resin covering an end face of the heat transfer layer, with the thickness of the heat fusion layer being "T1", the thickness of the heat transfer layer side edge laminated portion being "T2", the width of the heat transfer layer side edge laminated portion being "W1", and the width of the heat transfer layer end face covering portion being "W2", T1 = 0.02 mm to 0.5 mm T2 = 1 / 6 × T1 to 2 / 3 × T1 W1 = 2 mm to 15 mm W2 = 0.01 mm to 2 mm configured so that the relational expression holds, The inner fin for a heat exchanger, characterized in that the inner core laminate material has uneven portions formed thereon. **Claim 5** A method for manufacturing an inner fin for a heat exchanger, wherein a heat exchange medium flows inside, and the inner fin is configured to be accommodated in an outer casing constituted by an outer casing laminate material having a resin layer laminated on at least one side of a metal layer, with a part thereof being in contact with the inner surface of the outer casing. An inner core laminate material is produced by laminating heat-fusing layers made of resin on both sides of a heat-transfer layer made of metal. Heat press forming is performed on the side edges of the inner core laminate material to cover the side edges and end faces of the heat-transfer layer, and a thin edge portion is formed by a molten resin molded body of the heat-fusing layer. The thin edge portion includes a side edge of the heat-transfer layer, a heat-transfer layer side edge laminated portion made of resin laminated on both sides of the side edge, and a heat-transfer layer end face covering portion made of resin covering the end face of the heat-transfer layer. Let the thickness of the heat-fusing layer be "T1", the thickness of the heat-transfer layer side edge laminated portion be "T2", the width of the heat-transfer layer side edge laminated portion be "W1", and the width of the heat-transfer layer end face covering portion be "W2". T1 = 0.02 mm to 0.5 mm T2 = 1 / 6 × T1 to 2 / 3 × T1 W1 = 2 mm to 15 mm W2 = 0.01 mm to 2 mm configured so that the relational expression holds, A method for manufacturing an inner fin for a heat exchanger, characterized in that uneven portions are formed on the inner core laminate material after forming the thin edge portion to manufacture the inner fin.

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