Heat exchanger and method for manufacturing a heat exchanger

Abstract

A heat exchanger (1A) comprises: a fin (3A) having a thick plate section (35) and a thin plate section (36) that is thinner than the thick plate section (35) and is adjacent to the thick plate section (35), at least one plate surface of the fin being uneven as a result of the thick plate section (35) and the thin plate section (36) being adjacent to each other; and a plurality of heat transfer tubes (2) that is arranged in a direction perpendicular to the tube axis with the tube axes being parallel to each other, and sandwiches the fin (3A) therebetween. The fin (3A) has a portion protruding more than the plurality of heat transfer tubes (2) in at least one direction among directions perpendicular to the tube axis and the arrangement direction of the heat transfer tubes (2). At least a thick plate section (35) among the thick plate section (35) and the thin plate section (36) is provided at the protruding portion of the fin (3A).

Description

Technical Field

[0001] The present disclosure relates to a heat exchanger and a method for manufacturing the heat exchanger.

Background Art

[0002] In a heat exchanger, fins may be deformed during molding. Therefore, heat exchangers having fins with suppressed deformation during molding have been developed.

[0003] For example, Patent Document 1 discloses a heat exchanger having a metal strip formed into a corrugated shape and fins with both ends in the strip direction of the metal strip folded back.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the heat exchanger described in Patent Document 1, by folding back both ends in the strip direction of the metal strip, the rigidity of the fins is increased to prevent deformation of the fins themselves. However, in this heat exchanger, a large amount of metal material is used only for the folded-back portion of the metal strip. As a result, the material cost becomes high.

[0006] The present disclosure has been made to solve the above problems, and an object thereof is to provide a heat exchanger and a method for manufacturing the heat exchanger that have high rigidity and can be manufactured with less material.

Means for Solving the Problems

[0007] To achieve the above objective, the heat exchanger according to this disclosure comprises a fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and a plurality of heat transfer tubes arranged perpendicular to the tube axis with their tube axes parallel to each other, and sandwiching the fin between them. The fin has a portion that protrudes from the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. Furthermore, at least the thick plate portion is provided on the protruding portion of the fin. Furthermore, the thick plate portion is provided from the protruding part of the fin to the part that is sandwiched between the heat transfer tubes, and is joined to the heat transfer tubes at the part that is sandwiched between them. [Effects of the Invention]

[0008] According to the configuration of this disclosure, the fin has a portion that protrudes beyond the heat transfer tubes in at least one direction perpendicular to the tube axis and the arrangement direction of the heat transfer tubes. Furthermore, the protruding portion of the fin is provided with at least a thick plate portion among the thick plate portion and thin plate portion. As a result, the rigidity is higher than when the entire fin is made of thin plate. In addition, to ensure rigidity, the fin can be manufactured with less material than when the entire fin is made of thick plate. [Brief explanation of the drawing]

[0009] [Figure 1] Perspective view of a heat exchanger according to Embodiment 1 of the present disclosure [Figure 2] Front view of a heat exchanger according to Embodiment 1 of the present disclosure [Figure 3] Enlarged perspective view of a portion of the heat transfer tubes and a portion of the fins attached to a portion of the heat transfer tubes in a heat exchanger according to Embodiment 1 of the present disclosure. [Figure 4] Enlarged top view of some of the fins of the heat exchanger according to Embodiment 1 of this disclosure [Figure 5] Cross-sectional view of the VV cutting line shown in Figure 4. [Figure 6] Flowchart of the method for manufacturing a heat exchanger according to Embodiment 1 of the present disclosure [Figure 7] Conceptual diagram of a fin molding apparatus used in the heat exchanger manufacturing method according to Embodiment 1 of this disclosure. [Figure 8] Conceptual diagram of a modified example of a fin forming apparatus used in a method for manufacturing a heat exchanger according to Embodiment 1 of the present disclosure [Figure 9] Conceptual diagram of a rolling apparatus used in a method for manufacturing a heat exchanger according to Embodiment 1 of the present disclosure [Figure 10A] Cross-sectional view of a first modified example of fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 10B] Cross-sectional view of a second modified example of fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 10C] Cross-sectional view of a third modified example of fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 11A] Enlarged top view of a fourth modified example of fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 11B] Cross-sectional view taken along the cutting line XIB-XIB shown in FIG. 11A [Figure 12] Enlarged top view of some fins included in the heat exchanger according to Embodiment 2 of the present disclosure [Figure 13] Cross-sectional view taken along the cutting line XIII-XIII shown in FIG. 12 [Figure 14A] Partial cross-sectional view of a first modified example of a thick plate portion provided on fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 14B] Partial cross-sectional view of a second modified example of a thick plate portion provided on fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 14C] Partial cross-sectional view of a third modified example of a thick plate portion provided on fins included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 14D] Partial cross-sectional view of a fourth modified example of a thick plate portion provided on fins included in the heat exchanger according to Embodiment 1 of the present disclosure<0000​​​​​​​Partial cross-sectional view of the seventh modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 15C] Partial cross-sectional view of the eighth modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 15D] Partial cross-sectional view of the ninth modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 15E] Partial cross-sectional view of the tenth modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 15F] Partial cross-sectional view of the eleventh modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 16A] Partial cross-sectional view of the twelfth modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 16B] Partial cross-sectional view of the thirteenth modification of the thick plate portion provided on the fin included in the heat exchanger according to Embodiment 1 of the present disclosure [Figure 17A] Conceptual diagram of the first modification of the arrangement pattern of the thick plate portion and the thin plate portion provided on the fin included in the heat exchanger according to Embodiment 2 of the present disclosure [Figure 17B] Conceptual diagram of the second modification of the arrangement pattern of the thick plate portion and the thin plate portion provided on the fin included in the heat exchanger according to Embodiment 2 of the present disclosure [Figure 17C] Conceptual diagram of the third modification of the arrangement pattern of the thick plate portion and the thin plate portion provided on the fin included in the heat exchanger according to Embodiment 2 of the present disclosure [Figure 17D] Conceptual diagram of the fourth modification of the arrangement pattern of the thick plate portion and the thin plate portion provided on the fin included in the heat exchanger according to Embodiment 2 of the present disclosure [Figure 17E] Conceptual diagram of the fifth modification of the arrangement pattern of the thick plate portion and the thin plate portion provided on the fin included in the heat exchanger according to Embodiment 2 of the present disclosure

Embodiments for Carrying Out the Invention

[0010] Hereinafter, a heat exchanger and a method for manufacturing a heat exchanger according to embodiments of the present disclosure will be described in detail with reference to the drawings. In the drawings, the same or equivalent parts are denoted by the same reference numerals. Furthermore, in the Cartesian coordinate system XYZ shown in the drawings, the direction in which the tube axes of the multiple heat transfer tubes of the heat exchanger extend is the vertical direction, and the direction in which these heat transfer tubes are arranged is the left-right direction. The vertical direction is the Z-axis, the left-right direction is the X-axis, and the direction perpendicular to the Z-axis and X-axis is the Y-axis. Hereafter, this coordinate system will be referenced as appropriate in the explanation.

[0011] (Embodiment 1) The heat exchanger according to Embodiment 1 is a heat exchanger in which the thickness of the fins themselves changes, thereby creating irregularities on the surface of the fins. First, the overall configuration of the heat exchanger will be described with reference to Figures 1-3.

[0012] Figure 1 is a perspective view of a heat exchanger 1A according to Embodiment 1. Figure 2 is a front view of the heat exchanger 1A. Figure 3 is an enlarged perspective view of a part of the heat transfer tubes 2 of the heat exchanger 1A and a part of the fins 3A attached to a part of the heat transfer tubes 2. Note that in Figure 1, the fins 3A are omitted for ease of understanding. Also, in Figure 2, the shape of the fins 3A is simplified to a shape that is bent multiple times to the left and right in a front view. In Figures 1-3, the shape of the heat transfer tubes 2 is simplified to a rectangular parallelepiped shape with the internal flow paths omitted.

[0013] As shown in Figures 1 and 2, the heat exchanger 1A includes headers 11 and 12 connected to external equipment through which refrigerant is supplied and discharged, a plurality of heat transfer tubes 2 connected to the headers 11 and 12 through which refrigerant flows, and fins 3A attached to the heat transfer tubes 2.

[0014] As shown in Figure 1, the headers 11 and 12 are formed in a cylindrical shape. Although not shown, the headers 11 and 12 are provided with connecting pipes for connecting to external equipment that supplies and discharges refrigerant. Furthermore, flow paths for distributing and concentrating the refrigerant are formed inside the headers 11 and 12. As shown in Figure 1, the headers 11 and 12 are positioned vertically apart from each other, with their cylindrical axes oriented horizontally. Multiple heat transfer tubes 2 are connected to the headers 11 and 12 to allow refrigerant to flow between them.

[0015] Each of the heat transfer tubes 2 is formed in a tubular shape to allow the refrigerant to flow, with its axis oriented vertically. The upper and lower ends of the heat transfer tubes 2 are inserted into insertion holes (not shown) in the cylindrical walls of the headers 11 and 12. As a result, when the refrigerant flows through the headers 11 and 12, the refrigerant flows through the inside of the heat transfer tubes 2.

[0016] Furthermore, each heat transfer tube 2 is made of a metal with high thermal conductivity, such as pure aluminum or an aluminum alloy, to facilitate the transfer of heat from the refrigerant circulating inside it. In addition, the heat transfer tubes 2 are formed in a flattened tube shape with a flattened cross-section. The heat exchanger 1A is designed to exchange heat with air blown in the front-to-back direction during use. To reduce the resistance of the airflow, the heat transfer tubes 2 have their short axis oriented in the left-to-right direction and their long axis oriented in the front-to-back direction. The heat transfer tubes 2 are arranged in the left-to-right direction at regular intervals. As shown in Figure 2, fins 3A are sandwiched between the heat transfer tubes 2.

[0017] The fins 3A have a corrugated plate shape when viewed from the front in order to increase the contact area with air and improve heat exchange performance with air. In detail, the fins 3A are formed from a metal plate with high heat conductivity, such as pure aluminum or an aluminum alloy. As shown in Figure 3, the fins 3A are formed by bending the metal plate to create a corrugated shape with multiple peaks 31 and valleys 33 adjacent to each other in one direction when viewed in cross-section. The fins 3A are sandwiched between heat transfer tubes 2 with the direction in which the peaks 31 or valleys 33 are aligned oriented in the tube axis direction D1, i.e., the Z direction, of the heat transfer tubes 2. Furthermore, the fins 3A are brazed to the heat transfer tubes 2 with their tops 32 and bottoms 34 in contact with the heat transfer tubes 2.

[0018] In fins 3A having such a corrugated shape, a shape is sometimes adopted in which the width W1 of the fin 3A in the front-to-back direction, i.e., in the Y direction, is larger than the width W2 of the heat transfer tube 2 in the Y direction, in order to increase the surface area and improve heat exchange performance. In that case, for example, the fin 3A may be attached to the heat transfer tube 2 with its +Y end portion protruding from the heat transfer tube 2 by 1 / 5 to 1 / 50 of the width W1 of the fin 3A in the Y direction.

[0019] However, when the fins 3A are formed in this width W1 shape and positioned in this protruding location, the +Y end portion of the fins 3A that protrudes from the heat transfer tube 2 in the +Y direction may be deformed by external forces such as collisions or contact during manufacturing or use.

[0020] Furthermore, in order to reduce material costs, fin 3A is being made thinner. As a result, the thinning of fin 3A tends to decrease the strength and rigidity of fin 3A itself. Consequently, if fin 3A, which is formed into the shape described above and arranged as described above, is further thinned, the ends of fin 3A, including the +Y end, become more susceptible to deformation, making it difficult to manufacture fin 3A in the desired shape. It also becomes difficult to use fin 3A in the desired shape.

[0021] Therefore, in the heat exchanger 1A, in order to increase strength and rigidity, the thickness of the fins 3A themselves is changed, thereby creating irregularities on the surface of the fins 3A. Next, the detailed configuration of the fins 3A will be explained with reference to Figures 4 and 5.

[0022] Figure 4 is an enlarged top view of some of the fins 3A of the heat exchanger 1A. Figure 5 is a cross-sectional view of the VV cutting line shown in Figure 4. For ease of understanding, Figure 5 shows a cross-section of only the uppermost portion of the corrugated fin 3A when it is unfolded.

[0023] As shown in Figures 4 and 5, the fin 3A has a thick plate portion 35 provided at the +Y end and a thin plate portion 36 provided on the -Y side of the thick plate portion 35 and adjacent to the thick plate portion 35.

[0024] As shown in Figure 5, the thickness T1 of the thick plate portion 35 is greater than the thickness T2 of the thin plate portion 36. For example, the difference between the thickness T1 of the thick plate portion 35 and the thickness T2 of the thin plate portion 36 is 10% to 90% of the thickness T1 of the plate portion 35. Also, the thickness T1 of the thick plate portion 35 and the thickness T2 of the thin plate portion 36 are constant. Furthermore, the center line CL1 in the cross-sectional view of the thick plate portion 35 is located on the extension of the center line CL2 in the cross-sectional view of the thin plate portion 36. In addition, the thick plate portion 35 is adjacent to the thin plate portion 36. As a result, the thick plate portion 35 has a step between the thin plate portion 36 and one side of the fin 3A, and the other side of the fin 3A. Due to these, the thick plate portion 35 forms a convex portion 37 on one side of the fin 3A, i.e., the +Z surface, that protrudes from the thin plate portion 36 in the +Z direction. Furthermore, the thick plate portion 35 forms a protrusion 38 on the other surface of the fin 3A, i.e., the -Z plane, projecting in the -Z direction from the thin plate portion 36. As a result, the thick plate portion 35 and the thin plate portion 36 form irregularities on the +Z and -Z planes of the fin 3A. By having this configuration, the thick plate portion 35 and the thin plate portion 36 increase the strength and rigidity of the fin 3A.

[0025] Furthermore, the thick plate portion 35 is provided on the +Y end portion of the fin 3A, which protrudes in the +Y direction beyond the heat transfer tube 2, as shown in Figure 4. The width of the thick plate portion 35 in the Y direction is, for example, the same as or smaller than the protruding length of the fin 3A in the +Y direction. Alternatively, it is smaller than the period, i.e., the pitch of the corrugations, which is the distance between adjacent tops 32 of the corrugations of the fin 3A. To give a more specific example, the width of the thick plate portion 35 in the Y direction is 1 / 5 to 1 / 50 of the width of the fin 3A in the Y direction. As a result, the thick plate portion 35 increases the strength and rigidity of the +Y end portion of the fin 3A. The +Y end portion of the fin 3A is a part that protrudes beyond the heat transfer tube 2, and is therefore a part that is prone to collision and contact with other objects and is easily deformed. By providing the thick plate portion 35 on the +Y end portion of the fin 3A, deformation of the +Y end portion is prevented. Furthermore, the cross-sectional area of ​​the thick plate portion 35 is larger than that of the thin plate portion 36, and as a result, the thick plate portion 35 increases the strength and rigidity of the fin 3A.

[0026] Furthermore, the thick plate portion 35 extends along the peaks 31 and valleys 33 of the corrugated shape of the fin 3A shown in Figure 3, which are connected in the Z direction. In other words, the thick plate portion 35 extends in a direction perpendicular to the width direction of the fin 3A. As a result, the thick plate portion 35 increases the overall strength and rigidity of the corrugated fin 3A, making it easier for the fin 3A to maintain its corrugated shape.

[0027] Returning to Figure 4, the thin plate section 36 has multiple cut-out sections 39 formed therein to allow air to circulate around the fins 3A. The cut-out sections 39 are formed by making cuts in the metal plate of the fins 3A, and then bending the portion of the metal plate adjacent to the cuts to make it stand upright. The cut-out sections 39 are formed in the thin plate section 36 rather than the thick plate section 35, which facilitates the manufacturing of the fins 3A.

[0028] These thick plate portion 35 and thin plate portion 36 are formed by rolling the metal sheet that is the material for the fins 3A. Since the thin plate portion 36 is formed to be thinner than the metal sheet that is the material for the fins 3A, the heat exchanger 1A can be manufactured with less material compared to when the fins 3A are manufactured using the same thickness as the metal sheet. Next, the manufacturing method of the heat exchanger 1A will be described with reference to Figures 6 and 7.

[0029] Figure 6 is a flowchart of the manufacturing method of heat exchanger 1A. Figure 7 is a conceptual diagram of the fin molding apparatus 40 used in the manufacturing method of heat exchanger 1A.

[0030] First, although not shown in the diagram, headers 11 and 12 and heat transfer tubes 2 are prepared, specifying the material, shape, and number described above. Simultaneously with the preparation of the heat transfer tubes 2, a rolling process (step S1) is performed as shown in Figure 6 to produce a plate member, which is the material for the fins 3A. Then, a fin forming process (step S2) is performed following the rolling process to produce the fins 3A from the prepared plate member. For example, a fin forming apparatus 40, as shown in Figure 7, is used in these rolling and fin forming processes.

[0031] The fin forming apparatus 40 includes an uncoiler 42 that supports the core portion of the coil 41 around which the strip metal plate 4 is wound. Here, the strip metal plate 4 is the raw material for the fins 3A and is a strip of sheet metal made of a highly heat-conductive metal such as pure aluminum or an aluminum alloy. The fin forming apparatus 40 pulls out the strip metal plate 4 from one end of the coil 41 as the uncoiler 42 rotates the coil 41. The fin forming apparatus 40 also includes a plurality of dancer rolls 43 around which the pulled-out strip metal plate 4 is wrapped and a tension controller 44, thereby maintaining a constant tension in the strip metal plate 4.

[0032] Furthermore, the fin forming apparatus 40 is equipped with multiple sets of rolling rolls 45 arranged vertically to form pairs in order to perform the rolling process described above. These multiple sets of rolling rolls 45, although not shown in the figure, have irregularities on their outer circumference in order to form the thick plate portion 35 and the thin plate portion 36 described above. Between the pairs of rolling rolls 45, a strip of metal 4 is passed, with the tension maintained at a constant level by multiple dancer rolls 43 and a tension controller 44. As a result, the rolling rolls 45 rotate themselves, rolling the strip of metal 4 to form a plate member 5 having the thick plate portion 35 and the thin plate portion 36 described above. For example, the rolling rolls 45 form a thick plate portion 35 that is thicker than the thickness of the strip of metal 4, and a thin plate portion 36 that is 10% to 90% thicker than the thickness of the thick plate portion 35. In this way, the fin forming apparatus 40 performs the rolling process (step S1) shown in Figure 6.

[0033] During rolling by the rolling mill rolls 45, minute linear grooves are formed on the plate member 5 in the feeding direction D2 of the strip metal plate 4 due to the rotation of the rolling mill rolls 45. These minute linear grooves are preferably used to drain water that adheres to the fins 3A when the heat exchanger 1A is in use.

[0034] Furthermore, as shown in Figure 7, the fin forming apparatus 40 includes multiple sets of forming rolls 46, multiple sets of pitch-reducing rolls 47, and multiple pitch-adjusting rolls 48. These rolls are described as follows: the multiple sets of forming rolls 46, although not shown, have convex portions for forming a corrugated shape on their outer surface and recesses adjacent to these convex portions in the outer circumferential direction, forming semi-finished fins 6 with a corrugation pitch greater than that of the final fins 3A. The multiple sets of pitch-reducing rolls 47 rotate at a slower speed than the fin forming rolls 46, thereby reducing the corrugation pitch of the semi-finished fins 6. The multiple pitch-adjusting rolls 48 adjust the pitch of the semi-finished fins 6, whose corrugation pitch has been reduced by the pitch-reducing rolls 47, by adjusting their rotational speed or orienting their roll axes in the direction of the semi-finished fins 6's movement. With this configuration, the fin forming apparatus 40 forms semi-finished fins 6 having the same corrugation shape as the final fins 3A.

[0035] Furthermore, the fin forming apparatus 40 includes a hump unit 49 that loosens the semi-finished fins 6 whose pitch has been adjusted by a pitch adjustment roll 48, and a cutter unit 51 that counts the pitch of the loosened semi-finished fins 6 using a counting worm 50 and cuts the semi-finished fins 6 at predetermined pitch intervals. In this way, the fin forming apparatus 40 produces fins 3A with a desired number of pitches. The fin forming apparatus 40 then performs the fin forming process (step S2) described above.

[0036] After the rolling process (step S1) and the fin forming process (step S2) are performed using such a fin forming apparatus 40, the core assembly process shown in Figure 6 is performed using the fabricated fins 3A, the prepared headers 11 and 12, and the heat transfer tubes 2 (step S3).

[0037] In the core assembly process, although not shown in the diagram, multiple prepared heat transfer tubes 2 are arranged so that their tube axes are parallel to each other and their flattened surfaces face each other. Furthermore, fins 3A are sandwiched between the heat transfer tubes 2 with the direction of the corrugated waves facing the tube axis of the heat transfer tubes 2. This assembles a laminate in which the heat transfer tubes 2 and fins 3A are stacked alternately. The assembled laminate is then compressed in the stacking direction to make the fins 3A adhere tightly to the heat transfer tubes 2. In this state, one end and the other end of the heat transfer tubes 2 are inserted into insertion holes (not shown) of the prepared headers 11 and 12, and the laminate of heat transfer tubes 2 and fins 3A is assembled into the headers 11 and 12. This completes the core assembly process. After that, the compressive force applied to the laminate is adjusted, and in that state, a restraining jig is attached to the laminate to maintain the compressed state of the laminate. This completes the core assembly process.

[0038] Following the core assembly process, the brazing process shown in Figure 6 is performed (step S4). In detail, although not shown in the illustration, the heat transfer tubes 2 and fins 3A of the laminate with the restraining jig attached are brazed. The heat transfer tubes 2 and headers 11 and 12 are also brazed. After brazing, the restraining jig is removed from the laminate. This completes the fabrication of the heat exchanger 1A.

[0039] In the manufactured heat exchanger 1A, the rolling process (step S1) forms thick plate sections 35 and thin plate sections 36 on the fins 3A. As a result, the manufacturing method of the heat exchanger 1A allows for the production of fins 3A with less material than when the fins 3A are manufactured using the same thickness as the strip metal plate 4 drawn from the coil 41. Furthermore, since the plate member 5 produced in the rolling process and the semi-finished fins 6 and fins 3A produced in the fin forming process (step S2) are equipped with thick plate sections 35, these plate member 5, semi-finished fins 6 and fins 3A have high strength and rigidity. This makes them less prone to deformation during the manufacturing process of the heat exchanger 1A. As a result, the occurrence of defective fins 3A is reduced. In addition, the manufacturing method of the heat exchanger 1A allows for the production of highly accurate fins 3A.

[0040] The strip-shaped metal plate 4 described above is an example of a metal plate as defined in this disclosure. The plate member 5 described above is an example of a fin plate member as defined in this disclosure. Furthermore, the rolling process (step S1) and fin forming process (step S2) described above are examples of a fin manufacturing method as defined in this disclosure. The core assembly process (step S3) and brazing (step S4) described above are examples of assembly processes for attaching the fin 3A as defined in this disclosure to the heat transfer tube 2.

[0041] Furthermore, in the steel plate sector, thick plates are generally defined as having a thickness of 6 mm or more, and thin plates as having a thickness of less than 3 mm. However, in this specification, the thin plate portion 36 described above only needs to be thinner than the thick plate portion 35, and the regulations regarding the thickness of thick plates in the steel plate sector do not apply.

[0042] As described above, in the heat exchanger 1A according to Embodiment 1, the fins 3A comprise a thick plate portion 35 and a thin plate portion 36 that is thinner than the thick plate portion 35 and adjacent to the thick plate portion 35. Therefore, the strength and rigidity of the fins 3A are higher than when the entire fin 3A is made of thin plate material. Furthermore, in order to ensure the strength and rigidity of the fins 3A, the fins 3A can be manufactured with less material than when the entire fin 3A is made of thick plate material. As a result, the material cost can be reduced according to the configuration of the heat exchanger 1A.

[0043] In the heat exchanger 1A, the fins 3A protrude beyond the heat transfer tubes 2 in a direction perpendicular to the tube axis and the arrangement direction of the heat transfer tubes 2. The ends of the fins 3A that protrude beyond the heat transfer tubes 2 are prone to collision and contact with external objects, but thick plate sections 35 are provided at these ends. As a result, the strength and rigidity of the fins 3A are high. Consequently, the fins 3A are less prone to deformation.

[0044] Furthermore, although the fin 3A has a corrugated shape, the thick plate portion 35 extends in a direction in which the peaks 31 and valleys 33 of the corrugated shape are connected. As a result, the overall strength and rigidity of the fin 3A are high.

[0045] (Modified example of a fin molding apparatus) In the manufacturing method of the heat exchanger 1A, a fin forming apparatus 40 is used in the rolling process (step S1) and the fin forming process (step S2). The fin forming apparatus 40 is equipped with multiple sets of rolling rolls 45. However, the fin forming apparatus 40 is merely one example of an apparatus that performs the rolling process and the fin forming process. The fin forming apparatus 40 itself does not have to perform the rolling process. As a result, the fin forming apparatus 40 does not have to be equipped with rolling rolls 45.

[0046] Figure 8 is a conceptual diagram of a modified fin forming apparatus 40 used in the manufacturing method of heat exchanger 1A. Figure 9 is a conceptual diagram of a rolling mill 60 used in the manufacturing method of heat exchanger 1A.

[0047] As shown in Figure 8, the fin forming apparatus 40 does not necessarily have rolling rolls 45. In that case, the uncoiler 42 holds a coil 61 around which a strip-shaped plate member 5 having a thick portion 35 and a thin portion 36 is wound. The plate member 5 drawn from the coil 61 is then passed over a dancer roll 43 and then between multiple sets of forming rolls 46 without passing through the rolling rolls 45. Furthermore, the above coil 61 may be manufactured by the rolling apparatus 60 shown in Figure 9. This is because even with such a modified fin forming apparatus 40, fins 3A can be manufactured from a strip-shaped plate member 5 having a thick portion 35 and a thin portion 36.

[0048] The rolling mill 60 refers to a device equipped with means for rolling the strip-shaped metal sheet 4, such as rolling rolls 45. To give a specific example, as shown in Figure 9, the rolling mill 60 is a device equipped with an uncoiler 62 that supports the core portion of the coil 41 around which the strip-shaped metal sheet 4 is wound, a plurality of dancer rolls 63 that maintain a constant tension in the strip-shaped metal sheet 4 drawn from the uncoiler 62, a plurality of rolling rolls 65 having the same configuration as the plurality of rolling rolls 45 described in Embodiment 1, and a recoiler 66 that winds the strip-shaped plate member 5 produced by rolling by the rolling rolls 65 onto the coil 61.

[0049] (Finn's modified form) In the heat exchanger 1A, the thick plate portion 35 of the fin 3A has a rectangular cross-section, and as a result, the cross-sectional corners of the protrusions 37 and 38 are right angles. However, the cross-sectional shape of the protrusions 37 and 38 is not limited to this.

[0050] Figures 10A and 10C show cross-sectional views of the first and third modified examples of the fins 3A provided in the heat exchanger 1A.

[0051] As shown in Figures 10A and 10B, in the first and second modified examples of fin 3A, the front end of the thick plate portion 35, i.e., the +Y end, is rounded. As a result, the cross-sectional corner portions of the convex portions 37 and 38 on the +Y side are rounded. Similarly, the -Y end of the thin plate portion 36 is rounded, resulting in the cross-sectional corner portion of the thin plate portion 36 on the -Y side being rounded. Such shapes are formed by using a roll that holds down the widthwise end of the strip metal plate 4 when rolling the strip metal plate 4 with the rolling roll 45 described above, or by providing a guide mechanism on the rolling roll 45 that holds down the widthwise end. Thus, the cross-sectional corner portions of the convex portions 37 and 38 may be rounded as well as at right angles. Furthermore, the cross-sectional corner portions of the convex portions 37 and 38 may be chamfered.

[0052] Furthermore, as shown in Figures 10A and 10B, in the first and second modified examples of fin 3A, multiple steps are formed at the rear end, i.e., the -Y end, of the thick plate portion 35. Specifically, as shown in Figure 10A, in the first modified example of fin 3A, two steps are formed between the -Y end of the thick plate portion 35 and the thin plate portion 36. As shown in Figure 10B, in the second modified example of fin 3A, three steps are formed between the -Y end of the thick plate portion 35 and the thin plate portion 36. Such shapes are formed by the rolling rolls 45 described above. Thus, the thick plate portion 35 may have multiple steps between it and the thin plate portion 36.

[0053] Furthermore, as shown in Figure 10C, in the third modified example of the fin 3A, a recess is formed in the thick plate portion 35, resulting in the thick plate portion 35 not having a constant thickness, but rather having multiple thicknesses. Thus, the thick plate portion 35 may have multiple thicknesses as a result of its thickness varying in the extending direction.

[0054] In the heat exchanger 1A, the +Y end portion of the fin 3A protrudes beyond the heat transfer tube 2 in the +Y direction, which is the leeward side as shown in Figure 4, and the thick plate portion 35 is formed only on this protruding portion 30. In other words, the thick plate portion 35 is formed on the portion of the protruding portion 30 that is away from the heat transfer tube 2. However, the position of the thick plate portion 35 is not limited to this.

[0055] Figure 11A is a cross-sectional view of a fourth modified example of the fins 3A of the heat exchanger 1A. Figure 11B is a cross-sectional view of the XIB-XIB cutting line shown in Figure 11A.

[0056] In the heat exchanger 1A shown in Figures 11A and 11B, a thick plate portion 35 is formed on the fin 3A from the protruding portion 30 that extends in the -Y direction beyond the heat transfer tube 2 to the portion sandwiched between the heat transfer tubes 2. As a result, the base portion of the thick plate portion 35, i.e., region A1, is sandwiched between the heat transfer tubes 2. Furthermore, region A1 of the thick plate portion 35 is brazed to the heat transfer tubes 2. This increases the strength and rigidity of the protruding portion 30, as well as the strength and rigidity of the heat exchanger 1A itself. Thus, it is preferable that the thick plate portion 35 be formed not only on the protruding portion 30 of the fin 3A, but also on the portion of the fin 3A from the protruding portion 30 to the portion sandwiched between the heat transfer tubes 2.

[0057] In the fourth modified example of fin 3A shown in Figures 11A and 11B, the +Y end of fin 3A does not protrude in the +Y direction beyond the heat transfer tube 2, and its position in the Y direction is the same as that of the +Y end of the heat transfer tube 2. A thick plate portion 35 is formed from the +Y end of fin 3A to the portion sandwiched between the heat transfer tubes 2. In this case as well, the thick plate portion 35 is joined to the heat transfer tube 2, thereby increasing the strength and rigidity of the heat exchanger 1A itself.

[0058] Furthermore, in the fourth modification, the thin plate portion 36 may be provided with irregularities. In addition, in the fourth modification of the fin 3A, the protruding portion 30 is provided on the -Y side of the fin 3A, but the protruding portion 30 may be provided on the +Y side of the fin 3A.

[0059] (Embodiment 2) In the heat exchanger 1A according to Embodiment 1, one thick plate portion 35 is provided at the +Y end of the fin 3A. However, the fin 3A is not limited to this. The fin 3A may consist of a thick plate portion 35 and a thin plate portion 36 that is thinner than the thick plate portion 35 and adjacent to the thick plate portion 35, and at least one of the plate surfaces may be uneven due to the adjacent thick plate portion 35 and thin plate portion 36. Therefore, multiple thick plate portions 35 may be provided on the fin 3A. In addition, the thick plate portion 35 may be provided at a location other than the +Y end of the fin 3A.

[0060] In the heat exchanger 1B according to Embodiment 2, multiple thick plate sections 35 and thin plate sections 36 are provided across the entire fin 3B. The configuration of the fin 3B will be described below with reference to Figures 12 and 13. Embodiment 2 will be described mainly for its configuration which differs from that of Embodiment 1.

[0061] Figure 12 is an enlarged top view of some of the fins 3B of the heat exchanger 1B according to Embodiment 2. Figure 13 is a cross-sectional view taken along the line XIII-XIII shown in Figure 12. Note that in Figure 12, the cut-out portion 39 is omitted for ease of understanding. Also, in Figure 13, similar to Figure 5, a cross-section is shown when only the uppermost portion of the corrugated fin 3B is taken out and unfolded.

[0062] As shown in Figure 12, the fin 3B is provided with alternating thick plate sections 35 and thin plate sections 36, resulting in the formation of convex portions 37, 38 and concave portions 57, 58 on each plate surface of the fin 3B, as shown in Figure 13. In detail, the fin 3B is provided with alternating thick plate sections 35 and thin plate sections 36 in the order of thick plate section 35, then thin plate section 36, starting from the +Y end. As a result, convex portions 37 and concave portions 57 are alternately formed on the +Z surface of the fin 3B. Convex portions 38 and concave portions 58 are also alternately formed on the -Z surface of the fin 3B. The distance between adjacent convex portions 37 or adjacent convex portions 38, i.e., the pitch of the convex portions 37 or 38, is, for example, 1 mm or more. By having this configuration, the strength and rigidity of the fin 3B are enhanced.

[0063] The difference in thickness between the thick plate portion 35 and the thin plate portion 36 should be such that when the fins 3B are brought into contact with the heat transfer tube 2 and brazed, the brazing material penetrates into the recesses 57 and 58 of the thin plate portion 36, or a brazing fillet is formed.

[0064] Furthermore, in Embodiment 2, the +Y end portion of the fin 3B protrudes in the +Y direction beyond the heat transfer tube 2. Multiple thick plate portions 35 are provided at the +Y end portion of the fin 3B. As a result, similar to the fin 3A described in Embodiment 1, the strength and rigidity of the +Y end portion of the fin 3B are increased, and deformation of the +Y end portion is prevented.

[0065] Furthermore, although not shown in the figures, the thick plate portion 35 and the thin plate portion 36 extend in the direction in which the peak portion 31 and the valley portion 33 of the corrugated shape of the fin 3B, as described in Embodiment 1, are connected. As a result, the thick plate portion 35 and the thin plate portion 36 are provided throughout the entire fin 3B. Consequently, the thick plate portion 35 and the thin plate portion 36 increase the overall strength and rigidity of the fin 3B and prevent deformation of the corrugation of the entire fin 3B.

[0066] The manufacturing method of the heat exchanger 1B according to Embodiment 2 is the same as that of Embodiment 1, except that the fins 3B are manufactured by using a rolling roll (not shown) which has alternately arranged recesses and protrusions in the axial direction on its outer circumference, instead of the rolling roll 45 described in Embodiment 1. For this reason, a detailed explanation of the manufacturing method of the heat exchanger 1B is omitted.

[0067] As described above, in the heat exchanger 1B according to Embodiment 2, thick plate sections 35 and thin plate sections 36 are provided throughout the entire fin 3B. Therefore, the overall strength and rigidity of the fin 3B are high, and the fin 3B is less prone to deformation.

[0068] Furthermore, in fin 3B, the thick plate section 35 and the thin plate section 36 are arranged alternately, resulting in higher strength and rigidity compared to a fin 3B that is simply made thinner overall. Also, compared to a fin 3B that remains thick throughout, fin 3B can be manufactured with less material, resulting in lower material costs for fin 3B.

[0069] In the second embodiment, a cut-and-bent portion 39, which is not shown in Figure 12, is provided in the portion where the thick plate portion 35 and thin plate portion 36 of the fin 3B are arranged alternately. However, the fin 3B is not limited to this. The fin 3B may have a region where the thick plate portion 35 and thin plate portion 36 are not formed, and the cut-and-bent portion 39 may be provided in that region. This is because such a configuration makes it easier to manufacture the cut-and-bent portion 39, and allows for the production of a cut-and-bent portion 39 with high precision.

[0070] The heat exchangers 1A, 1B and the manufacturing methods for the heat exchangers 1A, 1B according to the embodiments of this disclosure have been described above, but the manufacturing methods for the heat exchangers 1A, 1B and the heat exchangers 1A, 1B are not limited thereto.

[0071] For example, in Embodiment 1, one thick plate portion 35 is provided at one end of fin 3A. Also, in Embodiments 1 and 2, fins 3A and 3B are provided with a thick plate portion 35, so that a protrusion 37 is provided on one surface of fins 3A and 3B and a protrusion 38 is provided on the other surface of fins 3A and 3B. However, fins 3A and 3B are not limited to these. Fins 3A and 3B may be provided with a thick plate portion 35 and a thin plate portion 36 that is thinner than the thick plate portion 35 and adjacent to the thick plate portion 35, and the adjacent thick plate portion 35 and thin plate portion 36 may result in at least one of their surfaces being uneven.

[0072] Figures 14A-14E are partial cross-sectional views of the first to fifth modified versions of the thick plate portion 35 provided on the fin 3A of the heat exchanger 1A according to Embodiment 1. Figures 15A-15F are partial cross-sectional views of the sixth to eleventh modified versions of the thick plate portion 35 provided on the fin 3A. Figures 16A and 16B are partial cross-sectional views of the twelfth and thirteenth modified versions of the thick plate portion 35 provided on the fin 3A.

[0073] As shown in Figures 14A and 14B, a thick plate portion 35 may be provided in the central part of the fin 3A, and thin plate portions 36 may be provided at each end. In this case, as shown in Figure 14A, convex portions 37 and 38 may be provided on each plate surface of the fin 3A, and recessed portions 57 and 58 may be provided on each plate surface of the fin 3A. Alternatively, as shown in Figure 14B, the convex portion 37 and recessed portion 57 may be provided on only one plate surface of the fin 3A.

[0074] Furthermore, as shown in Figures 14C and 14D, thick plate portions 35 may be provided at each end of the fin 3A, and a thin plate portion 36 may be provided in the central part of the fin 3A. In this case, as shown in Figure 14C, convex portions 37 and 38 may be provided on each plate surface of the fin 3A, and recessed portions 57 and 58 may be provided on each plate surface of the fin 3A. As shown in Figure 14D, convex portions 37 and recessed portions 57 may be provided on only one plate surface of the fin 3A.

[0075] Furthermore, as shown in Figure 14E, thick plate sections 35 and thin plate sections 36 may be arranged alternately, and convex portions 37 and concave portions 57 may be provided only on one plate surface of the fin 3A.

[0076] Furthermore, as shown in Figures 15A and 15B, if the end face of the thick plate portion 35 is an inclined surface, the convex portions 37 and 38 may have a trapezoidal shape in cross-section. Also, as shown in Figures 15C and 15D, if the end face of the thick plate portion 35 is an inclined surface and the width of the thick plate portion 35 is small, the convex portions 37 and 38 may have a triangular shape in cross-section. Furthermore, as shown in Figures 15E and 15F, if the end face of the thick plate portion 35 is an arc shape in cross-section, more specifically a semicircular shape in cross-section, the convex portions 37 and 38 may have a semicircular or semi-elliptical shape in cross-section.

[0077] Furthermore, as shown in Figure 16A, the fin 3A may have a thick plate portion 35 and a thin plate portion 36, as well as a thick plate portion 59 that is thinner than the thick plate portion 35 and thicker than the thin plate portion 36, so that the width of the protrusion 37 on one plate surface of the fin 3A and the protrusion 38 on the other plate surface of the fin 3A may be different. In that case, the protrusions 37 and 38 may be rectangular in shape. More specifically, the protrusion 37 may be trapezoidal in cross-section and the protrusion 38 may be rectangular in cross-section. Alternatively, although not shown, the protrusion 37 may be rectangular in cross-section and the protrusion 38 may be trapezoidal in cross-section. Moreover, as shown in Figure 16B, even if the thick plate portion 35 has the same thickness, depending on whether it is on one plate surface side or the other plate surface side relative to the thin plate portion 36, the thick plate portion 35 may have only the protrusion 37 on one plate surface or only the protrusion 38 on the other plate surface. In this case as well, the convex portion 37 may be trapezoidal in cross-section, and the convex portion 38 may be rectangular in cross-section. Although not shown in the figures, the convex portion 37 may be rectangular in cross-section, and the convex portion 38 may be trapezoidal in cross-section.

[0078] In Embodiment 2, thick plate portions 35 and thin plate portions 36 are alternately formed in the fin 3B. In other words, a combination of thick plate portions 35 and thin plate portions 36 adjacent to the thick plate portions 35 is formed throughout the fin 3B. However, the arrangement of the thick plate portions 35 and thin plate portions 36 is not limited to this. As described above, the thick plate portions 35 and thin plate portions 36 only need to form irregularities on at least one of the plate surfaces by having the thick plate portions 35 and thin plate portions 36 adjacent to each other.

[0079] Figures 17A-17E are conceptual diagrams of the first to fifth modified examples of the arrangement patterns of the thick plate portion 35 and thin plate portion 36 provided on the fin 3B of the heat exchanger 1B according to Embodiment 2. In Figures 17A-17E, for ease of understanding, the fin 3B is shown when the corrugation is unfolded straight. The longitudinal direction of the fin 3B is the feeding direction D2 in which the plate member 5 of the fin forming apparatus 40 shown in Figure 7 is fed to the forming roll 46. Also, for ease of understanding, the irregularities 7-10 formed by the combination of the thick plate portion 35 and thin plate portion 36, as explained in Figures 13(A)-13(F) and Figures 16A and 16B, are shown as solid lines. As a result, the parts of the fin 3B without solid lines are flat surfaces without irregularities 7-10.

[0080] As shown in Figure 17A, the fin 3B may have multiple protrusions 7 that extend in the longitudinal direction and are arranged in the transverse direction. Also, as shown in Figure 17B, the fin 3B may have multiple protrusions 8 that extend in the transverse direction and are arranged in the longitudinal direction. Furthermore, as shown in Figure 17C, the fin 3B may have a mixture of multiple protrusions 7 that extend in the longitudinal direction and are arranged in the transverse direction, and multiple protrusions 8 that extend in the transverse direction and are arranged in the longitudinal direction.

[0081] Here, the longitudinal direction of fin 3B refers to the longitudinal direction when fin 3B is unfolded into a flat plate shape, and is the direction in which the heat transfer tubes 2 are arranged in the heat exchanger 1B. The short direction of fin 3B refers to the short direction when fin 3B is unfolded into a flat plate shape, and is the direction perpendicular to the direction in which the heat transfer tubes 2 are arranged in the heat exchanger 1B.

[0082] As shown in Figure 17D, the fin 3B may have a plurality of parallel and interlocking grooves 9, each extending in a direction inclined with respect to the longitudinal direction of the fin 3B. Alternatively, the fin 3B may have a plurality of grooves 10 with different directions of inclination with respect to the longitudinal direction. For example, as shown in Figure 17E, the fin 3B may have a plurality of grooves 9 inclined at a constant angle with respect to the longitudinal direction, and a plurality of grooves 10 inclined symmetrically with respect to those grooves 9.

[0083] In embodiments 1 and 2, the fins 3A and 3B are corrugated. However, the overall shape of the fins 3A and 3B is arbitrary as long as they satisfy the condition that the thick plate portion 35 and the thin plate portion 36, which is thinner than the thick plate portion 35 and adjacent to the thick plate portion 35, are adjacent to each other, and that at least one of the plate surfaces is uneven. For example, the fins 3A and 3B may be flat overall.

[0084] Furthermore, in embodiments 1 and 2, the heat transfer tube 2 is flattened, but the shape of the heat transfer tube 2 is arbitrary. The heat transfer tube 2 may be, for example, a cylindrical tube.

[0085] As described above, the heat exchangers 1A and 1B and the manufacturing methods for heat exchangers 1A and 1B are not limited to the embodiments described above, and various modifications and substitutions can be made. Various forms of this disclosure are described below as appendices.

[0086] (Note 1) A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, of which the thick plate portion and the thin plate portion are provided. heat exchanger. (Note 2) The protruding portion of the fin is provided with both the thick plate portion and the thin plate portion. The heat exchanger described in Appendix 1. (Note 3) The thick plate portion is the portion of the fin that extends from the protruding portion. heat transfer tube It is provided up to the part that is sandwiched between the two, and the heat transfer tube The portion that is sandwiched between the above heat transfer tube It is joined to, The heat exchanger described in Appendix 1. (Note 4) The thick plate portion protrudes from the thin plate portion in a rectangular or trapezoidal shape when viewed in cross-section. A heat exchanger as described in any one of the notes 1 to 3. (Note 5) The aforementioned thick plate portion protrudes triangularly from the aforementioned thin plate portion in cross-sectional view. A heat exchanger as described in any one of the notes 1 to 3. (Note 6) The aforementioned thick plate portion protrudes semicircularly from the aforementioned thin plate portion in cross-sectional view. A heat exchanger as described in any one of the notes 1 to 3. (Note 7) The thick plate portion and the thin plate portion extend in the direction of the arrangement of the heat transfer tubes. A heat exchanger as described in any one of the notes 1 through 6. (Note 8) The thick plate portion and the thin plate portion extend in a direction perpendicular to the arrangement direction of the heat transfer tubes. A heat exchanger as described in any one of the notes 1 through 7. (Note 9) The thick plate portion and the thin plate portion extend in a direction inclined with respect to the arrangement direction of the heat transfer tubes. A heat exchanger as described in any one of the notes 1 through 7. (Note 10) The fin has a corrugated shape in which peaks and valleys are arranged in the direction of the tube axis. A heat exchanger as described in any one of the notes 1 through 9. (Note 11) A rolling process to produce a fin plate member having a thick plate portion and a thin plate portion adjacent to the thick plate portion, wherein at least one of the rolls has a convex portion and a recess adjacent to the convex portion on its outer surface, and the pair of rolls are rotated to roll the metal plate, thereby producing a fin plate member having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, and having the thick plate portion and the thin plate portion, such that at least one of the plate surfaces is uneven and the thick plate portion is formed at the end, A fin molding process for forming corrugated fins from the fin plate member, The process of assembling the fins to the heat transfer tubes involves arranging multiple heat transfer tubes perpendicular to their respective axis directions with their axis directions parallel to each other, and inserting the fins between the multiple heat transfer tubes. Equipped with, In the step of assembling the fins to the heat transfer tubes, the end of the fin where the thick plate portion is formed is made to protrude beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the arrangement direction of the heat transfer tubes. A method for manufacturing a heat exchanger. (Note 12) In the rolling process, the pair of rolls roll the metal plate to form the fin plate member having minute linear grooves. The aforementioned minute linear grooves extend in the feeding direction in which the pair of rolls rotate to feed the metal plate. A method for manufacturing a heat exchanger as described in Appendix 11. (Note 13) The aforementioned metal plate has the shape of a strip, In the rolling process, the pair of rolls rotate to feed the metal sheet, and the direction in which the strip of the metal sheet extends is oriented in the feeding direction, thereby producing the strip-shaped fin plate member. In the fin forming process, the fin plate member is bent in the direction in which the strip extends to produce the corrugated fin. A method for manufacturing a heat exchanger as described in Appendix 11 or 12.

[0087] This disclosure allows for various embodiments and modifications without departing from the broad spirit and scope of this disclosure. Furthermore, the embodiments described above are for illustrative purposes only and do not limit the scope of this disclosure. In other words, the scope of this disclosure is indicated by the claims, not by the embodiments. Various modifications made within the scope of the claims and the equivalent significance of the disclosure are considered to be within the scope of this disclosure.

[0088] This application is based on Japanese Patent Application No. 2023-51942, filed on 28 March 2023. The entire specification, claims, and drawings of Japanese Patent Application No. 2023-51942 are incorporated herein by reference. [Explanation of symbols]

[0089] 1A,1B Heat exchanger, 2 Heat transfer tube, 3A,3B Fin, 4 Strip metal plate, 5 Plate member, 6 Semi-finished fin, 7-10 Concave and concave, 11,12 Header, 30 Protruding part, 31 Peak part, 32 Top part, 33 Valley part, 34 Bottom part, 35 Thick plate part, 36 Thin plate part, 37,38 Convex part, 39 Cut and bevel part, 40 Fin forming device, 41 Coil, 42 Uncoiler, 43 Dancer roll, 44 Tension controller, 45 Rolling roll, 46 Forming roll, 47 Pitch adjustment roll, 48 Pitch adjustment roll, 49 Hump unit, 50 Counting worm, 51 Cutter unit, 57,58 Concave, 59 Thick plate part, 60 Rolling device, 61 Coil, 62 Uncoiler, 63 Dancer roll, 65 Rolling rolls, 66 recoilers, D1 axial direction of pipe, D2 feed direction, W1, W2 width, CL1, CL2 centerline.

Claims

1. A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, among the thick plate portion and the thin plate portion. The aforementioned thick plate portion is provided on the fin from the protruding portion to the portion sandwiched in the heat transfer tube, and is joined to the heat transfer tube at the portion sandwiched in the heat transfer tube. heat exchanger.

2. A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, among the thick plate portion and the thin plate portion. The aforementioned thick plate portion protrudes triangularly from the aforementioned thin plate portion in cross-sectional view. heat exchanger.

3. A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, among the thick plate portion and the thin plate portion. The aforementioned thick plate portion protrudes semicircularly from the aforementioned thin plate portion in cross-sectional view. heat exchanger.

4. A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, among the thick plate portion and the thin plate portion. The thick plate portion and the thin plate portion extend in the direction of the arrangement of the heat transfer tubes. heat exchanger.

5. A fin having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, wherein at least one of the plate surfaces is uneven due to the adjacent thick plate portion and thin plate portion, Multiple heat transfer tubes are arranged perpendicular to the tube axes, with their tube axes parallel to each other, and the fins are sandwiched between them. Equipped with, The fin has a portion that protrudes beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the direction of arrangement of the heat transfer tubes. The protruding portion of the fin is provided with at least the thick plate portion, among the thick plate portion and the thin plate portion. The thick plate portion and the thin plate portion extend in a direction inclined with respect to the arrangement direction of the heat transfer tubes. heat exchanger.

6. The protruding portion of the fin is provided with both the thick plate portion and the thin plate portion. A heat exchanger according to any one of claims 1 to 5.

7. The thick plate portion protrudes from the thin plate portion in a rectangular or trapezoidal shape when viewed in cross-section. A heat exchanger according to any one of claims 1, 4, or 5.

8. The thick plate portion and the thin plate portion extend in a direction perpendicular to the arrangement direction of the heat transfer tubes. A heat exchanger according to any one of claims 1 to 5.

9. The fin has a corrugated shape in which peaks and valleys are arranged in the direction of the tube axis. A heat exchanger according to any one of claims 1 to 5.

10. A rolling step to produce a fin plate member having a thick plate portion and a thin plate portion adjacent to the thick plate portion, wherein at least one of the rolls has a convex portion and a recess adjacent to the convex portion on its outer surface, and the pair of rolls are rotated to roll the metal plate, the fin plate member having a thick plate portion and a thin plate portion that is thinner than the thick plate portion and adjacent to the thick plate portion, and having the thick plate portion and the thin plate portion, at least one of the plate surfaces is uneven and the thick plate portion is formed at the end, A fin molding process for forming corrugated fins from the fin plate member, The process of assembling the fins to the heat transfer tubes involves arranging multiple heat transfer tubes so that their tube axes are parallel to each other and perpendicular to the tube axes, and inserting the fins between the multiple heat transfer tubes, Equipped with, In the step of assembling the fins to the heat transfer tubes, the ends of the fins on which the thick plate portion is formed are made to protrude beyond the plurality of heat transfer tubes in at least one direction perpendicular to the tube axis and the arrangement direction of the heat transfer tubes. In the rolling process, the pair of rolls roll the metal plate to form the fin plate member having minute linear grooves. The aforementioned minute linear grooves extend in the feeding direction in which the pair of rolls rotate to feed the metal plate. A method for manufacturing a heat exchanger.

11. The aforementioned metal plate has the shape of a strip, In the rolling process, the pair of rolls rotate to feed the metal sheet, and the direction in which the strip of the metal sheet extends is oriented in the feeding direction, thereby producing the strip-shaped fin plate member. In the fin forming process, the fin plate member is bent in the direction in which the strip extends to produce the corrugated fin. A method for manufacturing a heat exchanger according to claim 10.

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