Heat exchanger, method for manufacturing a heat exchanger
Ultrasonic bonding of comb-like channels in heat exchangers addresses the challenge of reducing carbon dioxide emissions and maintaining heat transfer performance by eliminating brazing and resin adhesives, enabling efficient and environmentally friendly manufacturing.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- DENSO CORP
- Filing Date
- 2022-05-19
- Publication Date
- 2026-05-11
AI Technical Summary
Conventional heat exchangers face challenges in reducing carbon dioxide emissions during manufacturing while maintaining heat transfer performance, as brazing methods used for joining plate members are energy-intensive and resin adhesives with low heat transfer rates compromise efficiency.
The heat exchanger employs ultrasonic bonding to join plate members, forming comb-like channels for fluid flow, eliminating the need for brazing and resin adhesives, thereby reducing carbon dioxide emissions and ensuring effective heat exchange.
This configuration ensures heat exchange performance while minimizing carbon dioxide emissions by using ultrasonic bonding, allowing for the use of recycled materials and low-melting-point alloys, and enhancing production efficiency.
Smart Images
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Abstract
Description
Technical Field
[0001] The present disclosure relates to a heat exchanger and a method for manufacturing the heat exchanger.
Background Art
[0002] Conventionally, there is a heat exchanger described in Patent Document 1 below. The heat exchanger described in Patent Document 1 includes a plurality of plate members arranged in a stacked manner. Between the plurality of plate members, a flat refrigerant passage for refrigerant and a flat heat medium passage for heat medium are formed. In this heat exchanger, heat exchange is performed between the refrigerant flowing through the refrigerant passage and the heat medium flowing through the heat medium flow path.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In a heat exchanger as described in Patent Document 1, in the manufacturing process, a plurality of plate members are joined by brazing. Since brazing has a large energy consumption, the amount of carbon dioxide emissions tends to increase. In recent years, in order to suppress global warming, efforts to reduce the emissions of carbon dioxide (CO₂) have been promoted in various fields. Therefore, it is desirable to minimize the carbon dioxide emissions during the manufacture of the heat exchanger. As one method of reducing energy consumption, a method of joining the plate members using, for example, a resin adhesive can be considered. However, when a plurality of plate members are joined by a resin adhesive in a heat exchanger as described in Patent Document 1, there is a concern that the heat transfer performance will be significantly reduced because a resin with a low heat transfer rate will exist in the heat dissipation path.
[0005] This disclosure has been made in view of these circumstances, and its purpose is to provide a heat exchanger that can reduce carbon dioxide emissions while ensuring heat exchange performance, and a method for manufacturing the same. [Means for solving the problem]
[0006] The heat exchanger (10) that solves the above problem is, The device comprises a core portion (20) including a plurality of plate members (21) stacked in a predetermined direction and ultrasonically bonded, and end joining members (30, 90) ultrasonically bonded to the ends of the core portion in a predetermined direction, wherein the plate members are formed with a first channel (W10) through which a first fluid flows and a second channel (W20) through which a second fluid flows, separated by a partition wall (212), and the partition walls formed on each of the plurality of plate members are stacked continuously in a predetermined direction, and the end joining members are provided with a first common channel (W13, W14) that communicates with the first channel formed on each of the plurality of plate members and a second common channel (W23, W24) that communicates with the second channel formed on each of the plurality of plate members, and the first channel and the second channel are formed in a comb-like shape on the plate members. The first channel (W10) has a first inflow channel section (W101) formed to extend in the left-right direction and a plurality of first branch channel sections (W102) branching off from the first inflow channel section, the second channel (W20) has a second inflow channel section (W201) formed to extend in the left-right direction and a plurality of second branch channel sections (W202) branching off from the second inflow channel section, the first branch channel sections and second branch channel sections are arranged alternately on the plate member, the plurality of first inflow channel sections (W101) and the plurality of first branch channel sections (W102) are in communication in a predetermined direction, the plurality of second inflow channel sections (W201) and the plurality of second branch channel sections (W202) are in communication in a predetermined direction, and the plurality of partition walls (212) are continuously stacked in a predetermined direction and ultrasonically bonded Yes, they are.
[0007] A method for manufacturing a heat exchanger that solves the above problems is: A plurality of plate members (21) are arranged such that the plurality of first branch channel sections and the plurality of second branch channel sections are alternately arranged, and the plurality of first branch channel sections (W102) are arranged in a comb-like manner and extend in the left-right direction, and the first channel (W10) through which the first fluid flows, and the first channel (W10) through which the first fluid flows, and the first channel (W20) through which the second fluid flows, which is arranged in a comb-like manner and extends in the left-right direction, and the plurality of second branch channel sections (W202) are arranged in a comb-like manner and extend in the left-right direction, and the plurality of first branch channel sections (W20) through which the second fluid flows, and the plurality of first branch channel sections and the plurality of second branch channel sections (W20) are alternately arranged, separated by a partition wall (212), and the plurality of first branch channel sections (W101) and the plurality of first branch channel sections (W102) are arranged in the stacking direction The process involves stacking partitions so that each partition wall is continuous in the stacking direction so that multiple second inflow channel sections (W201) and multiple second branch channel sections (W202) communicate in the stacking direction so that they communicate in (Z), and forming a core section (20) by applying ultrasonic vibration while applying a compressive force in the stacking direction to perform ultrasonic bonding; and stacking end joining members (30) on one end of the core section, each having first common channels (W13, W14) that communicate with first channels formed in each of the multiple plate members, and second common channels (W23, W24) that communicate with second channels formed in each of the multiple plate members, and applying ultrasonic vibration while applying a compressive force in the stacking direction to perform ultrasonic bonding. , including.
[0008] As in this configuration, if the partition walls formed on each of the multiple plate members are continuously stacked in a predetermined direction, these partition walls can be joined by ultrasonic bonding. Furthermore, after forming the core by joining the multiple plate members in this manner, end joining members can be further joined to the core by ultrasonic bonding. Thus, with the above configuration, since the multiple plate members and end joining members can be joined by ultrasonic bonding, carbon dioxide emissions can be reduced compared to joining by brazing. In addition, since there are no materials with low heat transfer coefficients such as resin adhesives between the multiple plate members, heat exchange performance can be ensured.
[0009] The symbols in parentheses in the above means and claims are examples that indicate the correspondence with the specific means described in the embodiments described later. [Effects of the Invention]
[0010] According to the heat exchanger and its manufacturing method described herein, it is possible to ensure heat exchange performance while reducing carbon dioxide emissions. [Brief explanation of the drawing]
[0011] [Figure 1] Figure 1 is a front view showing the front structure of the heat exchanger according to the first embodiment. [Figure 2]Figure 2 is a plan view showing the planar structure of the heat exchanger according to the first embodiment. [Figure 3] Figure 3 is a plan view showing the planar structure of the first core plate member of the first embodiment. [Figure 4] Figure 4 is a cross-sectional view showing the cross-sectional structure along the line IV-IV in Figure 2. [Figure 5] Figure 5 is a cross-sectional view showing the cross-sectional structure along the VV line in Figure 2. [Figure 6] Figure 6 is a cross-sectional view showing the cross-sectional structure along the line VI-VI in Figure 2. [Figure 7] Figure 7 is a plan view showing the planar structure of the second core plate member of the first embodiment. [Figure 8] Figure 8 is a plan view showing the planar structure of the first upper end plate member of the first embodiment. [Figure 9] Figure 9 is a plan view showing the planar structure of the second upper end plate member of the first embodiment. [Figure 10] Figure 10 is a cross-sectional view showing the cross-sectional structure along line XX in Figure 2. [Figure 11] Figure 11 is a cross-sectional view showing the cross-sectional structure along the line XI-XI in Figure 2. [Figure 12] Figures 12(A) to (C) are cross-sectional views showing the manufacturing process of the heat exchanger according to the first embodiment. [Figure 13] Figure 13 is a front view showing the front structure of the heat exchanger according to the second embodiment. [Figure 14] Figure 14 is a plan view showing the planar structure of the heat exchanger according to the second embodiment. [Figure 15] Figure 15 is a plan view showing the planar structure of the second core plate member of the second embodiment. [Figure 16] Figure 16 is a plan view showing the planar structure of the third core plate member of the second embodiment. [Figure 17] Figure 17 is a plan view showing the planar structure of the first upper end plate member of the second embodiment. [Figure 18] Figure 18 is a plan view showing the planar structure of the second upper end plate member of the second embodiment. [Figure 19] FIG. 19 is a plan view showing the planar structure of the first lower end plate member of the second embodiment. [Figure 20] FIG. 20 is a plan view showing the planar structure of the second lower end plate member of the second embodiment. [Figure 21] FIG. 21 is a cross-sectional view showing the cross-sectional structure along line XXI-XXI of FIG. 14. [Figure 22] FIG. 22 is a cross-sectional view showing the cross-sectional structure along line XXII-XXII of FIG. 14.
MODE FOR CARRYING OUT THE INVENTION
[0012] Hereinafter, an embodiment of a heat exchanger and a method for manufacturing the same will be described with reference to the drawings. For ease of understanding of the description, the same reference numerals are given to the same components in each drawing as much as possible, and duplicate descriptions are omitted. <First Embodiment> First, the heat exchanger of the first embodiment will be described. The heat exchanger 10 of the present embodiment shown in FIGS. 1 and 2 is a device capable of performing heat exchange between a first fluid and a second fluid flowing inside. As shown in FIG. 1, the heat exchanger 10 includes a core portion 20 and an upper end joining member 30. The core portion 20 and the upper end joining member 30 are formed of a metal material such as an aluminum alloy.
[0013] As shown in FIG. 2, a first inflow pipe 40, a first outflow pipe 41, a second inflow pipe 50, and a second outflow pipe 51 are provided on the upper surface of the heat exchanger 10. The first inflow pipe 40 is a portion where the first fluid flows in. The first outflow pipe 41 is a portion where the first fluid that has flowed inside the heat exchanger 10 flows out. The second inflow pipe 50 is a portion where the second fluid flows in. The second outflow pipe 51 is a portion where the second fluid that has flowed inside the heat exchanger 10 flows out.
[0014] As shown in Figure 1, the core portion 20 has a plurality of first core plate members 21, a second core plate member 22, and a third core plate member 23. These core plate members 21 to 23 are stacked and joined in the direction indicated by the arrow Z in the figure. In the following, the direction indicated by arrow Z will also be referred to as the plate stacking direction Z. Furthermore, within the plate stacking direction Z, the direction indicated by arrow Z1 in Figures 1 and 2 will also be referred to as upward, and the direction indicated by arrow Z2 will also be referred to as downward. In addition, the short-side direction X of the heat exchanger 10 shown in Figure 2 will also be referred to as the left-right direction. In this embodiment, the plate stacking direction Z corresponds to a predetermined direction.
[0015] Figure 3 shows the planar structure of the first core plate member 21. As shown in Figure 3, the first core plate member 21 is formed in the shape of a rectangular plate. The first core plate member 21 has a comb-shaped first channel W10 and a comb-shaped second channel W20 that penetrate through it in the thickness direction. The first fluid flows through the first channel W10. The second fluid flows through the second channel W20.
[0016] The first flow path W10 includes an inflow flow path section W101 formed to extend in the left-right direction along the back surface 211 of the first core plate member 21, and an inflow flow path section W101 It has multiple branched channel sections W102 that branch off from the first channel W10. The multiple branched channel sections W102 are formed to extend from the back surface 211 toward the front surface 210 of the first core plate member 21. In this embodiment, the branched channel sections W102 correspond to multiple channel sections that extend in a branch-like manner in the first channel W10.
[0017] The second flow path W20 has an inflow flow path section W201 formed to extend in the left-right direction along the front surface 210 of the first core plate member 21, and a plurality of branch flow path sections W202 that branch off from the inflow flow path section W201. The plurality of branch flow path sections W202 are formed to extend from the front surface 210 toward the back surface 211 of the first core plate member 21. In this embodiment, the branch flow path sections W202 correspond to a plurality of flow path sections that extend in a branch-like manner in the second flow path W20.
[0018] In the first core plate member 21, branch channel sections W102 of the first channel W10 and branch channel sections W202 of the second channel W20 are arranged alternately in the left-right direction. The first core plate member 21 has partition walls 212 that separate the multiple branch channel sections W102 of the first channel W10 and the multiple branch channel sections W202 of the second channel W20.
[0019] Figure 4 shows the cross-sectional structure along the line IV-IV in Figure 2. Figure 5 shows the cross-sectional structure along the line VV in Figure 2. Figure 6 shows the cross-sectional structure along the line VI-VI in Figure 2. As shown in Figures 4 to 6, the inflow channel section W101 and branch channel section W102 of the first channel W10 of each of the multiple first core plate members 21 are in communication in the plate stacking direction Z, and the inflow channel section W201 and branch channel section W202 of the second channel W20 of each of the multiple first core plate members 21 are also in communication in the plate stacking direction Z. Furthermore, the partition walls 212 of each of the multiple first core plate members 21 are continuously stacked and joined in the plate stacking direction Z.
[0020] As shown in Figure 1, the second core plate member 22 is joined to the upper surface of the first core plate member 21, which is positioned at the top of the plurality of first core plate members 21. Figure 7 shows the planar structure of the second core plate member 22. As shown in Figure 7, the second core plate member 22 is also formed in a rectangular plate shape, similar to the first core plate member 21. The second core plate member 22 is formed so that the inflow channel section W11, a plurality of outflow holes W22, a plurality of outflow holes W12, and the inflow channel section W21 penetrate through it in the thickness direction.
[0021] The inflow channel section W11 is formed to extend in the left-right direction along the back surface 221 of the second core plate member 22. Multiple outflow holes W22 are provided inside the inflow channel section W11 and are arranged at predetermined intervals in the left-right direction. The inflow channel section W11 communicates with the inflow channel section W101 of the first core plate member 21 shown in Figure 3. Multiple outflow holes W12 communicate with the respective ends of multiple branch channel sections W202 of the first core plate member 21 shown in Figure 3.
[0022] As shown in Figure 7, the inflow channel section W21 is formed to extend in the left-right direction along the front surface 220 of the second core plate member 22. Multiple outflow holes W12 are provided inside the inflow channel section W21 and are arranged at predetermined intervals in the left-right direction. The inflow channel section W21 communicates with the inflow channel section W201 of the first core plate member 21 shown in Figure 3. Multiple outflow holes W12 communicate with the respective ends of multiple branch channel sections W102 of the first channel W10 of the first core plate member 21 shown in Figure 3.
[0023] As shown in Figure 1, the third core plate member 23 is joined to the bottom surface of the first core plate member 21 that is positioned at the bottom of the plurality of first core plate members 21. The third core plate member 23 is also formed in a rectangular plate shape, similar to the first core plate member 21 and the second core plate member 22. Unlike the first core plate member 21 and the second core plate member 22, the third core plate member 23 is a flat plate-shaped member in which no flow channels are formed. As shown in Figures 4 to 6, the lower ends of the inflow channel section W101 and branch channel section W102 of the first flow channel W10 formed in the plurality of first core plate members 21, and the lower ends of the inflow channel section W201 and branch channel section W202 of the second flow channel W20, are closed by the third core plate member 23.
[0024] As shown in Figure 1, the upper end joining member 30 has a first upper end plate member 31 and a second upper end plate member 32. These upper end plate members 31 and 32 are stacked and joined in the plate stacking direction Z. Figure 8 shows the planar structure of the first upper end plate member 31. As shown in Figure 8, the first upper end plate member 31 is formed in a rectangular plate shape, similar to the core plate members 21 to 23. The first upper end plate member 31 has a distribution tank section W13, a collection tank section W24, a collection tank section W14, and a distribution tank section W23 that penetrate through it in the thickness direction. In this embodiment, the distribution tank section W13 and the collection tank section W14 correspond to the first common flow path, and the distribution tank section W23 and the collection tank section W24 correspond to the second common flow path.
[0025] The distribution tank section W13 is formed to extend in the left-right direction along the back surface 311 of the first upper end plate member 31. The distribution tank section W13 is connected to the inflow channel section W11 of the second core plate member 22 shown in Figure 7. As shown in Figure 8, the collection tank section W24 is located inside the distribution tank section W13 and is formed to extend in the left-right direction. The collection tank section W24 communicates with a plurality of outflow holes W22 of the second core plate member 22 shown in Figure 7.
[0026] As shown in Figure 8, the distribution tank section W23 is formed to extend in the left-right direction along the front surface 310 of the first upper end plate member 31. The distribution tank section W23 is connected to the inflow channel section W21 of the second core plate member 22 shown in Figure 7. As shown in Figure 8, the collection tank section W14 is located inside the distribution tank section W23 and is formed to extend in the left-right direction. The collection tank section W14 is connected to a plurality of outflow holes W12 of the second core plate member 22 shown in Figure 7.
[0027] As shown in Figures 4 to 6, the first upper end plate member 31 is joined to the upper surface of the second core plate member 22. As a result, as shown in Figure 5, the upper ends of the intermediate portions of the branch channel sections W102 of the first channel W10 and the upper ends of the intermediate portions of the branch channel sections W202 of the second channel W20, which are formed in the plurality of first core plate members 21, are closed by the first upper end plate member 31.
[0028] Figure 9 shows the planar structure of the second upper end plate member 32. As shown in Figure 9, the second upper end plate member 32 is formed in a rectangular plate shape, similar to the core plate members 21-23 and the first upper end plate member 31. The second upper end plate member 32 has an inlet hole W15, an outlet hole W26, an outlet hole W16, and an inlet hole W25 that penetrate through it in the thickness direction.
[0029] The inlet W15 is located in a position that allows communication with the right end of the distribution tank section W13 shown in Figure 8. The outlet W26 is located in a position that allows communication with the left end of the manifold tank section W24 shown in Figure 8. The outlet W16 is located in a position that allows communication with the left end of the manifold tank section W14 shown in Figure 8. The inlet W25 is located in a position that allows communication with the right end of the distribution tank section W23 shown in Figure 8.
[0030] As shown by the dashed line in Figure 9, the upper surface of the second upper end plate member 32 is provided with a first inlet pipe 40 that communicates with the inlet hole W15, and a second outlet pipe 51 that communicates with the outlet hole W26. Furthermore, the upper surface of the second upper end plate member 32 is provided with a first outlet pipe 41 that communicates with the outlet hole W16, and a second inlet pipe 50 that communicates with the inlet hole W25.
[0031] Next, an example of the operation of the heat exchanger 10 in this embodiment will be described. In this heat exchanger 10, a first fluid flows into the first inlet pipe 40 through piping connected to the first inlet pipe 40. As shown in Figure 4, the first fluid that has flowed into the first inlet pipe 40 flows into the inlet channel W101 of the first channel W10 of each first core plate member 21 through the inlet hole W15 of the second upper end plate member 32, the distribution tank section W13 of the first upper end plate member 31, and the inlet channel section W11 of the second core plate member 22. As shown in Figure 3, the first fluid that has flowed into the inlet channel W101 of the first channel W10 of each first core plate member 21 is distributed into a plurality of branch channel sections W102 of the first channel W10, and then flows from one end to the other of the branch channel section W102 in the direction indicated by arrow D1.
[0032] Figure 10 shows the cross-sectional structure along line XX in Figure 2. As shown in Figure 10, the first fluid that has flowed to the other end of the branched flow channel section W102 of the first flow channel W10 of each first core plate member 21 is collected in the collection tank section W14 of the first upper end plate member 31 through multiple outlet holes W12 of the second core plate member 22. The first fluid collected in the collection tank section W14 of the first upper end plate member 31 flows out through the outlet hole W16 of the second upper end plate member 32 and the first outlet pipe 41 to the piping connected to the first outlet pipe 41.
[0033] Meanwhile, in the heat exchanger 10, the second fluid flows into the second inlet pipe 50 through piping connected to the second inlet pipe 50. As shown in Figure 6, the second fluid that has flowed into the second inlet pipe 50 flows into the inlet channel W201 of the second flow path W20 of each first core plate member 21 through the inlet hole W25 of the second upper end plate member 32, the distribution tank section W23 of the first upper end plate member 31, and the inlet channel section W21 of the second core plate member 22. As shown in Figure 3, the second fluid that has flowed into the inlet channel section W201 of the second flow path W20 of each first core plate member 21 is distributed into a plurality of branched channel sections W202 of the second flow path W20, and then flows from one end to the other of the branched channel section W202 in the direction indicated by arrow D2.
[0034] Figure 11 shows the cross-sectional structure along the line XI-XI in Figure 2. As shown in Figure 11, the second fluid that has flowed to the other end of the branched channel section W202 of the second channel W20 of each first core plate member 21 is collected in the collection tank section W24 of the first upper end plate member 31 through multiple outlet holes W22 of the second core plate member 22. The second fluid collected in the collection tank section W24 of the first upper end plate member 31 flows out through the outlet hole W26 and the second outlet pipe 51 of the second upper end plate member 32 to the piping connected to the second outlet pipe 51.
[0035] In this heat exchanger 10, as shown in Figure 3, the first fluid flowing through the branch channel section W102 of the first flow path W10 and the second fluid flowing through the branch channel section W202 of the second flow path W20 can exchange heat via the partition wall 212. Next, the manufacturing method of the heat exchanger 10 of this embodiment will be described.
[0036] When manufacturing the heat exchanger 10, first, a plurality of first core plate members 21, a second core plate member 22, and a third core plate member 23 are stacked and arranged as shown in Figure 12(A). As a result, as shown in Figure 12(A), the outer peripheral walls 213 and partition walls 212 of each of the plurality of first core plate members 21 are stacked in the plate stacking direction Z. Furthermore, the upper surface of the second core plate member 22 is in contact with the bottom surface of the outer peripheral wall 213 and partition wall 212 of the first core plate member 21 that is positioned at the bottom of the lowermost of the plurality of first core plate members 21. In addition, the bottom surface of the third core plate member 23 is in contact with the upper surface of the outer peripheral wall 213 and partition wall 212 of the first core plate member 21 that is positioned at the top of the plurality of first core plate members 21.
[0037] Next, ultrasonic bonding is performed on the laminate shown in Figure 12(A). Specifically, first, a compressive force is applied to the laminate in the plate stacking direction Z, as indicated by arrows A11 and A12, using a predetermined jig. At this time, the second core plate member 22, the partition walls 212 and outer peripheral walls 213 of the multiple first core plate members 21, and the third core plate member 23 are stacked in the plate stacking direction Z, so a load is applied to them. By applying ultrasonic vibration to the laminate in this state, the second core plate member 22, the partition walls 212 and outer peripheral walls 213 of the multiple first core plate members 21, and the third core plate member 23 are bonded together. This completes the molding of the core portion 20.
[0038] Furthermore, the first upper end plate member 31 and the second upper end plate member 32 are stacked and arranged as shown in Figure 12(B). As a result, as shown in Figure 12(B), the first upper end plate member 31 and the second upper end plate member 32 are stacked in the plate stacking direction Z, except for the portion where the flow path is formed.
[0039] Next, ultrasonic bonding is performed on the laminate shown in Figure 12(B). Specifically, first, a compressive force is applied to the laminate in the plate stacking direction Z, as indicated by arrows A13 and A14, using a predetermined jig. At this time, since the first upper end plate member 31 and the second upper end plate member 32 are stacked in the plate stacking direction Z, a load is applied to them. By applying ultrasonic vibration to the laminate in this state, the first upper end plate member 31 and the second upper end plate member 32 are bonded together. This completes the molding of the upper end bonding member 30 shown in Figure 12(B).
[0040] Next, the molded core portion 20 shown in Figure 12(A) and the molded upper end joining member 30 shown in Figure 12(B) are ultrasonically bonded. Specifically, as shown in Figure 12(C), the molded core portion 20 and the molded upper end joining member 30 are stacked, and then a compressive force is applied in the plate stacking direction Z as indicated by arrows A15 and A16. In this state, ultrasonic vibrations are applied to the stacked body shown in Figure 12(C) to bond the molded core portion 20 and the molded upper end joining member 30.
[0041] According to the heat exchanger 10 of this embodiment described above, the following operations and effects can be obtained (1) to (5). (1) The heat exchanger 10 includes a core portion 20 which includes a plurality of first core plate members 21 that are stacked and joined in the plate stacking direction Z, and an upper end joining member 30 which is joined to the end of the core portion 20 in the plate stacking direction Z. The first core plate members 21 have a first flow path W10 through which a first fluid flows and a second flow path W20 through which a second fluid flows, separated by a partition wall 212. The partition walls 212 formed in each of the plurality of first core plate members 21 are stacked continuously in the plate stacking direction Z. The upper end joining member 30 is provided with a distribution tank portion W13 and a collection tank portion W14 which are in communication with the first flow path W10 formed in each of the plurality of first core plate members 21, and a distribution tank portion W23 and a collection tank portion W24 which are in communication with the second flow path W20 formed in each of the plurality of first core plate members 21. With this configuration, the core plate members 21-23 and the upper end plate members 31, 32 can be joined by ultrasonic bonding. Ultrasonic bonding reduces carbon dioxide emissions compared to brazing. Furthermore, since no materials with low heat transfer coefficients, such as resin adhesives, are placed between the core plate members 21-23 and the upper end plate members 31 and 32, heat exchange performance can be ensured. Additionally, since the tank sections W13, W14, W23, and W24 can be integrally molded with the core section 20, production efficiency can be increased.
[0042] (2) In order to significantly reduce carbon dioxide emissions, it is effective to use recycled aluminum alloy in heat exchangers as well. However, if recycled material is used for brazing, the flux may not function properly. In other words, when using a manufacturing method that joins multiple plate members by brazing, as in conventional heat exchangers, it is difficult to use recycled aluminum alloy. In this respect, the heat exchanger 10 of this embodiment does not require brazing, so it is possible to use recycled aluminum alloy. Furthermore, if ultrasonic bonding can be used as in the heat exchanger 10 of this embodiment, the manufacturing process does not involve exposure to high temperatures of 300°C or higher, so it is possible to use low-melting-point aluminum alloys that contain many impurities. As a low-melting-point aluminum alloy containing many impurities, for example, it is possible to use secondary aluminum ingots that produce less carbon dioxide. Thus, the heat exchanger 10 of this embodiment can use materials that produce less carbon dioxide, and therefore it is possible to reduce carbon dioxide emissions.
[0043] (3) The partition walls 212 of each of the multiple first core plate members 21 are stacked continuously without gaps in the plate stacking direction Z. With this configuration, it is easier to apply compressive force to each of the partition walls 212 of the multiple first core plate members 21 during ultrasonic bonding, thereby enabling more reliable bonding of the multiple first core plate members 21.
[0044] (4) The upper end joining member 30 has a distribution tank section W13, a collection tank section W14, a distribution tank section W23, and a collection tank section W24. The distribution tank section W13 is connected to one end of the first flow path W10 formed in each of the multiple first core plate members 21. The collection tank section W14 is connected to the other end of the first flow path W10 formed in each of the multiple first core plate members 21. The distribution tank section W23 is connected to one end of the second flow path W20 formed in each of the multiple first core plate members 21. The collection tank section W24 is connected to the other end of the second flow path W20 formed in each of the multiple first core plate members 21. With this configuration, as shown in Figure 1, it is possible to arrange all of the pipes 40, 41, 50, and 51 at one end of the heat exchanger 10.
[0045] (5) The first core plate member 21 has alternately arranged branch channel sections W102 of the first channel W10 and branch channel sections W202 of the second channel W20. With this configuration, heat exchange can be easily performed between the first fluid flowing through the first channel W10 and the second fluid flowing through the second channel W20, thereby improving heat exchange performance.
[0046] <Second Embodiment> Next, the heat exchanger 10 of the second embodiment will be described. The following description will focus on the differences from the heat exchanger 10 of the first embodiment. As shown in Figures 13 and 14, the heat exchanger 10 of this embodiment differs from the heat exchanger 10 of the first embodiment in that the first outlet pipe 41 and the second inlet pipe 50 are provided on the bottom surface.
[0047] As shown in Figure 15, the second core plate member 22 of this embodiment does not have a plurality of outflow holes W12 and inflow channel W21, which is clear when compared to the second core plate member 22 of the first embodiment shown in Figure 7. As shown in Figure 16, the third core plate member 23 of this embodiment is provided with a plurality of outflow holes W12 and inflow channel sections W21. The plurality of outflow holes W12 and inflow channel sections W21 are arranged in the same positions as the second core plate member 22 of the first embodiment shown in Figure 7.
[0048] As shown in Figure 17, the first upper end plate member 31 of this embodiment does not have a collection tank section W14 and a distribution tank section W23, which is clear when compared to the first upper end plate member 31 of the first embodiment shown in Figure 8. As shown in Figure 18, the second upper end plate member 32 of this embodiment does not have an outflow hole W16 and an inflow hole W25, which is clear when compared to the second upper end plate member 32 of the first embodiment shown in Figure 9.
[0049] As shown in Figures 13 and 14, the heat exchanger 10 of this embodiment includes a lower end joining member 90 that is joined to the bottom surface of the core portion 20. In this embodiment, the upper end joining member 30 corresponds to the first end joining member, and the lower end joining member 90 corresponds to the second end joining member. The lower end joining member 90 has a first lower end plate member 91 and a second lower end plate member 92. These lower end plate members 91 and 92 are stacked and joined in the plate stacking direction Z.
[0050] As shown in Figure 19, the first lower end plate member 91 is provided with a collection tank section W14 and a distribution tank section W23. The collection tank section W14 and the distribution tank section W23 are positioned in the same locations as the first upper end plate member 31 in the first embodiment shown in Figure 8. As shown in Figure 20, the second lower end plate member 92 is provided with an outflow hole W16 and an inflow hole W25. The outflow hole W16 and the inflow hole W25 are positioned in the same locations as the second upper end plate member 32 in the first embodiment shown in Figure 9. As shown by the dashed line in Figure 20, the bottom surface of the second lower end plate member 92 is provided with a first outflow pipe 41 that communicates with the outflow hole W16 and a second inflow pipe 50 that communicates with the inflow hole W25.
[0051] Next, an example of the operation of the heat exchanger 10 in this embodiment will be described. Figure 21 shows a cross-sectional structure along the line XX-XX in Figure 14. As shown in Figure 21, in the heat exchanger 10 of this embodiment, the first fluid that has flowed to the other end of the branched flow path W102 of the first flow path W10 of each first core plate member 21 is collected in the collection tank W14 of the first lower end plate member 91 through a plurality of outlet holes W12 of the third core plate member 23. The first fluid collected in the collection tank W14 of the first lower end plate member 91 flows out through the outlet hole W16 of the second lower end plate member 92 and the first outlet pipe 41 to piping connected to the first outlet pipe 41.
[0052] Furthermore, Figure 22 shows the cross-sectional structure along the line XXI-XXI in Figure 14. As shown in Figure 22, in the heat exchanger 10 of this embodiment, the second fluid flows into the second inlet pipe 50 through piping connected to the second inlet pipe 50. The second fluid that has flowed into the second inlet pipe 50 flows into the inlet channel W201 of the second channel W20 of each first core plate member 21 through the inlet hole W25 of the second lower end plate member 92, the distribution tank section W23 of the first lower end plate member 91, and the inlet channel section W21 of the third core plate member 23.
[0053] In the manufacturing process of the heat exchanger 10 of this embodiment, first, the core portion 20, the upper end joining member 30, and the lower end joining member 90 are each individually formed by ultrasonic bonding. Then, the molded core portion 20, the molded upper end joining member 30, and the molded lower end joining member 90 are joined together by ultrasonic bonding.
[0054] According to the heat exchanger 10 of this embodiment described above, the effects and benefits shown in (6) below can be obtained instead of the effects and benefits shown in (4) above. (6) The upper end joining member 30 has a distribution tank section W13 and a collection tank section W24 formed therein. The lower end joining member 90 has a collection tank section W14 and a distribution tank section W23 formed therein. With this configuration, as shown in Figure 13, it is possible to arrange the first inlet pipe 40 and the second outlet pipe 51 at the upper end of the heat exchanger 10, and the first outlet pipe 41 and the second inlet pipe 50 at the lower end of the heat exchanger 10.
[0055] <Other Embodiments> Furthermore, the above embodiment can also be implemented in the following form. The arrangement of each pipe 40, 41, 50, and 51 is not limited to the arrangement in the first embodiment and the arrangement in the second embodiment, and can be changed as appropriate.
[0056] This disclosure is not limited to the above-described examples. Modifications made to the above-described examples by those skilled in the art are also included within the scope of this disclosure, as long as they possess the features of this disclosure. The elements, their arrangement, conditions, shapes, etc., of each of the above-described examples are not limited to those exemplified and can be modified as appropriate. The elements of each of the above-described examples can be combined in different ways as appropriate, as long as no technical inconsistencies arise.
[0057] <Note> The features of this invention are as follows. The plate member has the first and second flow channels formed in a comb-like shape, and when a plurality of flow channels extending in a branch-like manner in the first flow channel are designated as the first branch flow channel section (W102), and a plurality of flow channels extending in a branch-like manner in the second flow channel are designated as the second branch flow channel section (W202), the plate member has the first branch flow channel section and the second branch flow channel section arranged alternately, according to any one of claims 1 to 4. [Explanation of Symbols]
[0058] W10: First channel W13: Distribution tank section (first common flow path) W14: Collective tank section (first common flow path) W20: Second channel W23: Distribution tank section (second common flow path) W24: Collective tank section (second common flow path) W102: Branch channel section (First branch channel section) W202: Branch channel section (Second branch channel section) 10: Heat exchanger 20: Core 21: First core plate member 30: Upper end joint member (first end joint member) 90: Lower end joint member (second end joint member) 212: Bulkhead
Claims
1. A core portion (20) including a plurality of plate members (21) stacked in a predetermined direction and ultrasonically bonded, The system comprises end joining members (30, 90) ultrasonically bonded to the ends of the core portion in the predetermined direction, The plate member is formed with a first channel (W10) through which a first fluid flows and a second channel (W20) through which a second fluid flows, separated by a partition wall (212). The partition walls formed on each of the multiple plate members are continuously stacked in the predetermined direction. The end joining member is provided with a first common channel (W13, W14) that communicates with the first channel formed in each of the multiple plate members, and a second common channel (W23, W24) that communicates with the second channel formed in each of the multiple plate members. The plate member has the first channel and the second channel formed in a comb-like shape. The first flow path (W10) has a first inflow flow path section (W101) formed to extend in the left-right direction, and a plurality of first branch flow path sections (W102) that branch off and extend from the first inflow flow path section. The second flow path (W20) has a second inflow flow path section (W201) formed to extend in the left-right direction, and a plurality of second branch flow path sections (W202) that branch off and extend from the second inflow flow path section. The plate member has the first branch channel section and the second branch channel section arranged alternately. The multiple first inflow channel sections (W101) and the multiple first branch channel sections (W102) are in communication in the predetermined direction. The multiple second inflow channel sections (W201) and the multiple second branch channel sections (W202) are in communication in the predetermined direction. Multiple partition walls (212) are continuously stacked in the predetermined direction and ultrasonically bonded. heat exchanger.
2. The end joining member (30) includes: The first common channel is formed as a common channel (W13) that communicates with one end of the first channel formed in each of the multiple plate members, and a common channel (W14) that communicates with the other end of the first channel formed in each of the multiple plate members, The second common channel includes a common channel (W23) that communicates with one end of the second channel formed in each of the multiple plate members, and a common channel (W24) that communicates with the other end of the second channel formed in each of the multiple plate members. The heat exchanger according to claim 1.
3. The end joining member comprises a first end joining member (30) joined to one end of the core portion in the predetermined direction, and a second end joining member (90) joined to the other end of the core portion in the predetermined direction. The first end joining member includes: As the first common channel, either a common channel (W13) that communicates with one end of the first channel formed in each of the multiple plate members, or a common channel (W14) that communicates with the other end of the first channel formed in each of the multiple plate members, As the second common channel, either a common channel (W23) that communicates with one end of the second channel formed in each of the multiple plate members, or a common channel (W24) that communicates with the other end of the second channel formed in each of the multiple plate members, is formed. The second end joining member has, As the first common channel, a common channel is formed which communicates with one end of the first channel formed in each of the multiple plate members, and a common channel is formed which communicates with the other end of the first channel formed in each of the multiple plate members, The second common channel is formed such that it is connected to one end of the second channel formed in each of the multiple plate members, and the other of the two common channels connected to the other end of the second channel formed in each of the multiple plate members. A heat exchanger according to claim 1 or 2.
4. A first channel (W10) through which a first fluid flows, comprising a first inflow channel section (W101) formed in a comb-like shape and extending in the left-right direction, and a plurality of first branch channel sections (W102) branching off and extending from the first inflow channel section, and a second channel (W20) through which a second fluid flows, comprising a second inflow channel section (W201) formed in a comb-like shape and extending in the left-right direction, and a plurality of second branch channel sections (W202) branching off and extending from the second inflow channel section, and separated by a partition wall (212), wherein a plurality of first branch channel sections and a plurality A process to form a core portion (20) by applying ultrasonic vibrations while applying a compressive force in the stacking direction and performing ultrasonic bonding, wherein a plurality of plate members (21) having a second branch channel section arranged alternately are stacked such that a plurality of the first inflow channel sections (W101) and a plurality of the first branch channel sections (W102) communicate in the stacking direction (Z), a plurality of the second inflow channel sections (W201) and a plurality of the second branch channel sections (W202) communicate in the stacking direction, and each of the partition walls is continuous in the stacking direction, and a core portion (20) is formed by ultrasonic bonding, The process includes stacking end joining members (30), each having first common channels (W13, W14) that communicate with the first channels formed in each of the multiple plate members, and second common channels (W23, W24) that communicate with the second channels formed in each of the multiple plate members, on one end of the core portion, and applying ultrasonic vibration while applying a compressive force in the stacking direction to perform ultrasonic bonding. A method for manufacturing a heat exchanger.