Cooler manufacturing method

Abstract

To provide a manufacturing method of a cooler, in which a coolant is hardly contaminated during use.SOLUTION: A manufacturing method of a cooler, for fixing a first metal plate, a metal material having an uneven structure, and a second metal plate by a convex part of the metal material, comprises a step of selectively bonding a flux to the convex part of the metal material. The manufacturing method of the cooler for fixing the first metal plate, the metal material having the uneven structure, and the second metal plate by the convex part of the metal material, comprises step of: scattering a powder like flux to an uneven surface of the metal material; fixing the first metal plate, the metal material, and the second metal plate to the convex part of the metal material after the scattering; and removing the flux bonded to a concave part by splaying gas to the concave part after the fixing.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] For example, as an automotive heat exchanger, a roll bond panel type cooler made of aluminum, which is lightweight and has excellent thermal conductivity, is adopted.

[0003] In such a method for manufacturing a cooler, a method of fixing metal plates to each other is employed. In the fixing, in order to promote the joining of the metal plates, a chemical agent called a flux for removing the oxide film formed on the surface of the metal plates may be used.

[0004] Patent Document 1 discloses "a method for applying a flux to a member to be brazed, wherein after heating the member, the flux mixture is adhered to the member, and the liquid component of the mixture is vaporized by the heat of the member brought about by the heating."

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the above conventional method for manufacturing a cooler, since the flux is applied to the entire surface of the metal plate, after the cooler is manufactured, the flux remains in the refrigerant flow path in the cooler, and there is a problem that the refrigerant is easily contaminated during use, such as increasing the electrical conductivity of the refrigerant. <000003>

[0007] Therefore, an object of the present invention is to provide a method for manufacturing a cooler that is difficult to contaminate the refrigerant during use. [Means for solving the problem]

[0008] The means for solving the above problems include the following embodiments. <1> A method for manufacturing a cooler comprising fixing a first metal plate, a metal material having an uneven structure, and a second metal plate using the protrusions of the metal material, A method for manufacturing a cooler, comprising the step of selectively attaching flux to the protrusions of the aforementioned metal material. <2> The step of selectively applying flux to the protrusions of the metal material is: A step of selectively applying a solvent to the protruding portion of the metal material, The process involves spraying flux onto the uneven surface of the aforementioned metal material, A step of removing flux adhering to the recess of the metal material, including, <1> A method for manufacturing a cooler as described above. <3> Furthermore, after the removal step, the process includes a step of fixing the first metal plate, the metal material, and the second metal plate with the protrusions of the metal material. <2> Manufacturing method of the cooler described above <4> A method for manufacturing a cooler comprising fixing a first metal plate, a metal material having an uneven structure, and a second metal plate using the protrusions of the metal material, The process involves spraying powdered flux onto the uneven surface of the metal material, After spraying, the first metal plate, the metal material, and the second metal plate are fixed together by the protrusions of the metal material. A step of removing the flux adhering to the recessed area by blowing gas into the recessed area after fixation, A method for manufacturing a cooler that includes [a specific component]. <5> The step of blowing gas into the recessed area after fixation to remove the flux adhering to the recessed area includes a step of pressurizing either the first metal plate or the second metal plate at a pressure of 0.1 kPa to 300 kPa in the thickness direction. <4> A method for manufacturing a cooler as described above. [Effects of the Invention]

[0009] According to the present invention, a method for manufacturing a cooler that is less likely to contaminate the refrigerant during use is provided. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a schematic process diagram showing an example of a method for manufacturing a cooler according to the first aspect of the present invention. Figure 1(A) is a schematic diagram showing an example of a coating process in the method for manufacturing a cooler according to the first aspect of the present invention. Figure 1(B) is a schematic diagram showing an example of a spraying process in the method for manufacturing a cooler according to the first aspect of the present invention. Figure 1(C) is a schematic diagram showing an example of a removal process in the method for manufacturing a cooler according to the first aspect of the present invention. Figure 1(D) is a schematic diagram showing an example of a fixation process in the method for manufacturing a cooler according to the first aspect of the present invention. [Figure 2] Figure 2 is a schematic diagram showing an example of a removal step in a method for manufacturing a cooler according to a second aspect of the present invention. [Modes for carrying out the invention]

[0011] Embodiments of the present invention will be described below. The description is illustrative and does not limit the scope of the present invention.

[0012] In this specification, numerical ranges indicated using "~" represent a range that includes the numbers before and after "~" as the minimum and maximum values, respectively. In numerical ranges described stepwise within this specification, the upper or lower limit of one numerical range may be replaced with the upper or lower limit of another numerical range described stepwise. Furthermore, in numerical ranges described within this specification, the upper or lower limit of that range may be replaced with the values ​​shown in the examples.

[0013] In this specification, the term "process" includes not only independent processes but also processes that cannot be clearly distinguished from other processes, provided that their intended purpose is achieved.

[0014] In this specification, when embodiments are described with reference to the drawings, the configurations of the embodiments are not limited to the configurations shown in the drawings. Also, the sizes of the members in each drawing are conceptual, and the relative relationships of the sizes between the members are not limited thereto.

[0015] In this specification, each component may include a plurality of corresponding substances. When referring to the amounts of each component in a composition, if there are a plurality of substances corresponding to each component in the composition, unless otherwise specified, it means the total amount of the plurality of substances present in the composition.

[0016] In this specification, the term "alloy number" means "the alloy number defined in JIS H 4000:2014".

[0017] <Method for manufacturing a cooler> (First aspect) The method for manufacturing a cooler according to the first aspect of the present invention is to fix a first metal plate, a metal material having a concavo-convex structure, and a second metal plate at the convex portions of the metal material, and includes a step of selectively attaching a flux to the convex portions of the metal material (hereinafter, also referred to as the "attachment step"). By selectively attaching the flux to the convex portions, a cooler can be manufactured in a state where the flux is selectively attached to the convex portions of the metal material, so that a cooler that is difficult to contaminate the refrigerant during use can be obtained.

[0018] Hereinafter, the details of the method for manufacturing a cooler according to the first aspect of the present invention will be described.

[0019] - First metal plate and second metal plate - The first and second metal plates are flat metal materials. Examples of materials include aluminum or aluminum alloys. Examples of aluminum or aluminum alloys include pure Al (alloy number: 1000 series) such as 1050, 1100, and 1200; Al-Cu alloys (alloy number: 2000 series) such as 2011, 2014, 2017, and 2024; Al-Mn alloys (alloy number: 3000 series) such as 3003 and 3004; Al-Si alloys (alloy number: 4000 series) such as 4032 and 4545; Al-Mg alloys (alloy number: 5000 series) such as 5005, 5052, 5083, and 5454; Al-Mg-Si alloys (alloy number: 6000 series) such as 6061 and 6063; and Al-Zn alloys (alloy number: 7000 series) such as 7075. When the first and second metal plates are made of aluminum or an aluminum alloy, a plate-like body made of alloy number 3003 is preferred from the viewpoint of excellent formability, weldability, and corrosion resistance.

[0020] The dimensions of the first and second metal plates are not particularly limited, as long as they allow for the manufacture of the cooler. For example, they may be 600 mm x 300 mm.

[0021] The thicknesses of the first and second metal plates are not particularly limited, as long as the cooler can be manufactured. For example, they may be between 100 μm and 1000 μm.

[0022] -Metal material with an uneven surface- A metal material having an uneven structure is a metal material having an uneven structure in at least a part of it. For example, it may be a metal plate having an uneven structure in part or all of its in-plane direction. Preferably, the uneven structure is formed so that it can be fixed to the first metal plate and the second metal plate to manufacture a cooler, and so as to form a refrigerant flow path in the cooler when the cooler is manufactured. The uneven structure may be formed by press molding. As for the material, it may be the same as those exemplified for the first metal plate and the second metal plate.

[0023] The metal material having an uneven structure may also have a single-layer or multi-layer structure. When the metal material having an uneven structure is made of aluminum or an aluminum alloy, a clad material with a three-layer structure is preferred from the viewpoint of manufacturing a cooler by fixing it with a first metal plate and a second metal plate, consisting of a surface layer (e.g., 80 μm thick) made of Al-Si alloy alloy number 4545 (melting point: 577°C) acting as a brazing material, and a middle layer (e.g., 640 μm thick) made of alloy number 3003 (melting point: 643°C to 654°C).

[0024] The size of the metal material having an uneven surface is not particularly limited, as long as it can be used to manufacture a cooler. For example, it may be 600 mm x 300 mm.

[0025] The thickness of the metal material having an uneven structure is not particularly limited, as long as it allows for the manufacture of a cooler. For example, it may be between 100 μm and 1000 μm.

[0026] (Adhesion process) In the adhesion process, flux is selectively applied to the protruding parts of a metal material having an uneven structure. Methods of adhesion include coating (roll coating, etc.) and immersion. Selective application of flux to the protruding parts of the metal material means that it is preferable that the flux is applied only to the protruding parts of the uneven structure. The adhesion process preferably includes a step of selectively applying a solvent to the protruding parts of the metal material having an uneven structure (hereinafter also referred to as the "coating process"; see Figure 1(A)).

[0027] (Coating process) In the coating process, the solvent is selectively applied to the raised portions of the metal material having an uneven structure. The specific method of coating is not particularly limited, as long as the solvent can be selectively applied to the raised portions of the metal material. For example, it can be appropriately selected from known coating methods such as brushes or roll coaters.

[0028] -solvent- The solvent is used to improve the adhesion of the flux to the protrusions of the metal material. By applying the solvent to the protrusions, the flux adheres selectively to the protrusions, making it easier to obtain the desired condenser. Examples of solvents include organic solvents and water. Examples of organic solvents include methanol, ethanol, and acetone. The solvent is not particularly limited as long as it improves the adhesion of the flux, but among the examples, water is preferred because it has a relatively high boiling point and there is less concern that the solvent will vaporize and disappear before the flux adheres.

[0029] The adhesion process preferably includes a step of selectively applying a solvent to the protruding parts of the metal material (application step), followed by a step of spraying flux onto the uneven surface of the metal material (hereinafter also referred to as the "spraying step"; see Figure 1(B)), and a step of removing the flux sprayed onto the uneven surface of the metal material (hereinafter also referred to as the "removal step"; see Figure 1(C)). By including the spraying step and the removal step, the cooler can be manufactured with the flux selectively adhered to the protruding parts of the metal material having an uneven structure, making it easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0030] (Spraying process) In the spraying process, flux is sprayed onto the uneven surface of a metal material that has an uneven structure.

[0031] -Flux- Examples of fluxes to be sprayed include resin-based fluxes, organic fluxes, and inorganic fluxes. Examples of resin-based fluxes include rosin mainly composed of abietic acid, palastic acid, dehydroabietic acid, isopimal acid, neoabietic acid, and pima acid. Examples of organic acid-based fluxes include aliphatic carboxylic acids and aromatic carboxymethyl Examples of inorganic acid-based fluxes include ammonium bromide, ammonium chloride, and potassium aluminotetrafluoride (KAlF4). In particular, when the metal material is made of aluminum or an aluminum alloy, potassium aluminote (KAlF4) is preferred because it melts at high temperatures (546°C), exhibits strong activity, and is especially effective in removing oxide films (films of aluminum oxide (Al2O3)) formed on the surface of the metal material. Furthermore, since there is no concern that the flux's activity will be inhibited and it does not require the heat removal of binder resin or other materials prior to immobilization, it is preferable to use the flux in a standalone form. In addition, since the flux is easily removed in the removal process, it is preferable that it be in powder form.

[0032] When the flux is in powder form, the particle size of the flux is preferably 3 μm to 10 μm from the viewpoint of dispersibility and adhesion to the convex parts of the metal material to which the solvent is applied.

[0033] The method for applying flux to the uneven surface of a metal material is not particularly limited, as long as it allows for the flux to be applied to the uneven surface of the metal material. It can be applied using known application methods such as spray coating.

[0034] (Removal process) The removal process removes flux adhering to the recesses of metal materials having an uneven structure. The removal process may remove all of the flux adhering to the recesses, or it may remove only a portion of the flux. If only a portion is removed, it is preferable that the amount of flux remaining in the recesses is small from the viewpoint of preventing refrigerant contamination during use.

[0035] The removal is preferably carried out by blowing a gas. The gas is preferably air. The removal is preferably carried out at a wind speed of 1 m / s to 5 m / s, more preferably at a wind speed of 2 m / s to 5 m / s, and even more preferably at a wind speed of 3 m / s to 4 m / s. By removing the flux at a wind speed within the above range, the amount of flux required to manufacture the cooler can be selectively attached to the protrusions of the metal material, while less flux remains in the refrigerant flow path after the manufacture of the cooler, making it easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0036] A method for manufacturing a cooler according to the first aspect of the present invention preferably further includes, after the removal step described above, a step of fixing the first metal plate, the metal material, and the second metal plate with the protrusions of the metal material (hereinafter also referred to as the "fixation step"; see Figure 1(D)). Including the fixation step makes it easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0037] (immobilization process) In the fixing process, the first metal plate, the metal material, and the second metal plate are fixed together by the protrusions of the metal material.

[0038] The method of fixation is not particularly limited, as long as the first metal plate, the metal material, and the second metal plate can be fixed together by the protrusions of the metal material. When the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, fixation is preferably performed by brazing.

[0039] The fixation temperature is not particularly limited, as long as the first metal plate, the metal material, and the second metal plate can be fixed together by the protrusions of the metal material. When the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, the temperature is preferably 580°C to 630°C. The fixing time is not particularly limited, as long as the first metal plate, the metal material, and the second metal plate can be fixed together by the protrusions of the metal material. The fixing method is not particularly limited, as long as the first metal plate, the metal material, and the second metal plate can be fixed together by the protrusions of the metal material. If the first metal plate, the metal material, and the second metal plate are made of aluminum or an aluminum alloy, for example, furnace brazing under a nitrogen atmosphere may be used.

[0040] According to the method for manufacturing a cooler according to the first aspect of the present invention described above, the present invention can provide a method for manufacturing a cooler that is less likely to contaminate the refrigerant during use.

[0041] (Second aspect) A method for manufacturing a cooler according to a second aspect of the present invention involves fixing a first metal plate, a metal material having an uneven structure, and a second metal plate on the protrusions of the metal material, and includes the steps of: scattering powdered flux on the uneven surface of the metal material (hereinafter also referred to as the "scattering step"), fixing the first metal plate, the metal material, and the second metal plate on the protrusions of the metal material after scattering (hereinafter also referred to as the "fixing step"), and removing the flux adhering to the recesses by blowing gas into the recesses after fixation (hereinafter also referred to as the "removal step"; see Figure 2). Since excess flux remaining after scattering flux on the uneven surface including the parts of the metal material other than the protrusions and after the fixing step is completed is removed, a cooler that is less likely to contaminate the refrigerant during use can be obtained.

[0042] The details of the method for manufacturing a cooler according to a second aspect of the present invention will be described below.

[0043] -First metal plate and second metal plate- The first and second metal plates can be the same as those exemplified in the method for manufacturing a cooler according to the first aspect of the present invention.

[0044] -Metal material with an uneven surface- As the metal material having an uneven structure, the same material as that exemplified in the method for manufacturing a cooler according to the first aspect of the present invention can be used.

[0045] (Spraying process) The spraying process can be carried out in the same manner as described in the method for manufacturing a cooler according to the first aspect of the present invention. However, the flux is in powder form.

[0046] (immobilization process) The immobilization process can be carried out in the same manner as described in the method for manufacturing a cooler according to the first aspect of the present invention.

[0047] (Removal process) In the removal process, flux adhering to the recesses is removed by blowing gas onto the recesses after fixation. The gas is preferably air. Removal is preferably carried out at a wind speed of 1 m / s to 5 m / s, more preferably at 2 m / s to 5 m / s, and even more preferably at 3 m / s to 4 m / s. By removing the flux at a wind speed within the above range, unwanted flux remaining in the refrigerant flow path of the cooler can be removed, resulting in a cooler that is less likely to contaminate the refrigerant during use.

[0048] Furthermore, the removal process preferably includes a step of applying pressure to either the first or second metal plate in the thickness direction with a pressure of 0.1 kPa to 300 kPa. In this case, the pressure is preferably 0.1 kPa to 300 kPa, more preferably 10 kPa to 250 kPa, and even more preferably 50 kPa to 200 kPa. By having the pressure within the above range, the cooler is not damaged, the flux is removed from the refrigerant flow path, and it becomes easier to obtain a cooler that is less likely to contaminate the refrigerant during use.

[0049] According to the method for manufacturing a cooler according to the second aspect of the present invention described above, the present invention can provide a method for manufacturing a cooler that is less likely to contaminate the refrigerant during use. [Explanation of Symbols]

[0050] 10 Metal material having an uneven surface 20 First metal plate and second metal plate 30 Cooler S solvent R. Laura F Flux

Claims

1. A method for manufacturing a cooler comprising fixing a first metal plate, a metal material having an uneven structure, and a second metal plate using the protrusions of the metal material, The process includes selectively applying flux to the protrusions of the metal material, The step of selectively applying flux to the protrusions of the metal material is: A step of selectively applying a solvent to the protruding portion of the metal material, The process involves spraying flux onto the uneven surface of the aforementioned metal material, A step of removing flux adhering to the recess of the metal material, Includes, After the removal step, the first metal plate, the metal material, and the second metal plate are fixed together by the protrusions of the metal material, thereby forming a refrigerant flow path for the cooler with the first metal plate, the second metal plate, and the recesses of the metal material. A method for manufacturing a cooler, including the method described above.

2. A method for manufacturing a cooler comprising fixing a first metal plate, a metal material having an uneven structure, and a second metal plate using the protrusions of the metal material, The process involves spraying powdered flux onto the uneven surface of the metal material, After spraying, the first metal plate, the metal material, and the second metal plate are fixed together by the protrusions of the metal material, thereby forming a refrigerant flow path for the cooler with the first metal plate, the second metal plate, and the recesses of the metal material. A method for manufacturing a cooler, comprising the step of blowing gas into a recess in the metal material after the step of forming the refrigerant flow path to remove the flux adhering to the recess.

3. The method for manufacturing a cooler according to Claim 2, wherein the step of blowing gas into the recesses of the metal material after the step of forming the refrigerant flow path to remove the flux adhering to the recesses includes a step of pressurizing either the first metal plate or the second metal plate with a pressure of 0.1 kPa to 300 kPa in the thickness direction of the plate.

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