Total heat exchange element and method for manufacturing total heat exchange element

Abstract

A total heat exchange element (100) comprises a plurality of partition members (1) arranged in parallel at intervals, and waveform-shaped interval-retaining members (2) disposed between the adjacent partition members (1). A plurality of the partition members (1) and the interval-retaining members (2) are alternately laminated, and an air supply flow path (3) and an exhaust flow path (4) are formed by the partition members (1) and the interval-retaining members (2). The partition members (1) are made of a water-retentive material to which a water-soluble moisture absorbent is added. The interval-retaining member (2) has a waterproof layer (20) formed on some or all of the apexes of the waveform by using a waterproof agent, and an adhesive part (21) formed by bonding the waterproof layer (20) and the partition members (1) using an adhesive.

Description

Total heat exchange element and method for manufacturing the same

[0001] The present disclosure relates to a total heat exchange element and a method for manufacturing a total heat exchange element.

[0002] A total heat exchange element has been known as a component of a total heat exchanger that can simultaneously exchange temperature and humidity between an intake air flow and an exhaust air flow. Such a total heat exchange element includes, for example, a plurality of partition members arranged in parallel at intervals and a corrugated spacing member arranged between adjacent partition members, and the partition members and spacing members are alternately stacked in multiple layers to form an intake air flow path and an exhaust air flow path.

[0003] The partition members are pre-added with a water-soluble moisture absorbent to efficiently exchange latent heat. However, when a total heat exchange element is used for a long period of time in a high-humidity environment, the moisture absorbent continues to absorb large amounts of water vapor from the air. When the amount of absorbed moisture exceeds the water retention capacity of the partition members, the moisture absorbent flows out of the partition members together with the water and migrates to the spacing members, which may result in a decrease in humidity exchange performance.

[0004] Therefore, in the total heat exchange element disclosed in Patent Document 1, a moisture absorbent is contained in the liner sheet, which is the partition member, and the corrugated sheet, which is the spacing member, so that the humidity exchange efficiency is maintained over time.

[0005] International Publication No. 2015 / 098592

[0006] However, in the total heat exchange element disclosed in Patent Document 1, the spacing member also contains a moisture absorbent, which increases the material cost of the moisture absorbent and increases the effort required to manufacture the spacing member, which may result in an increase in manufacturing costs.

[0007] The present disclosure has been made in consideration of the above, and aims to obtain a total heat exchange element that can suppress the phenomenon of the moisture absorbent contained in the partition member migrating to the spacing member without applying the moisture absorbent to the spacing member.

[0008] In order to solve the above-mentioned problems and achieve the objectives, the total heat exchange element of the present disclosure comprises a plurality of partition members arranged in parallel at intervals and a corrugated spacing member arranged between adjacent partition members, in which the partition members and spacing members are alternately stacked in multiple layers, and the partition members and spacing members form an air intake flow path and an exhaust flow path, and the partition members are made of a water-retaining material to which a water-soluble moisture absorbent has been added, and the spacing member has a waterproof layer formed on part or all of the peaks of the corrugations using a waterproofing agent, and an adhesive portion formed by bonding the waterproof layer and the partition members with an adhesive.

[0009] The total heat exchange element according to the present disclosure has the advantage that it is possible to suppress the phenomenon in which the moisture absorbent contained in the partition member migrates to the spacing member without applying a moisture absorbent to the spacing member.

[0010] 1 is an external perspective view schematically illustrating a total heat exchange element according to a first embodiment; FIG. 2 is a partially enlarged view of the total heat exchange element according to the first embodiment, showing one spacing member and two partition members above and below the spacing member; FIG. 3 is an explanatory view showing a first step of a manufacturing method for a total heat exchange element according to the first embodiment; FIG. 4 is an explanatory view showing a second step of a manufacturing method for a total heat exchange element according to the first embodiment;

[0011] A total heat exchange element and a method for manufacturing a total heat exchange element according to an embodiment of the present disclosure will be described in detail below with reference to the drawings.

[0012] Embodiment 1. Fig. 1 is an external perspective view that schematically shows a total heat exchange element according to embodiment 1. Fig. 2 is a partially enlarged view of the total heat exchange element according to embodiment 1, showing one spacing member and two partition members above and below it. In this embodiment, the stacking direction of partition member 1 and spacing member 2 is defined as the Z direction, and two mutually perpendicular directions in a plane perpendicular to the Z direction are defined as the X direction and the Y direction.

[0013] 1, the total heat exchange element 100 according to the first embodiment includes a plurality of flat partition members 1 arranged in parallel at intervals, and a corrugated spacing member 2 arranged between adjacent partition members 1. The total heat exchange element 100 has a plurality of partition members 1 and spacing members 2 alternately stacked, and air supply passages 3 and exhaust passages 4 provided in layers by the partition members 1 and spacing members 2 are alternately formed.

[0014] The partition member 1 is made of a water-retentive material to which a water-soluble moisture absorbent has been added. Specifically, the material for the partition member 1 may be paper, a mixture of pulp and resin, resin, or metal foil. The water-soluble moisture absorbent is added to the material of the partition member 1 in advance to enable efficient exchange of latent heat. Examples of water-soluble moisture absorbents include alkali metal salts such as lithium chloride, and alkaline earth metal salts such as calcium chloride. However, other substances may also be used as moisture absorbents as long as they are water-soluble and moisture-absorbent.

[0015] The spacing members 2 are corrugated members that maintain the spacing between adjacent partition members 1. The corrugated shape refers to a wave-shaped configuration consisting of peaks and valleys. The spacing members 2 are made of paper, a pulp-resin mixture, resin, or metal foil, among other materials. Adjacent spacing members 2 in the stacking direction are arranged so that the directions in which the corrugated peaks and valleys extend are perpendicular to each other. Note that "perpendicular" does not necessarily mean strictly perpendicular, but also includes cases where the directions are roughly perpendicular. In other words, spacing members 2 whose corrugated peaks and valleys extend in the X direction and spacing members 2 whose corrugated peaks and valleys extend in the Y direction are alternately stacked in the Z direction. The spacing members 2 whose corrugated peaks and valleys extend in the X direction and the partition member 1 form an intake air flow path 3 through which the intake air flow 5 flows. The spacing members 2 whose corrugated peaks and valleys extend in the Y direction and the partition member 1 form an exhaust air flow path 4 through which the exhaust air flow 6 flows. The air intake path 3 and the exhaust path 4 are independent of each other and intersect with each other in a plan view. An air intake flow 5 flowing through the air intake path 3 is, for example, an air flow taken in from outdoors into the room. An exhaust flow 6 flowing through the exhaust path 4 is, for example, an air flow discharged from indoors to outdoors. Latent heat and sensible heat are exchanged between the air intake flow 5 flowing through the air intake path 3 and the exhaust flow 6 flowing through the exhaust path 4 using the partition member 1 as a medium.

[0016] The peaks of the corrugated peaks and valleys of the spacing member 2 form adhesion points where they are bonded to the partition member 1. The spacing member 2 has a waterproof layer 20 formed at the adhesion points with a waterproofing agent, and an adhesive portion 21 formed by bonding the waterproof layer 20 to the partition member 1 with an adhesive. The material of the spacing member 2 is not in direct contact with the partition member 1 because the waterproof layer 20 is formed thereon.

[0017] Examples of the waterproofing agent that forms the waterproof layer 20 include a water repellent agent whose main component is fluororesin or silicone resin, a solvent-based coating agent containing nitrocellulose, vinyl chloride, polyamide, alkyd, acrylic or urethane resin, or an ultraviolet (UltraViolet: UV) curing coating agent containing epoxy acrylate, urethane acrylate, polyester acrylate, polyether acrylate, polyacrylic acrylate or unsaturated polyester resin.

[0018] The adhesive portion 21 is formed with an adhesive containing a moisture absorbent at a concentration equal to or higher than the moisture absorbent content in the partition member 1, so that the moisture absorbent contained in the adhesive can be transferred to the partition member 1. This increases the concentration of the moisture absorbent in the partition member 1, and is expected to improve heat exchange performance. On the other hand, since the waterproof layer 20 exists between the adhesive portion 21 and the spacing member 2, the moisture absorbent contained in the adhesive will not transfer to the spacing member 2.

[0019] The adhesive portion 21 may also be formed from a water-based adhesive impregnated with a chemical agent containing a water-soluble moisture absorbent. This is because a water-based adhesive has no effect on the human body, and it is easy to control the working environment against fire, etc., the heating process before bonding, and the drying process after bonding, and it is expected to be effective in terms of workability, productivity, and manufacturing costs.

[0020] The spacing members 2 are not limited to the corrugated shape shown in the figure, and may be any member capable of maintaining a predetermined distance between adjacent partition members 1. Specifically, the spacing members 2 may be a sheet folded into a rectangular wave or triangular wave shape, or a plurality of plate pieces, etc.

[0021] Incidentally, total heat exchangers are becoming increasingly important as a means for efficiently ventilating a room while maintaining a comfortable indoor air environment. A total heat exchanger can simultaneously exchange temperature and humidity between an intake air flow 5 that supplies fresh outside air and an exhaust air flow 6 that discharges polluted indoor air. A total heat exchanger is equipped with a total heat exchange element 100 as a heat exchanging component. The total heat exchange element 100 performs ventilation while performing total heat exchange between the intake air flow 5 flowing through the intake air flow path 3 and the exhaust air flow 6 flowing through the exhaust air flow path 4, thereby reducing loss of heating and cooling efficiency in indoor air conditioning.

[0022] A total heat exchanger may be installed in an environment where the temperature difference between the intake air flow 5 and the exhaust air flow 6 is large and condensation is likely to occur, such as in a cold region, a bathroom, or a heated swimming pool. In such an environment, for example, when the total heat exchanger starts operating without air conditioning on the indoor side, the humidity of both the intake air flow 5 and the exhaust air flow 6 may become high, and the total heat exchange element 100 may be temporarily exposed to a very humid environment. Furthermore, depending on outdoor weather conditions, the condition of the outside air intake, and the condition of the air intake piping to the total heat exchanger, mist or rainwater may be taken in together with the intake air and supplied to the total heat exchange element 100.

[0023] When the total heat exchange element 100 is used for a long period of time in a high-humidity environment, the moisture absorbent added to the partition member 1 continues to absorb large amounts of water vapor from the air, and when the amount of absorbed moisture exceeds the water retention capacity of the partition member 1, there is a risk that the moisture absorbent will flow out of the partition member 1 along with the water and migrate to the spacing member 2. The outflow of the moisture absorbent from the partition member 1 is thought to be caused by the movement of the moisture absorbent due to the concentration diffusion of moisture, or by movement due to the concentration diffusion of the moisture absorbent itself. Concentration diffusion is caused by differences in the spatial distribution of the concentration of moisture or the moisture absorbent itself. If the moisture absorbent flows out of the partition member 1 and migrates to the spacing member 2, there is a risk that the humidity exchange performance of the total heat exchange element 100 will decrease.

[0024] Therefore, in the total heat exchange element 100 according to the first embodiment, the spacing member 2 is characterized in that it has a waterproof layer 20 formed at the top of the corrugations using a waterproofing agent, and an adhesive portion 21 formed by bonding the waterproof layer 20 and the partition member 1 with an adhesive. As a result, in the total heat exchange element 100, even if the moisture absorbent tries to flow out of the partition member 1 together with water, the waterproof layer 20 acts as a barrier, preventing the moisture absorbent from migrating to the spacing member 2 and diffusing in concentration, thereby suppressing a decrease in humidity exchange performance.

[0025] In the total heat exchange element 100 according to the first embodiment, it is desirable to form the waterproof layer 20 on all apexes of the peaks and valleys of the waveform of the spacing member 2, but this is not limited thereto. For example, the waterproof layer 20 may be formed on only some of the apexes of the peaks and valleys, such as on every other peak and valley along the waveform. In this case, the apexes of the spacing member 2 on which the waterproof layer 20 is not formed are directly bonded to the partition member 1 with an adhesive. This adhesive may be the same as the adhesive used to form the adhesive portion 21, or may be a different adhesive.

[0026] Next, a method for manufacturing the total heat exchange element 100 according to the first embodiment will be described. Fig. 3 is an explanatory diagram showing a first step of the manufacturing process in the method for manufacturing the total heat exchange element according to the first embodiment. Fig. 4 is an explanatory diagram showing a second step of the manufacturing process in the method for manufacturing the total heat exchange element according to the first embodiment. Fig. 5 is an explanatory diagram showing a lamination step in the method for manufacturing the total heat exchange element according to the first embodiment.

[0027] As shown in Figures 3 to 5, the manufacturing method of the total heat exchange element 100 includes a manufacturing process in which one partition member 1 and one spacing member 2 are bonded together with an adhesive to produce multiple single-sided corrugated materials 10a, and a stacking process in which the partition member 1 of one single-sided corrugated material 10a and the spacing member 2 of the other single-sided corrugated material 10a are bonded together with an adhesive to form multiple alternating stacks of partition members 1 and spacing members 2.

[0028] The process for producing the single-sided corrugated material 10a includes a first step of producing a long single-sided corrugated material 10 and a second step of cutting the long single-sided corrugated material 10 produced in the first step to a predetermined size. In the first step, a long material is first formed into a corrugated sheet to produce a long spacing member 2. The long material may be, for example, paper, a pulp-and-resin mixture, resin, or metal foil. Next, a waterproofing agent is applied to the peaks of the ridges of the produced spacing member 2 to form a waterproof layer 20, and an uncured adhesive is applied onto the waterproof layer 20. Then, as shown in FIG. 3 , a partition member 1 containing a water-soluble moisture absorbent is brought into contact with the spacing member 2. The uncured adhesive is then cured to form an adhesive joint 21, and the partition member 1 and spacing member 2 are bonded together to produce the long single-sided corrugated material 10. As shown in FIG. 4, in the second step, the long single-sided corrugated material 10 produced in the first step is cut to a predetermined size to produce a plurality of units of single-sided corrugated material 10a.

[0029] In the lamination process of the single-sided corrugated materials 10a, a waterproofing agent is applied to the tops of the valleys of the spacing members 2 that make up the single-sided corrugated materials 10a to form a waterproof layer 20, and uncured adhesive is applied onto the waterproof layer 20. Next, as shown in Figure 5, the single-sided corrugated materials 10a are sequentially laminated while checking the orientation of the single-sided corrugated materials 10a so that the corrugations of the spacing members 2 of adjacent single-sided corrugated materials 10a are perpendicular to each other in the lamination direction, and the uncured adhesive is cured to form adhesive joints 21, thereby producing the total heat exchange element 100. Note that "perpendicular" does not necessarily mean strictly perpendicular, but also includes cases where the corrugations are roughly perpendicular.

[0030] In the lamination process of the single-sided corrugated material 10a, the work of forming the waterproof layer 20 on the top of the valley portion of the spacing member 2 may be performed in the manufacturing process of the single-sided corrugated material 10a. In this case, the work of forming the waterproof layer 20 on the spacing member 2 in the lamination process is omitted.

[0031] As described above, in the manufacturing method of the total heat exchange element 100 according to the first embodiment, the waterproof layer 20 is formed on the spacing member 2 to prevent the moisture absorbent from migrating from the partition member 1 to the spacing member 2. Therefore, in the manufacturing process of the total heat exchange element 100, the spacing member 2 does not soften due to moisture absorption. Furthermore, deformation of the single-sided corrugated material 10a caused by expansion and contraction or changes in strength due to moisture absorption of the partition member 1 and the spacing member 2 can be suppressed. In other words, the workability when manufacturing the single-sided corrugated material 10a and the handleability of the single-sided corrugated material 10a are improved, resulting in improved workability and productivity when manufacturing the total heat exchange element 100.

[0032] Second Embodiment Next, a total heat exchange element 101 according to the second embodiment will be described. Fig. 6 is a partially enlarged view of the total heat exchange element according to the second embodiment, showing one spacing member and two partition members above and below the spacing member.

[0033] As shown in FIG. 6 , the total heat exchange element 101 according to the second embodiment is characterized in that the waterproof layer 20 and adhesive portions 21 are formed only on the apexes of the valley portions of the spacing members 2. The waterproof layer 20 is not formed on the apexes of the peak portions of the spacing members 2, and adhesive portions 22 are formed by directly bonding the spacing members 2 to the partition members 1 with an adhesive. The adhesive for forming adhesive portions 22 may be the same as or different from the adhesive used for forming adhesive portions 21. Although not shown, it is also possible to form the waterproof layer 20 only on the apexes of the peak portions of the spacing members 2. In this case, the waterproof layer 20 is not formed on the apexes of the valley portions of the spacing members 2, and adhesive portions 22 are formed by directly bonding the spacing members 2 to the partition members 1 with an adhesive. The total heat exchange element 101 according to the second embodiment can omit the step of applying a waterproofing agent to the spacing members 2 in the manufacturing process of the single-sided corrugated material 10 or the step of applying a waterproofing agent to the spacing members 2 in the lamination process, thereby reducing material costs and manufacturing costs.

[0034] Furthermore, in the total heat exchange element 101 of this embodiment 2, even if the moisture absorbent tries to flow out of the partition member 1 together with water, the waterproof layer 20 formed in the valley portion of the spacing member 2 acts as a barrier, preventing the moisture absorbent from migrating into the spacing member 2, thereby preventing a decrease in humidity exchange performance.

[0035] In the total heat exchange element 101 according to the second embodiment, it is desirable to form a waterproof layer 20 on all the apexes of the peaks or valleys of the spacing member 2, but this is not limited to this, and the waterproof layer 20 may be formed only on some of the apexes of the peaks or valleys, for example, by forming the waterproof layer 20 on every other peak or valley along the waveform.

[0036] The configurations shown in the above embodiments are merely examples, and may be combined with other known technologies, or different embodiments may be combined with each other. It is also possible to omit or modify parts of the configurations as long as they do not deviate from the gist of the invention.

[0037] 1 Partition member, 2 Spacing member, 3 Air intake flow path, 4 Exhaust flow path, 5 Air intake flow, 6 Exhaust flow, 10, 10a Single-sided corrugated material, 20 Waterproof layer, 21, 22 Adhesive portion, 100, 101 Total heat exchange element.

Claims

1. A total heat exchange element comprising a plurality of partition members arranged in parallel with a gap therebetween, and a corrugated spacing member arranged between adjacent partition members, the partition members and the spacing members being alternately stacked in a plurality of layers, and the partition members and the spacing members forming an air intake flow path and an exhaust flow path, wherein the partition members are made of a water-retentive material to which a water-soluble moisture absorbent has been added, and the spacing member has a waterproof layer formed on some or all of the tops of the corrugations using a waterproofing agent, and an adhesive portion formed by bonding the waterproof layer and the partition members with an adhesive.

2. The total heat exchange element described in claim 1, characterized in that the waterproofing agent includes a water repellent agent mainly composed of fluororesin or silicone resin, or a solvent-based coating agent containing nitrocellulose, vinyl chloride, polyamide, alkyd, acrylic or urethane resin, or an ultraviolet-curing coating agent containing epoxy acrylate, urethane acrylate, polyester acrylate, polyether acrylate, polyacrylic acrylate or unsaturated polyester resin.

3. A total heat exchange element as claimed in claim 1 or 2, characterized in that the waterproof layer is formed on either the tops of the peaks or the bottoms of the corrugations of the spacing member.

4. A total heat exchange element as claimed in any one of claims 1 to 3, characterized in that the adhesive portion is formed from a water-solvent-based adhesive impregnated with a chemical agent including a water-soluble moisture absorbent.

5. A method for manufacturing a total heat exchange element as described in any one of claims 1 to 4, comprising: a production process for producing a plurality of single-sided corrugated materials by bonding one partition member and one spacing member with an adhesive; and a stacking process for bonding the spacing member of one of the single-sided corrugated materials and the partition member of the other single-sided corrugated material with the adhesive and stacking them so that the partition members and the spacing members are stacked alternately in a plurality of layers.

6. A method for manufacturing a total heat exchange element as described in claim 5, characterized in that in the fabrication process, a waterproof layer is formed on one of the apexes of the peaks and valleys of the corrugations of the spacing member, and the waterproof layer and the partition member are bonded with an adhesive, and in the lamination process, a waterproof layer is formed on the other of the apexes of the peaks and valleys of the corrugations of the spacing member, and the waterproof layer and the partition member of the other single-sided corrugated material are bonded with an adhesive.

7. A method for manufacturing a total heat exchange element as described in claim 5, characterized in that in the manufacturing process, a waterproof layer is formed on the tops of the peaks and valleys of the corrugations of the spacing member.

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