Heat exchanger and air conditioner

Abstract

Provided is a heat exchanger comprising: a pair of headers that extend in a first direction and through which a refrigerant passes; a plurality of flat heat transfer tubes that are aligned at a predetermined interval in the first direction and both ends of each of which in a second direction intersecting the first direction are connected to the headers; side plates that are disposed at a predetermined interval on outer sides of end parts of the plurality of flat heat transfer tubes in the first direction; and a plurality of corrugated fins that are disposed between the plurality of flat heat transfer tubes and between the plurality of flat heat transfer tubes and the side plates. Protrusions that protrude toward the plurality of corrugated fins are formed at both ends of the side plates in the second direction.

Description

Heat exchanger and air conditioner

[0001] The present disclosure relates to a heat exchanger and an air conditioner.

[0002] A corrugated fin type heat exchanger including a plurality of flat heat transfer tubes whose both ends are connected to headers, side plates disposed outside the flat heat transfer tubes at both ends, and a plurality of corrugated fins between the flat heat transfer tubes at both ends and the side plates is widespread. In such a heat exchanger, there is a problem that the corrugated fins between the flat heat transfer tubes at both ends and the side plates are likely to fall off, particularly at both longitudinal ends. In Patent Document 1, it has been proposed to hold the entire corrugated fin by a protrusion provided on the side plate and a protruding rib continuous from the protrusion.

[0003] Japanese Patent No. 3517228

[0004] The protrusion of Patent Document 1 is provided at the center in the width direction of the side plate, and the protruding rib continuous from the protrusion is provided over the entire length in the longitudinal direction of the side plate. Therefore, the corrugated fin is crushed over the longitudinal direction. When the corrugated fin is crushed, it leads to a decrease in heat exchange performance. Therefore, there is a demand for a heat exchanger that can prevent the corrugated fin from falling off without degrading the heat exchange performance.

[0005] An object of the present disclosure is to provide a heat exchanger and an air conditioner that can prevent the fins from falling off while maintaining the heat exchange performance.

[0006] The heat exchanger according to the present disclosure includes a pair of headers that extend in a first direction and through which a refrigerant passes, a plurality of flat heat transfer tubes that are aligned at a predetermined interval in the first direction and whose both ends in a second direction intersecting the first direction are connected to the headers, side plates disposed outside the ends of the plurality of flat heat transfer tubes in the first direction at a predetermined interval, and a plurality of corrugated fins disposed between the plurality of flat heat transfer tubes and between the plurality of flat heat transfer tubes and the side plates, and protrusions protruding toward the plurality of corrugated fins are formed at both ends of the side plate in the second direction.

[0007] Furthermore, the air conditioner related to this disclosure is equipped with the heat exchanger described above.

[0008] According to the heat exchanger and air conditioner of this disclosure, a projection is formed at the end of the side plate in the second direction, projecting toward the corrugated fin. Therefore, while maintaining heat exchange performance, the detachment of the corrugated fin can be suppressed by the frictional force between the projection and the corrugated fin.

[0009] This is a circuit diagram of an air conditioner equipped with a heat exchanger according to Embodiment 1. This is a perspective view of the heat exchanger according to Embodiment 1. This is a side view of the heat exchanger according to Embodiment 1. This is a schematic diagram showing the arrangement of the flat heat transfer tubes, corrugated fins, and side plates in the heat exchanger according to Embodiment 1. This is a perspective view showing the heat exchanger according to Embodiment 1 during manufacturing. This is a top view showing the heat exchanger according to Embodiment 1 during manufacturing. This is a flowchart explaining the manufacturing process of the heat exchanger according to Embodiment 1. This is a side view of a heat exchanger according to a comparative example. This is a side view of a heat exchanger according to Embodiment 2. This is a schematic diagram showing the arrangement of the heat exchanger according to Embodiment 3. This is a perspective view of the side plate of the heat exchanger according to Embodiment 4. This is a perspective view of the side plate of a heat exchanger according to a modified example of Embodiment 4. This is a side view of the heat exchanger according to Embodiment 5. This is a schematic diagram showing the arrangement of the heat exchanger according to Embodiment 5. This is a top view of the heat exchanger according to Embodiment 5.

[0010] The embodiments for implementing this disclosure will be described with reference to the attached drawings. In each drawing, the same or corresponding parts are denoted by the same reference numerals, and redundant explanations are simplified or omitted as appropriate. In the following description, for convenience, the positional relationships of each structure may be expressed based on the illustrated state. This disclosure is not limited to the following embodiments, and any combination of embodiments, any modification of any component of each embodiment, or any omission of any component of each embodiment is possible without departing from the spirit of this disclosure. In addition, the dimensional relationships or shapes of each component in each drawing may differ from those of the actual components. Furthermore, the positional relationships between each component, such as the up-down relationship, are, in principle, as they are when installed in a usable state. However, in order to facilitate understanding, terms indicating direction, such as "up," "down," "right," "left," "front," and "back," will be used as appropriate, but these notations are used only for the convenience of explanation and do not limit the arrangement and orientation of the device or parts.

[0011] Embodiment 1. Figure 1 is a circuit diagram of an air conditioner 10 equipped with a heat exchanger 1 according to Embodiment 1. As shown in Figure 1, the air conditioner 10 comprises an outdoor unit 200 and an indoor unit 100, and a refrigerant circuit is formed by connecting them with refrigerant piping 300. In Embodiment 1, the air conditioner 10 comprises one outdoor unit 200 and one indoor unit 100, but is not limited to this, and the air conditioner 10 may comprise two or more outdoor units 200 and two or more indoor units 100.

[0012] The outdoor unit 200 includes a compressor 201, a flow path switching device 202, an outdoor heat exchanger 203, and an outdoor fan 204.

[0013] The compressor 201 draws in low-temperature and low-pressure refrigerant, compresses the drawn-in refrigerant, and discharges it as high-temperature and high-pressure refrigerant. The compressor 201 is, for example, an inverter compressor whose capacity, which is the amount of refrigerant delivered per unit time, is controlled by changing the operating frequency.

[0014] The flow path switching device 202 is, for example, a four-way valve, and switches between cooling and heating operation by changing the direction of refrigerant flow. Alternatively, a combination of two-way and three-way valves may be used as the flow path switching device 202 instead of a four-way valve.

[0015] The outdoor heat exchanger 203 functions as either an evaporator or a condenser. The outdoor heat exchanger 203 exchanges heat between air and refrigerant, evaporating the refrigerant to gaseous form when functioning as an evaporator, and condensing it to liquefy form when functioning as a condenser. The outdoor heat exchanger 203 functions as an evaporator during heating operation and as a condenser during cooling operation. Here, the heat exchanger 1 according to Embodiment 1 is used as the outdoor heat exchanger 203.

[0016] The outdoor fan 204 is installed near the outdoor heat exchanger 203 and supplies outdoor air to the outdoor heat exchanger 203.

[0017] The indoor unit 100 includes an indoor heat exchanger 101, an indoor fan 102, and a throttling device 103.

[0018] The indoor heat exchanger 101 functions as either an evaporator or a condenser. The indoor heat exchanger 101 exchanges heat between air and refrigerant. When functioning as an evaporator, it evaporates the refrigerant into a gas, and when functioning as a condenser, it condenses it into a liquid. The indoor heat exchanger 101 functions as a condenser during heating operation and as an evaporator during cooling operation.

[0019] The indoor fan 102 is installed near the indoor heat exchanger 101 and supplies indoor air to the indoor heat exchanger 101.

[0020] The throttling device 103 reduces the pressure of the refrigerant and causes it to expand. The throttling device 103 is, for example, an electronic expansion valve that can adjust the opening of the throttling valve. By adjusting the opening of the throttling device 103, the pressure of the refrigerant flowing into the indoor heat exchanger 101 is controlled during cooling operation, and the pressure of the refrigerant flowing into the outdoor heat exchanger 203 is controlled during heating operation.

[0021] Next, the operating modes of the air conditioner 10 will be explained. First, the cooling operation will be explained. In cooling operation, the flow path switching device 202 is switched so that the discharge side of the compressor 201 and the outdoor heat exchanger 203 are connected, as shown by the dashed line in Figure 1. The high-temperature and high-pressure gaseous refrigerant compressed and discharged by the compressor 201 passes through the flow path switching device 202 and flows into the outdoor heat exchanger 203. The gaseous refrigerant that flows into the outdoor heat exchanger 203 condenses and liquefies by exchanging heat with the outdoor air supplied from the outdoor fan 204. The liquefied refrigerant is depressurized as it passes through the throttling device 103 and becomes a gas-liquid two-phase state. The gas-liquid two-phase refrigerant flows into the indoor heat exchanger 101, where it evaporates and becomes gas by exchanging heat with the air of the space to be air-conditioned supplied from the indoor fan 102. The gasified refrigerant passes through the flow path switching device 202 and is drawn back into the compressor 201.

[0022] Next, the heating operation will be explained. In heating operation, the flow path switching device 202 is switched so that the discharge side of the compressor 201 and the indoor heat exchanger 101 are connected, as shown by the solid line in Figure 1. The high-temperature, high-pressure gaseous refrigerant compressed and discharged by the compressor 201 passes through the flow path switching device 202 and flows into the indoor heat exchanger 101. The gaseous refrigerant that flows into the indoor heat exchanger 101 condenses and liquefies by exchanging heat with the air of the space to be air-conditioned supplied by the indoor fan 102. The liquefied refrigerant is depressurized as it passes through the throttling device 103, where it becomes a gas-liquid two-phase state. The gas-liquid two-phase refrigerant flows into the outdoor heat exchanger 203, where it evaporates and becomes gas by exchanging heat with the outdoor air supplied by the outdoor fan 204. The gasified refrigerant passes through the flow path switching device 202 and is drawn back into the compressor 201.

[0023] Figure 2 is a perspective view of the heat exchanger 1 according to Embodiment 1. Figure 3 is a side view of the heat exchanger 1 according to Embodiment 1. Figure 4 is a schematic diagram showing the arrangement of the flat heat transfer tubes 2, corrugated fins 3, and side plates 6 in the heat exchanger 1 according to Embodiment 1. In Figures 2 to 4, arrow AF indicates the direction of airflow to the heat exchanger 1. Arrow X indicates the first direction, arrow Y indicates the second direction, and arrow Z indicates the third direction, and the same applies to the drawings described later.

[0024] As shown in Figures 2 to 4, the heat exchanger 1 is a corrugated fin tube type heat exchanger. The heat exchanger 1 comprises a plurality of flat heat transfer tubes 2, a plurality of corrugated fins 3, a pair of headers 4, and side plates 6.

[0025] The flat heat transfer tube 2 is a tube having a flat cross-section and having multiple internal coolant flow paths 20 formed inside, and has a flat section 2A and a curved section 2B. The flat heat transfer tube 2 is preferably made of a metal with good heat conductivity, for example, aluminum is used. Multiple flat heat transfer tubes 2 are arranged at intervals from each other in a first direction that is perpendicular to the second direction and the third direction which is the ventilation direction, with the second direction being the tube extension direction. Here, the multiple flat heat transfer tubes 2 do not have to be arranged at intervals from each other in a direction that is strictly perpendicular to the second and third directions, but it is sufficient if they are arranged at intervals from each other in a direction that is approximately perpendicular to the second and third directions. Hereinafter, the first direction may also be called the X direction or left-right direction, the second direction may also be called the Y direction or up-down direction, and the third direction may also be called the Z direction or front-back direction. Also, in Figure 3, the direction from left to right on the paper is the +X direction, and the direction from right to left on the paper is the -X direction.

[0026] Each of the multiple corrugated fins 3 is a plate-like member formed by repeatedly folding in the mountain and valley directions, and has a flat portion 3A and a curved portion 3B. Hereinafter, a configuration in which the curved portion 3B is folded in the +X direction will be referred to as a mountain fold, and a configuration in which the curved portion 3B is folded in the -X direction will be referred to as a valley fold.

[0027] Each of the multiple corrugated fins 3 is joined to the flat portion 2A of the flat heat transfer tube 2 by brazing at the curved portion 3B. The multiple corrugated fins 3 are arranged between multiple flat heat transfer tubes 2 that are adjacent to each other in the left-right direction. The multiple corrugated fins 3 are joined to multiple flat heat transfer tubes 2 that are adjacent to each other in the left-right direction, extending in the vertical direction. It is desirable that the multiple corrugated fins 3 be made of a metal with good heat conductivity, for example, aluminum.

[0028] Multiple corrugated fins 3 have multiple louvers 31 formed on them. The multiple louvers 31 are arranged in parallel in a third direction. Each of the multiple louvers 31 is formed by cutting and bending a plate portion 31a from a flat portion 3A. The multiple louvers 31 include a first louver group 31A formed upstream of the drainage slit 32 formed in the flat portion 3A in the air flow direction, and a second louver group 31B formed downstream of the drainage slit 32 in the air flow direction. The first louver group 31A and the second louver group 31B are each composed of multiple plate portions 31a arranged in parallel in a third direction, for example, three plate portions 31a. In the first louver group 31A, the -Z side end of the plate portion 31a is cut and bent, and in the second louver group 31B, the +Z side end of the plate portion 31a is cut and bent.

[0029] A drainage slit 32, which is a through hole, is formed in the flat section 3A. The drainage slit 32 is provided to drain condensed water generated in the flat section 3A. The drainage slit 32 has a rectangular shape extending in a first direction. The condensed water generated in the flat section 3A flows along the plate portion 31a of the louver 31 formed in the flat section 3A and is guided toward the drainage slit 32 in the flat section 3A. In a third direction, the drainage slit 32 is positioned between the first louver group 31A and the second louver group 31B.

[0030] When the outdoor heat exchanger 203 functions as an evaporator, the surface temperatures of the multiple flat heat transfer tubes 2 and the multiple corrugated fins 3 are lower than the temperature of the air passing through the outdoor heat exchanger 203. As a result, moisture in the air condenses on the surfaces of the multiple flat heat transfer tubes 2 and the multiple corrugated fins 3, generating condensed water. When heating is performed in low outdoor temperature conditions where the outside temperature is below freezing, condensed water forms on the surfaces of the multiple corrugated fins 3, and this condensed water creates resistance for the air passing through the heat exchanger 1, thus reducing the heat transfer performance of the multiple corrugated fins 3. The presence of drainage slits 32 improves the drainage of the multiple corrugated fins 3, making it easier to drain the condensed water generated on the surfaces of the multiple corrugated fins 3, and suppressing the reduction in heat transfer performance due to condensation.

[0031] The pair of headers 4 includes an upper header 41 and a lower header 42. The upper header 41 and the lower header 42 are spaced apart vertically. A refrigerant pipe 300 is connected to one end of the upper header 41 in the first direction, and a refrigerant pipe 300 is also connected to one end of the lower header 42. The refrigerant, which is a fluid that serves as a heat exchange medium, flows in and out through the refrigerant pipe 300. When the heat exchanger 1 is used as an evaporator, liquid refrigerant passes through the upper header 41, and gaseous refrigerant passes through the lower header 42.

[0032] The side plates 6 are provided in pairs on the outside of the end flattened heat transfer tubes 21, which are located at both ends in the first direction of the plurality of flattened heat transfer tubes 2. When viewed in the first direction, the side plates 6 are rectangular plate-like members with their long sides extending in the second direction and their short sides extending in the third direction. The ends of the side plates 6 in the third direction extend, for example, in the second direction, which is opposite to the end flattened heat transfer tubes 21. In other words, when viewed in the second direction, the side plates 6 have an angular U-shape.

[0033] The side plate 6 is positioned at a distance from the end flattened heat transfer tube 21 in the first direction. The distance between the side plate 6 and the end flattened heat transfer tube 21 may be the same as the distance between multiple flattened heat transfer tubes 2. Between the side plate 6 and the end flattened heat transfer tube 21, one of the multiple corrugated fins 3, is positioned an end corrugated fin 33. The end corrugated fin 33 is joined to the end flattened heat transfer tube 21 in the vertical direction.

[0034] A projection 61 is formed on the side plate 6. The projection 61 is formed on the surface of the side plate 6 facing the end flattened heat transfer tube 21. The projection 61 protrudes in the direction approaching the end flattened heat transfer tube 21. The projection 61 has a height L1 in the first direction and is, for example, hemispherical in shape. The projection 61 is formed, for example, by drawing the plate material that will become the side plate 6. The projection 61 may also be formed separately from the side plate 6 and attached to the side plate 6 by brazing.

[0035] A pair of projections 61 are provided at both ends in the second direction. A pair of projections 61 are provided at both ends in the third direction. In other words, a total of four projections 61 are provided at the four corners of the side plate 6.

[0036] The pair of projections 61 in the second direction are located outward in the second direction from the end corrugated fin 33. The pair of projections 61 in the second direction are in contact with the outside of the outermost flat portion 3A of the end corrugated fin 33.

[0037] The pair of protrusions 61 are in contact with the outside of the flat portion 3A of the end corrugated fin 33, generating frictional force between the protrusions 61 and the flat portion 3A. This prevents the end corrugated fin 33 from falling off in a direction intersecting the second direction during the manufacturing of the heat exchanger 1. Furthermore, the pair of protrusions 61 acting as a physical stopper by being in contact with the outside of the flat portion 3A of the end corrugated fin 33 prevents the end corrugated fin 33 from extending in the second direction during the manufacturing of the heat exchanger 1.

[0038] The pair of protrusions 61 in the third direction are positioned outside the drainage slits 32 formed in the end corrugated fins 33 in the third direction. In other words, the pair of protrusions 61 are positioned to avoid the drainage slits 32. Because the pair of protrusions 61 are positioned outside the drainage slits 32, the drainage slits 32 are not blocked by the pair of protrusions 61, and the drainage of the end corrugated fins 33 can be maintained. As a result, condensation on the end corrugated fins 33 is suppressed, condensed water does not become a resistance to the air passing through the heat exchanger 1, and a decrease in heat exchange efficiency can be suppressed.

[0039] Next, the manufacturing process of the air conditioner 10 will be described. Figure 5 is a perspective view showing the manufacturing of the heat exchanger 1 according to Embodiment 1. Figure 6 is a top view showing the manufacturing of the heat exchanger 1 according to Embodiment 1. Figure 7 is a flowchart illustrating the manufacturing process of the heat exchanger 1 according to Embodiment 1.

[0040] As shown in Figures 5 to 7, the manufacturing process of the heat exchanger 1 includes a first arrangement step S01, a second arrangement step S02, a compression step S03, and a joining step S04. First, in step S01, a plurality of corrugated fins 3 and a plurality of flat heat transfer tubes 2 are arranged so that the third direction is the vertical direction, and are stacked alternately in the first direction.

[0041] Next, the process moves to step S02, where the end corrugated fins 33 are placed on the outside of the end flattened heat transfer tubes 21 located at the ends in the stacking direction, and the side plates 6 are placed further outside the end corrugated fins 33. At this time, the side plates 6 are positioned so that the surface on which the protrusions 61 are formed faces the end flattened heat transfer tubes 21. In addition, the end corrugated fins 33 are located inward in the second direction from the pair of protrusions 61.

[0042] Next, in step S03, the plurality of flat heat transfer tubes 2, the plurality of corrugated fins 3, and the side plates 6 are compressed in the first direction. At this time, the plurality of corrugated fins 3 are slightly crushed, for example, by several tens of μm per piece, so that the hole pitch of the pair of headers 4 and the pitch of the plurality of flat heat transfer tubes 2 match. A pair of headers 4 are arranged at both ends of the plurality of flat heat transfer tubes 2 in the second direction, and both ends of the plurality of flat heat transfer tubes 2 are inserted into the pair of headers 4. Further, although the end corrugated fins 33 are pushed in the second direction, the protrusions 61 serve as physical stoppers, suppressing the extension outside the protrusions 61.

[0043] Next, in step S04, the plurality of flat heat transfer tubes 2, the plurality of corrugated fins 3, and the side plates 6 are temporarily fixed with a wire or the like and then brazed and joined to each other. Thereby, the manufacture of the heat exchanger 1 is completed.

[0044] Here, since the temporary fixing force by the wire is smaller than the reaction force of the compression force in the first direction, a force that tries to expand acts on the plurality of flat heat transfer tubes 2 and the plurality of corrugated fins 3 in a direction intersecting the second direction. On the other hand, at the portions where the plurality of flat heat transfer tubes 2 are inserted into the pair of headers 4, the expansion of the plurality of flat heat transfer tubes 2 and the plurality of corrugated fins 3 arranged between the plurality of flat heat transfer tubes 2 is restricted by the pair of headers 4. As a result, as a whole, it tries to bulge in a convex shape.

[0045] At this time, the plurality of corrugated fins 3 sandwiched between the adjacent plurality of flat heat transfer tubes 2 are restricted in movement by the upper header 41 and the lower header 42 in the second direction and do not extend in the second direction. Further, since they are sandwiched between the adjacent plurality of flat heat transfer tubes 2, the plurality of corrugated fins 3 do not fall in the third direction either.

[0046] On the other hand, the end corrugated fin 33 sandwiched between the end flat heat transfer tube 21 and the side plate 6 is restricted from moving by the protruding portion 61 of the side plate 6 in the second direction, instead of being restricted by the upper header 41 and the lower header 42. Therefore, since no elongation occurs in the end corrugated fin 33 either, it is possible to suppress the end corrugated fin 33 from dropping in the third direction, and also to suppress the end corrugated fin 33 from being brazed together with other parts and melting.

[0047] FIG. 8 is a side view of the heat exchanger 1 according to the comparative example. As shown in FIG. 8, in the heat exchanger 1 according to the comparative example, the surface facing the end corrugated fin 33 of the side plate 6 is flat and does not include a protruding portion 61 protruding from the side plate 6. That is, the movement of the end corrugated fin 33 in the first and third directions is not restricted.

[0048] During manufacturing, when a compressive force acts on the plurality of flat heat transfer tubes 2, the outer end flat heat transfer tube 21 in the first direction bulges in a middle-convex shape. That is, the end flat heat transfer tube 21 bends in a direction intersecting the second direction in the vicinity of the portion inserted into the pair of headers 4, and in the middle portion, it has a curved shape so as to be farthest from the other plurality of flat heat transfer tubes 2. While the end flat heat transfer tube 21 has a curved shape, the end corrugated fin 33 and the side plate 6 extend straight in the second direction. For this reason, in the middle portion in the second direction, the end corrugated fin 33 and the end flat heat transfer tube 21 are in contact with each other, but at both ends in the second direction, the end corrugated fin 33 and the end flat heat transfer tube 21 cannot be in contact with each other, and a space G is formed. The space G between the end corrugated fin 33 and the end flat heat transfer tube 21 is, for example, 1 mm to 2 mm. As a result, the end corrugated fin 33 is likely to drop in the third direction, which is the direction of gravity.

[0049] Furthermore, the end corrugated fin 33, which is sandwiched between the end flattened heat transfer tube 21 of the multiple flattened heat transfer tubes 2 and the side plate 6, is not restricted from elongating in the second direction. This also causes gaps to form between the end flattened heat transfer tube 21 or the side plate 6, particularly at both ends in the longitudinal direction, leading to the end corrugated fin 33 falling off in the third direction. In addition, if the end corrugated fin 33 extends in the second direction and comes into contact with the header 4, it may be brazed together with the header 4 and the end flattened heat transfer tube 21, potentially causing melting.

[0050] In contrast, the heat exchanger 1 of Embodiment 1 has projections 61 formed on both ends of the side plate 6 in the second direction on the inside. The projections 61 can physically suppress the extension of the end corrugated fins 33 in the second direction. In addition, the projections 61 generate frictional force between themselves and the end corrugated fins 33. Therefore, even if there is a gap between the end corrugated fins 33 and the end flattened heat transfer tubes 21, or between the end corrugated fins 33 and the side plate 6, it is possible to prevent the end corrugated fins 33 from falling off or shifting position in a direction intersecting the second direction.

[0051] Furthermore, the projection 61 is provided at the end of the side plate 6 in the third direction. Since the projection 61 is positioned to avoid the drainage slit 32 formed in the central part of the end corrugated fin 33 in the third direction, the projection 61 does not block the drainage slit 32. As a result, it is possible to suppress the accumulation of condensed water on the flat portion 3A of the end corrugated fin 33, so that the condensed water does not become a resistance to the air passing through the heat exchanger 1, and the heat transfer performance of the heat exchanger 1 can be maintained.

[0052] As described above, according to the first embodiment of the heat exchanger 1, projections 61 are formed at both ends of the side plate 6 in the second direction, projecting toward the end corrugated fins 33. Therefore, the projections 61 physically suppress the elongation of the end corrugated fins 33 in the second direction, and the frictional force between the end corrugated fins 33 and the projections 61 prevents them from falling off in the third direction intersecting the second direction. In addition, the end corrugated fins 33 are not crushed, and the heat exchange performance of the heat exchanger 1 can be maintained.

[0053] Furthermore, the pair of protrusions 61 are positioned in the third direction to avoid the drainage slits 32 formed in the end corrugated fins 33. As a result, the drainage slits 32 formed in the multiple corrugated fins 3 are prevented from being blocked by the protrusions 61 formed at the ends in the third direction, thereby maintaining the heat exchange performance of the heat exchanger 1.

[0054] Furthermore, since the projection 61 is in contact with the outside of both ends of the end corrugated fin 33 in the second direction, it is possible to physically restrict the extension of the end corrugated fin 33 in the second direction.

[0055] Furthermore, since the projections 61 are provided in pairs at both ends of the side plate 6 in the third direction, the extension of the end corrugated fin 33 in the second direction can be more firmly restricted compared to when they are provided at only one end. In addition, the frictional force with the end corrugated fin 33 is increased, and the detachment of the end corrugated fin 33 can be more reliably suppressed.

[0056] Furthermore, because the protrusion 61 is hemispherical, it does not obstruct the airflow through the heat exchanger 1, and the detachment of the end corrugated fins 33 can be suppressed without reducing the heat exchange performance.

[0057] Embodiment 2. Figure 9 is a side view of the heat exchanger 1 according to Embodiment 2. The heat exchanger 1 according to Embodiment 2 differs from Embodiment 1 in that the projection 61 is specified to a height L1. In Embodiment 2, parts common to Embodiment 1 are given the same reference numerals and their descriptions are omitted, and the explanation will focus on the differences from Embodiment 1.

[0058] As shown in Figure 9, the heat exchanger 1 is configured such that the height L1 of the projection 61 in the first direction is set to be between 15% and 40% of the peak height L2 of the end corrugated fin 33 in the first direction. The peak height L2 of the end corrugated fin 33 is approximately the same as the distance between the multiple flat heat transfer tubes 2 and the distance between the end flat heat transfer tube 21 and the side plate 6. By setting the height L1 of the projection 61 to 15% or more of the peak height L2, the extension of the end corrugated fin 33 in the second direction can be prevented.

[0059] Furthermore, since the height L1 of the projection 61 is 40% or less of the peak height L2 of the end corrugated fin 33, the end corrugated fin 33 can overcome the projection 61 even when a different manufacturing method is used.

[0060] As an alternative manufacturing method, for example, when the heat exchanger 1 is manufactured automatically, the side plates 6 are first placed, and then multiple corrugated fins 3 and multiple flat heat transfer tubes 2 are alternately stacked between them. In this method, after the multiple corrugated fins 3 and multiple flat heat transfer tubes 2 are stacked, the end corrugated fins 33 are transported between the end flat heat transfer tubes 21 and the side plates 6, and the end corrugated fins 33 are pushed in.

[0061] Furthermore, in order to allow for variations in the lengths of the multiple corrugated fins 3, there is a method in which the multiple corrugated fins 3, including the end corrugated fins 33, are made longer than a predetermined length in advance, and their lengths are made uniform by pushing them in from both ends in the second direction while they are stacked. In this method, the operation of pushing in the multiple corrugated fins 3, including the end corrugated fins 33, is performed in a compressed state. The end corrugated fins 33 are pushed in the second direction so that they are inside the pair of protrusions 61.

[0062] As described above, in the method in which the end corrugated fin 33 is pushed in, if the size of the projection 61 exceeds 40% of the peak height L2 of the end corrugated fin 33, the end corrugated fin 33 cannot overcome the projection 61.

[0063] In the heat exchanger 1 according to Embodiment 2, the height L1 of the projection 61 relative to the peak height L2 of the end corrugated fin 33 is set to 15% or more and 40% or less, so the manufacturing of the heat exchanger 1 can be automated and carried out smoothly.

[0064] In the heat exchanger 1 according to Embodiment 2 described above, the height L1 of the projection 61 in the first direction is 15% to 40% of the peak height L2 of the end corrugated fin 33 in the first direction. Therefore, while suppressing the elongation of the end corrugated fin 33, it is possible to make the end corrugated fin 33 overcome the projection 61 during the manufacturing process.

[0065] Embodiment 3. Figure 10 is a schematic diagram showing the arrangement of the heat exchanger 1 according to Embodiment 3. The heat exchanger 1 according to Embodiment 3 differs from Embodiments 1 and 2 in the shape of the projection 61. In Embodiment 3, parts common to Embodiments 1 and 2 are given the same reference numerals and their descriptions are omitted, and the explanation will focus on the differences from Embodiments 1 and 2.

[0066] As shown in Figure 10, the heat exchanger 1 has a rectangular projection 61. Specifically, the projection 61 is prismatic in shape and protrudes from the inner surface of the side plate 6 toward the end flattened heat transfer tube 21. When the projection 61 is prismatic, the surface area of ​​the projection 61 is larger compared to when the projection 61 is spherical, making it easier to repel water. Therefore, accumulation of condensed water is less likely to occur between the end corrugated fin 33 and the side plate 6, and a decrease in the performance of the heat exchanger 1 can be suppressed.

[0067] In this way, the prismatic projection 61 prevents the end corrugated fin 33 from extending in the second direction, prevents it from falling in the vertical direction due to the frictional force between the end corrugated fin 33 and the projection 61, and improves drainage.

[0068] As described above, the heat exchanger 1 according to Embodiment 5 has a prismatic projection 61, which increases the surface area of ​​the projection 61 compared to the case where the projection 61 is hemispherical, making it easier to repel wastewater. This makes it less likely for condensation to accumulate, and prevents a decrease in the performance of the heat exchanger 1.

[0069] Embodiment 4. Figure 11 is a perspective view of the side plate 6 of the heat exchanger 1 according to Embodiment 4. The heat exchanger 1 according to Embodiment 4 differs from Embodiments 1 to 3 in the processing method of the protrusions 61. In Embodiment 4, parts common to Embodiments 1 to 3 are denoted by the same reference numerals and their descriptions are omitted, and the explanation will focus on the differences from Embodiments 1 to 3.

[0070] As shown in Figure 11, the height L1 of the projection 61 in the first direction is set to 80% or less of the plate thickness T of the side plate 6. When the height L1 of the projection 61 is 80% or less of the plate thickness T, the projection 61 can be formed by press processing such as embossing of the side plate 6. Since the embossing of the projection 61 can be done at the same time as the manufacturing process of the side plate 6, the processing man-hours do not increase and processing costs can be suppressed. If the height L1 of the projection 61 is greater than or equal to the plate thickness T, areas where the thickness of the side plate 6 is reduced will occur due to embossing, resulting in insufficient strength. However, if the height L1 of the projection 61 is 80% or less of the plate thickness T, no problems with reduced strength will occur.

[0071] As described above, the projection 61 is provided on the inside of the side plate 6, which suppresses the elongation of the end corrugated fin 33 in the second direction. In addition, the frictional force with the projection 61 restricts the movement of the end corrugated fin 33 in a direction intersecting the first direction. Furthermore, the drainage performance of the end corrugated fin 33 is improved, and the heat exchange performance of the heat exchanger 1 can be maintained. Moreover, since the height L1 of the projection 61 is 80% or less of the plate thickness T, the processing costs for the heat exchanger 1 can be reduced without causing insufficient strength of the heat exchanger 1.

[0072] Figure 12 is a perspective view of the side plate 6 of the heat exchanger 1 according to a modified example of Embodiment 4. As shown in Figure 12, even when the projection 61 is prismatic, the height L1 of the projection 61 can be set to 80% or less of the plate thickness T of the side plate 6. In this case as well, as with the case where the projection 61 is spherical, the projection 61 can be formed by embossing, which does not increase the processing time and reduces processing costs. Although the projection 61 is shown with angular corners, it may also have rounded corners.

[0073] According to the heat exchanger 1 of Embodiment 4 described above, the height L1 of the projection 61 in the first direction is 80% or less of the plate thickness T of the side plate 6. Therefore, the projection 61 can be formed on the plate material that will become the side plate 6 by embossing, without increasing the number of processing steps, without insufficient strength, and without reducing processing costs.

[0074] Embodiment 5. Figure 13 is a side view of the heat exchanger 1 according to Embodiment 5. Figure 14 is a schematic diagram showing the arrangement of the heat exchanger 1 according to Embodiment 5. The heat exchanger 1 according to Embodiment 5 differs from Embodiments 1 to 4 in the configuration of the projection 61. In Embodiment 5, parts common to Embodiments 1 to 4 are given the same reference numerals and their descriptions are omitted, and the explanation will focus on the differences from Embodiments 1 to 4.

[0075] As shown in Figures 13 and 14, the projection 61 formed on the side plate 6 of the heat exchanger 1 is inserted into and thrust into the end corrugated fin 33 when viewed in the third direction. The projection 61 is thrust into and thrust into the inside of the peaks of the end corrugated fin 33. The projection 61 is located inside the flat portions 3A located at both ends in the second direction and is in contact with the inner surface of the flat portions 3A. Because the projection 61 is located inside the flat portions 3A of the end corrugated fin 33, it is possible to more firmly prevent the end corrugated fin 33 from falling off in the direction intersecting the second direction and from extending the end corrugated fin 33 in the second direction.

[0076] The shape of the projection 61 is not particularly limited, but a pointed shape at the tip, such as a cone or a triangular pyramidal shape, is desirable because it makes it easier to insert into the end corrugated fin 33.

[0077] Figure 15 is a top view of the heat exchanger 1 according to Embodiment 5. As shown in Figure 15, in the end corrugated fin 33, the position where the projection 61 is inserted is formed within a distance L3 from the windward 1 / 3 position in the second louver group 31B to the leeward end, when viewed in the second direction.

[0078] In a configuration where the projection 61 is pierced into the end corrugated fin 33, the end corrugated fin 33 may be physically crushed. If the projection 61 is formed on the windward side, the crushed portion will be located on the design surface and will stand out. In contrast, by positioning the projection 61 within a distance L3, the projection 61 is not visible from the windward side, thus not compromising the design. Furthermore, the impact on the multiple louvers 31 for drainage is limited, and the accumulation of condensed water on the end corrugated fin 33 can be suppressed.

[0079] In this embodiment 5, the projection 61 of the side plate 6 is inserted so as to pierce the end corrugated fin 33. This prevents the end corrugated fin 33 from extending in the direction of both ends in the second direction, and also prevents it from falling in the third direction, which is vertical. Furthermore, since the projection 61 of the side plate 6 is positioned to avoid the drainage slit 32, condensed water does not accumulate on the end corrugated fin 33, and no deterioration in the performance of the heat exchanger 1 occurs.

[0080] As described above, according to the heat exchanger 1 of Embodiment 5, the projection 61 is inserted into the inside of the end corrugated fin 33. Therefore, the detachment of the end corrugated fin 33 and the extension of the end corrugated fin 33 in the direction of both ends in the second direction can be more firmly suppressed.

[0081] Furthermore, since the projection 61 tapers from its base to its tip, it bites into the end corrugated fin 33, effectively suppressing the extension of the end corrugated fin 33 in the second direction towards both ends.

[0082] Furthermore, the projection 61 is located between the leeward one-third of the second louver group 31B on the leeward side and the leeward edge of the end corrugated fin 33. As a result, the projection 61 is positioned so that it is not visible from the windward side, the aesthetic design of the heat exchanger 1 is not compromised, the impact on the multiple louvers 31 provided for drainage is limited, and the accumulation of condensed water on the end corrugated fin 33 is suppressed.

[0083] Furthermore, embodiments 1 to 5 can be combined as appropriate.

[0084] 1 Heat exchanger, 2 Flat heat transfer tube, 2A Flat section, 2B Curved section, 3 Corrugated fin, 3A Flat section, 3B Curved section, 4 Header, 6 Side plate, 10 Air conditioner, 20 Refrigerant flow path, 21 End flat heat transfer tube, 31 Louver, 31A First louver group, 31B Second louver group, 31a Plate section, 32 Drainage slit, 33 End corrugated fin, 41 Upper header, 42 Lower header, 61 Protrusion, 100 Indoor unit, 101 Indoor heat exchanger, 102 Indoor fan, 103 Throttle device, 200 Outdoor unit, 201 Compressor, 202 Flow path switching device, 203 Outdoor heat exchanger, 204 Outdoor fan, 300 Refrigerant piping.

Claims

1. A heat exchanger comprising: a pair of headers extending in a first direction through which a refrigerant passes; a plurality of flat heat transfer tubes aligned at predetermined intervals in the first direction and having both ends in a second direction intersecting the first direction connected to the headers; side plates arranged at predetermined intervals outside the ends of the plurality of flat heat transfer tubes in the first direction; and a plurality of corrugated fins arranged between the plurality of flat heat transfer tubes and between the plurality of flat heat transfer tubes and the side plates, wherein projections are formed at both ends of the side plates in the second direction, projecting toward the plurality of corrugated fins.

2. The heat exchanger according to claim 1, wherein the plurality of corrugated fins have drainage slits for draining condensed water, and the protrusions are provided at positions that avoid the drainage slits.

3. The heat exchanger according to claim 1 or 2, wherein the dimension of the projection of the side plate in the first direction is 80% or less of the thickness of the side plate.

4. The heat exchanger according to any one of claims 1 to 3, wherein the projection of the side plate is 15% or more and 40% or less of the peak height, which is the dimension of the plurality of corrugated fins in the first direction.

5. The heat exchanger according to any one of claims 1 to 4, wherein the projection of the side plate abuts against the outer edges of both ends in the second direction of the end corrugated fins of the plurality of corrugated fins that the side plate faces.

6. The heat exchanger according to any one of claims 1 to 5, wherein the projection of the side plate is provided at both ends of the side plate in a third direction intersecting the first and second directions.

7. The heat exchanger according to any one of claims 1 to 6, wherein the projection of the side plate is hemispherical.

8. The heat exchanger according to any one of claims 1 to 6, wherein the projection of the side plate is prismatic in shape.

9. The heat exchanger according to any one of claims 1 to 4, wherein the projection of the side plate is pierced into the end corrugated fin of the plurality of corrugated fins on which the side plate faces.

10. The heat exchanger according to claim 9, wherein the plurality of corrugated fins are provided with a plurality of louvers, and the projection of the side plate is provided such that, in a third direction intersecting the first and second directions of the end corrugated fin, it is located between the leeward louvers of the plurality of louvers, at a position one-third of the way from the leeward louvers, and the leeward edge of the end corrugated fin.

11. The heat exchanger according to any one of claims 1 to 10, wherein the projection of the side plate has a shape that tapers from the base end to the tip.

12. An air conditioner equipped with a heat exchanger according to any one of claims 1 to 11.

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