Heat exchange element and method for manufacturing heat exchange element

Abstract

In this heat exchange element, a plurality of corrugated plate-like heat transfer members 30 are stacked, the heat exchange element having a countercurrent part in which a supply air passage and an exhaust air passage are arranged in opposition to each other. In the corrugated plate-like heat transfer members 30, first protruding parts 64 protruding to a first-surface 60 side and second protruding parts 66 protruding to a second-surface 62 side are alternately arranged. In the countercurrent part, one heat transfer member 30 and another heat transfer member 30 from among the plurality of heat transfer members 30 are stacked such that the first protruding parts 64 of the one heat transfer member 30 are in opposition to the second surface 62 of the other heat transfer member 30, which is adjacent on the first-surface 60 side of the one heat transfer member 30. Each of the plurality of heat transfer members 30 has a moisture-permeable member 32 permeable to moisture and a shape-retaining member 34 for maintaining the corrugated plate-like shape, and an opening 70 in the shape-retaining member 34 is covered by the moisture-permeable member 32.

Description

Heat exchange element, method for manufacturing heat exchange element

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

[0002] The heat exchange element is configured by stacking a plurality of flow path forming members, and heat exchange is performed by flowing air through a flow path formed in a layered manner between the plurality of flow path forming members. The flow path forming member is manufactured by subjecting a sheet material having good thermal conductivity to a corrugated uneven bending process (see, for example, Patent Document 1). Further, in the heat exchange element, a manifold portion for connecting a flat portion of the cross-flow portion to both ends of the counter-flow portion formed in a corrugated plate shape is provided. By bringing the manifold portion into contact with the corrugated plate shape portion, an air passage of the heat exchange element is formed (see, for example, Patent Document 2).

[0003] Japanese Patent Application Laid-Open No. 2023-174894, Japanese Patent Publication No. 2015-509178

[0004] The heat exchange element is installed, for example, in the attic of a house together with a blower fan. As the heat exchange element at that time, a total heat exchange element that exchanges heat (sensible heat) and humidity (latent heat) is used. Since the heat exchange element of Patent Document 1 uses a material that transmits only sensible heat, it cannot pass water vapor and cannot exchange latent heat. In order to exchange latent heat, it is necessary to use a resin film having water vapor permeability. However, if the film thickness is thin or the strength is insufficient, the shape bent by the film alone cannot be maintained, and the structure of the heat exchange element cannot be realized. Further, when the resin film having water vapor permeability is stretched while applying heat along the mold, the water vapor transmission characteristics may deteriorate due to the reduction in the film thickness or the influence of heat. Further, when the stretching amount of the three-dimensional shape processing becomes large, the film may be broken.

[0005] In Patent Document 2, when the air flow enters from the flat portion into the corrugated air passage, the air flow passes through the interface between the manifold member and the corrugated plate shape portion. Just bringing the manifold portion into contact with the corrugated plate shape portion cannot sufficiently ensure airtightness at this contact interface, and leakage occurs between the air passages for heat exchange. The occurrence of leakage between the air passages for heat exchange reduces the heat exchange performance.

[0006] Therefore, this disclosure aims to solve the above problems and provide a technology that maintains shape while enabling highly efficient exchange of sensible and latent heat. It also aims to provide a technology that ensures airtightness between heat exchange air passages.

[0007] To solve the above problems, a heat exchange element according to one embodiment of the present disclosure is a heat exchange element having a counter-flow section in which a supply air passage through which a supply air flow flows and an exhaust air passage through which an exhaust air flow flowing in the opposite direction to the supply air flow flow are arranged opposite to each other, wherein a plurality of corrugated heat transfer members are stacked, and a supply air passage through which a supply air flow flows is arranged opposite to the supply air flow, wherein the corrugated heat transfer members have a first surface and a second surface facing opposite directions, and a first protrusion protruding towards the first surface and a second protrusion protruding towards the second surface are arranged alternately, and in the counter-flow section, one heat transfer member and another heat transfer member are stacked while the first protrusion of one heat transfer member and the second protrusion of another heat transfer member adjacent to the first surface of the one heat transfer member face each other, and each of the plurality of heat transfer members has a moisture-permeable member that can pass through moisture and a shape-retaining member for maintaining a corrugated shape. The opening of the shape-retaining member is covered by the moisture-permeable member.

[0008] Another aspect of the present disclosure is a method for manufacturing a heat exchange element. This method is a method for manufacturing a heat exchange element having a counterflow section configured in which an air intake passage through which an air intake flow flows and an exhaust passage through which an exhaust flow flowing in the opposite direction to the air intake flow flow face each other, comprising the steps of bending a rectangular heat transfer member having a first surface and a second surface facing opposite directions into a corrugated shape so that a first protrusion protruding toward the first surface and a second protrusion protruding toward the second surface are alternately arranged along the first direction, and the direction intersecting the first direction is defined as the second direction, and at the first end of the heat transfer member in the second direction The method comprises the steps of: forming a first flat portion by crushing a corrugated sheet; forming a second flat portion by crushing a corrugated sheet at the second end of the heat transfer member in the second direction; and stacking multiple heat transfer members by preparing multiple corrugated sheet-shaped heat transfer members having the first flat portion and the second flat portion, and stacking one heat transfer member with another heat transfer member while facing the first protrusion of one of the multiple heat transfer members with the second protrusion of another heat transfer member adjacent to the first surface side of the first heat transfer member.

[0009] According to this disclosure, it is possible to exchange sensible and latent heat with high efficiency while maintaining the shape. In addition, airtightness between the heat exchange air passages can be ensured.

[0010] This is a perspective view showing the configuration of the heat exchange element according to Example 1. Figures 2(a)-2(b) are perspective views showing the configuration of the first heat transfer layer in Figure 1. Figures 3(a)-2(e) are diagrams showing the manufacturing procedure of the heat transfer member in Figures 2(a)-2(b). Figures 4(a)-2(b) are perspective views showing the configuration of the second heat transfer layer in Figure 1. This is an exploded perspective view showing the configuration of the heat exchange element in Figure 1. This is a cross-sectional view showing the configuration of the heat exchange element in Figure 1. Figures 7(a)-2(e) are diagrams showing the manufacturing procedure of the heat transfer member according to Modification 1. Figures 8(a)-2(e) are diagrams showing the manufacturing procedure of the heat transfer member according to Modification 2. Figures 9(a)-2(e) are diagrams showing the manufacturing procedure of the heat transfer member according to Modification 3. This is a cross-sectional view showing the configuration of the heat exchange element in Figure 1. This is a perspective view showing the configuration of the heat exchange element according to Example 2. Figures 12(a)-2(b) are perspective views showing the configuration of the first heat transfer layer in Figure 11. Figures 13(a)-2(c) are diagrams showing the manufacturing procedure of the heat transfer member in Figures 12(a)-2(b). Figures 14(a) and 14(b) are perspective views showing the configuration of the second heat transfer layer in Figure 11. Figure 14 is an exploded perspective view showing the configuration of the heat exchange element in Figure 11. Figure 14 is a cross-sectional view showing the configuration of the heat exchange element in Figure 11.

[0011] The embodiments of this disclosure will be described below with reference to the drawings. Each embodiment described below represents a preferred specific example of this disclosure. Therefore, the numerical values, shapes, materials, components, arrangement and connection configurations of components, as well as the steps (processes) and the order of steps shown in the following embodiments are examples and are not intended to limit this disclosure. Accordingly, components in the following embodiments that are not described in the independent claims representing the highest-level concepts of this disclosure will be described as arbitrary components. In addition, substantially identical components are denoted by the same reference numerals in each figure, and redundant explanations are omitted or simplified.

[0012] (Example 1) Figure 1 is a perspective view showing the configuration of the heat exchange element 100. In the heat exchange element 100, a first heat transfer layer 2a and a second heat transfer layer 2b, collectively referred to as the heat transfer layer 2, are stacked alternately in the vertical direction. The heat transfer layer 2 has a first intersecting flow section 22a, a counter-flow section 20, and a second intersecting flow section 22b arranged in order in the horizontal direction. The first intersecting flow section 22a and the second intersecting flow section 22b are collectively referred to as the intersecting flow section 22. The intersecting flow section 22 includes a wall material 4, a rib material 6, an inlet 10, and an outlet 12, but the arrangement of the wall material 4, rib material 6, inlet 10, and outlet 12 differs between the first heat transfer layer 2a and the second heat transfer layer 2b.

[0013] The opposing flow section 20 is an airflow forming member that creates an airflow path with opposing airflow, and the intersecting flow section 22 is an airflow forming member that creates an airflow path with intersecting airflow. Opposing and intersecting airflow will be described later. In the first heat transfer layer 2a, the direction of air flow from the inlet 10 to the outlet 12 is opposite to the direction of air flow from the inlet 10 to the outlet 12 in the second heat transfer layer 2b, and sensible heat and latent heat are exchanged between them. For example, if the air flowing through the first heat transfer layer 2a is the supply airflow, then the air flowing through the second heat transfer layer 2b is the exhaust airflow.

[0014] Figures 2(a) and 2(b) are perspective views showing the configuration of the first heat transfer layer 2a. Here, Figure 2(b) is an exploded perspective view showing the configuration of the first heat transfer layer 2a in Figure 2(a). The frame 8 constitutes the skeleton of the first heat transfer layer 2a, that is, the frame of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b. The frame 8 includes a first wall material 4a, a second wall material 4b, and a third wall material 4c, collectively referred to as wall material 4, and a first rib material 6a and a second rib material 6b, collectively referred to as rib material 6. The first wall material 4a, the second wall material 4b, and the third wall material 4c all have a rectangular prism shape, and the first rib material 6a and the second rib material 6b all have a triangular tubular shape (a triangular cylindrical structure). In other words, the first rib member 6a and the second rib member 6b have a triangular frame shape in plan view and are composed of a base and a pair (two) hypotenuses. Each base that makes up the first rib member 6a and the second rib member 6b constitutes the opposing flow section 20.

[0015] When the two first wall members 4a are assembled with their long sides facing each other and the bottoms of the first rib member 6a and the second rib member 6b facing each other, a rectangular tube shape (a square cylindrical structure) is formed, which serves as the frame for the opposing flow section 20. In other words, one end of the first wall member 4a is connected to one end of the bottom of the first rib member 6a, and the other end of the first wall member 4a is connected to one end of the bottom of the second rib member 6b, thereby forming an opposing flow section 20 that has a frame-like (rectangular) shape in plan view. Furthermore, when the second wall member 4b is assembled so as to overlap one of the hypotenuses of the first rib member 6a, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the first intersecting flow section 22a. Furthermore, when the third wall material 4c is assembled so as to overlap one of the hypotenuses of the second rib material 6b, a triangular tubular shape (a triangular cylindrical structure) is formed, which serves as the frame for the second intersecting flow section 22b. The top and bottom surfaces of each of these rectangular tubular shapes are open.

[0016] The rib material 6 is processed in one piece to the required shape, for example, by vacuum forming a resin sheet. The first rib material 6a and the second rib material 6b may be processed from a single resin sheet. Similarly, the wall material 4 is also formed in one piece by vacuum forming using a single resin sheet, just like the rib material 6. As a result, the frame 8 is assembled from resin sheet molded products that form the vacuum-formed wall material 4 and rib material 6. Different materials may be used for the wall material 4 and the rib material 6. For example, a urethane sheet may be used for the wall material 4, and perforated plastic corrugated cardboard may be used for the rib material 6.

[0017] An opening is provided in the first rib member 6a as an inlet 10. That is, the inlet 10 of the first rib member 6a is provided on the side of the pair of slanted edges that make up the first rib member 6a that is located on the negative side of the first direction D1. An opening is provided in the second rib member 6b as an outlet 12. That is, the outlet 12 of the second rib member 6b is provided on the side of the pair of slanted edges that make up the second rib member 6b that is located on the positive side of the first direction D1. Furthermore, openings are also provided in the portions of the first rib member 6a and the second rib member 6b that are on the opposing flow section 20 side. That is, openings are also provided in the sides of the first rib member 6a and the second rib member 6b that are on the base side of the triangle in a plan view and that make up the opposing flow section 20. As a result, in the first heat transfer layer 2a, the first intersecting flow section 22a penetrates the outside, the first intersecting flow section 22a penetrates the opposing flow section 20 and the second intersecting flow section 22b in sequence, and the second intersecting flow section 22b penetrates the outside. In other words, in the first heat transfer layer 2a, the air introduced from the inlet 10 of the first intersecting flow section 22a flows in the order of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b, and is discharged from the outlet 12 of the second intersecting flow section 22b.

[0018] A heat transfer member 30 is attached to the central part of the frame of the opposing flow section 20. The heat transfer member 30 includes a moisture-permeable member 32, a shape-retaining member 34, and a first flat section 36a and a second flat section 36b, collectively referred to as a flat section 36. The heat transfer member 30 will be described below using Figures 3(a)-(e).

[0019] Figures 3(a)-3(e) show the manufacturing procedure for the heat transfer member 30. Figure 3(a) shows the shape-retaining member 34. The shape-retaining member 34 has a first surface 60 and a second surface 62 facing opposite directions and is a member for maintaining the corrugated shape of the heat transfer member 30. The shape-retaining member 34 is made of a metal film that can be bent at room temperature and retain its shape. Among the metal films, aluminum is particularly used for its thermal conductivity or light weight. Aluminum tape, which is an aluminum film coated with adhesive, may also be used. Considering processability and shape retention, an aluminum film thickness of about 50 μm is preferred. For example, an aluminum tape with a thickness of 100 μm, made by coating a 50 μm aluminum film with 50 μm of adhesive, is used. The shape-retaining member 34 has a lattice shape, and a plurality of openings 70 are provided in the lattice shape. For example, a lattice-shaped hole is made in the aluminum tape. Details of the lattice shape will be described later.

[0020] Furthermore, a resin sheet may be used instead of a metal film for the shape-retaining member 34. The resin sheet can be formed into a corrugated shape by applying heat and bending, and can retain its shape after cooling.

[0021] Figure 3(b) shows the moisture-permeable member 32. The moisture-permeable member 32, like the shape-retaining member 34, has a first surface 60 and a second surface 62 facing opposite directions, and is a member that can permeate moisture without allowing air to pass through. The moisture-permeable member 32 is, for example, a water vapor-permeable polymer thin film. Polymer thin films are very soft and do not easily maintain their shape even when given a corrugated shape. In other words, the moisture-permeable member 32 does not easily maintain its shape without being combined with a framework made of other materials.

[0022] Figure 3(c) shows a configuration in which the moisture-permeable member 32 is attached to the shape-retaining member 34 in a layered manner. In other words, the moisture-permeable member 32 is attached to the shape-retaining member 34 with adhesive so that the moisture-permeable member 32 is exposed at each of the multiple openings 70 of the shape-retaining member 34. That is, the openings 70 of the shape-retaining member 34 are covered by the moisture-permeable member 32. As a result, even though the moisture-permeable member 32 is thin, soft, and difficult to maintain its shape, the shape-retaining member 34 acts as a framework, making it possible to maintain the corrugated shape.

[0023] In the shape-retaining member 34, the portion of the moisture-permeable member 32 exposed through the multiple openings 70 is responsible for humidity exchange performance. Therefore, to improve the efficiency of humidity (latent heat) exchange, the exposed area of ​​the moisture-permeable member 32 should be increased. For this reason, it is desirable that the area of ​​the multiple openings 70 provided in the shape-retaining member 34 is larger than the area of ​​the shape-retaining member 34 excluding the multiple openings 70. It is required to increase the area of ​​the openings 70 while maintaining the minimum area necessary to maintain the strength of the shape-retaining member 34. In other words, the area of ​​the moisture-permeable member 32 exposed through the openings 70 of the shape-retaining member 34 is larger than the area of ​​the shape-retaining member 34 excluding the openings 70.

[0024] Figure 3(d) shows the configuration of the heat transfer member 30 after the process following Figure 3(c). The shape-retaining member 34 to which the moisture-permeable member 32 is attached is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, first protrusions 64 that protrude toward the first surface 60 and second protrusions 66 that protrude toward the second surface 62 are arranged alternately. Here, the direction in which the first protrusions 64 and the second protrusions 66 are arranged alternately is defined as the first direction D1, and the direction that intersects (is perpendicular to) the first direction D1 is defined as the second direction D2. If the aspect ratio of the corrugated shape is 5 or less, bending using rollers can be performed sequentially, resulting in high productivity.

[0025] In this embodiment, in order to improve the efficiency of total heat exchange, the corrugated shape of the heat transfer member 30 is formed from a moisture-permeable member 32. However, as mentioned above, since the moisture-permeable member 32 is thin and soft, it cannot maintain its shape even after being processed into a corrugated shape. Therefore, a shape-retaining member 34 that can maintain its shape even after being formed is used as a framework for maintaining the shape of the moisture-permeable member 32. As shown in Figure 3(d), a cell-type heat exchange element structure with water vapor permeability is realized by drilling holes in the shape-retaining member 34 in a grid pattern, attaching the moisture-permeable member 32, and then bending it into a corrugated shape.

[0026] Here, the grid-like shape of the shape-retaining member 34 is a shape that spans both the first direction D1 and the second direction D2 with a constant width, and is arranged at intervals that can maintain the wave shape of the moisture-permeable member 32. If the span is too narrow, it will be difficult to maintain the shape, and if it is too wide, the exposed area of ​​the moisture-permeable member 32 will be small. Similarly, if the spacing of the grid shape is too wide, it will be difficult to maintain the shape, and if the spacing is too narrow, the exposed area of ​​the moisture-permeable member 32 will be small.

[0027] Figure 3(e) shows the configuration of the heat transfer member 30 after the process following Figure 3(d). The first end portion 72 in the second direction D2 of the heat transfer member 30 is processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a first flat portion 36a by crushing the corrugated shape. The tapered portion provided on the inside of the outermost edge of the press die enables flattening processing that suppresses tearing of the heat transfer member 30. Similarly, the second end portion 74 in the second direction D2 of the heat transfer member 30 is also processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a second flat portion 36b by crushing the corrugated shape. This is done to facilitate the attachment of one end of the rib material 6 for introducing air into the corrugated shape, as shown in Figure 2(b).

[0028] As described above, the heat transfer member 30 has a wave-shaped structure in which first protrusions 64 projecting toward the first surface 60 and second protrusions 66 projecting toward the second surface 62 are arranged alternately. When the direction in which the first protrusions 64 and the second protrusions 66 are arranged alternately is defined as the first direction D1, and the direction intersecting the first direction D1 is defined as the second direction D2, a first flat portion 36a formed by flattening a corrugated sheet is arranged at the first end 72 of the heat transfer member 30 in the second direction D2, and a second flat portion 36b formed by flattening a corrugated sheet is arranged at the second end 74 of the heat transfer member 30 in the second direction D2.

[0029] Returning to Figure 2(b), the heat transfer member 30 is attached to the frame of the opposing flow section 20 from below, with the second direction D2 of the heat transfer member 30 aligned with the direction from the first intersecting flow section 22a toward the second intersecting flow section 22b. A flat plate-shaped first external heat transfer member 40a is attached from below so as to fit into the frame of the first intersecting flow section 22a. As a result, the first external heat transfer member 40a is installed so as to communicate with the first flat portion 36a of the heat transfer member 30. A flat plate-shaped second external heat transfer member 40b is attached from below so as to fit into the frame of the second intersecting flow section 22b. As a result, the second external heat transfer member 40b is installed so as to communicate with the second flat portion 36b of the heat transfer member 30. Here, the first external heat transfer member 40a and the second external heat transfer member 40b are collectively referred to as the external heat transfer member 40. The external heat transfer member 40 is a moisture-permeable member and is made of the same material as the moisture-permeable member 32.

[0030] Here, "connecting" means that two members are connected by another member interposed between them, or that the two members are directly connected; in either case, it is sufficient that air or other fluids can flow between the two members.

[0031] When the first heat transfer layer 2a (heat transfer layer 2) is stacked as shown in Figure 1, a gap is secured by the rib material 6, so that an air supply passage 50 is formed within the first heat transfer layer 2a. The air supply passage 50 enters the inlet 10 from the outside, passes through the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b, and in particular passes over the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b, before exiting to the outside from the outlet 12. Therefore, it can be said that the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b constitute the air supply passage 50. Air supply flows through the air supply passage 50.

[0032] Here, in the heat transfer member 30, it is desirable that the positions of the first flat portion 36a and the second flat portion 36b be located near the center with respect to the height direction of the wave shape. Since the first flat portion 36a and the second flat portion 36b are flat in the shape-retaining member 34, the airflow to the opposing flow portion 20 and the intersecting flow portion 22 is made smooth.

[0033] Figures 4(a) and 4(b) are perspective views showing the configuration of the second heat transfer layer 2b. Here, Figure 4(b) is an exploded perspective view showing the configuration of the second heat transfer layer 2b in Figure 4(a). The frame 8 constitutes the skeleton of the second heat transfer layer 2b, that is, the frame of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b. The frame 8 includes the first wall material 4a, the fourth wall material 4d, and the fifth wall material 4e, collectively referred to as wall material 4, and the third rib material 6c and the fourth rib material 6d, collectively referred to as rib material 6. The first wall material 4a, the fourth wall material 4d, and the fifth wall material 4e all have a rectangular prism shape, and the third rib material 6c and the fourth rib material 6d all have a triangular tubular shape (a triangular cylindrical structure).

[0034] When the two first wall members 4a are assembled facing each other, and the third rib member 6c and the fourth rib member 6d are assembled facing each other, a rectangular tube shape (a square cylindrical structure) is formed, which serves as the frame for the opposing flow section 20. Furthermore, when the fourth wall member 4d is assembled so as to overlap one of the hypotenuses of the third rib member 6c, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the first intersecting flow section 22a. In addition, when the fifth wall member 4e is assembled so as to overlap one of the hypotenuses of the fourth rib member 6d, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the second intersecting flow section 22b. The top and bottom surfaces of each of these rectangular tube shapes are open.

[0035] An opening is provided in the fourth rib member 6d as an inlet 10, and an opening is provided in the third rib member 6c as an outlet 12. Furthermore, openings are also provided in the portions of the third rib member 6c and the fourth rib member 6d on the side facing the opposing flow section 20. As a result, in the second heat transfer layer 2b, the outside and the first intersecting flow section 22a are penetrated, the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b are penetrated in order, and the second intersecting flow section 22b is penetrated to the outside. In other words, in the second heat transfer layer 2b, air introduced from the inlet 10 of the second intersecting flow section 22b flows in the order of the second intersecting flow section 22b, the opposing flow section 20, and the first intersecting flow section 22a, and is discharged from the outlet 12 of the first intersecting flow section 22a.

[0036] As before, the heat transfer member 30 is attached to the frame of the opposing flow section 20 from below, the first external heat transfer member 40a is fitted into the frame of the first intersecting flow section 22a from below, and the second external heat transfer member 40b is fitted into the frame of the second intersecting flow section 22b from below. The exhaust air passage 52 enters the inlet 10 from the outside, passes through the second intersecting flow section 22b, the opposing flow section 20, and the first intersecting flow section 22a, and in particular passes over the second external heat transfer member 40b, over the heat transfer member 30, and over the first external heat transfer member 40a, before exiting to the outside from the outlet 12. Therefore, the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b can be said to constitute the exhaust air passage 52. The supply air flow passes through the exhaust air passage 52. Since the intake air passage 50 and the exhaust air passage 52 are oriented in opposite directions, the exhaust flow flows in the opposite direction to the intake air flow.

[0037] Figure 5 is an exploded perspective view showing the configuration of the heat exchange element 100. The first heat transfer layer 2a and the second heat transfer layer 2b described above are stacked alternately in the vertical direction. In the opposing flow section 20, the first heat transfer layer 2a and the second heat transfer layer 2b are also stacked in the vertical direction, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged along the second direction D2, but they face opposite directions. Therefore, in the opposing flow section 20, the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged opposite each other, but the direction of airflow is opposite. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become opposing flows.

[0038] In the first intersecting flow section 22a, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked vertically, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged to intersect each other. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become intersecting flows.

[0039] In the second intersecting flow section 22b, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked vertically, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged to intersect each other. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become intersecting flows.

[0040] As shown in Figure 5, the heat exchange element 100 has multiple corrugated heat transfer members 30 stacked on top of each other. In the opposing flow section 20 of the second heat transfer layer 2b, an overlap prevention member 14 extending in the first direction D1 is placed between the heat transfer member 30 of the second heat transfer layer 2b and the heat transfer member 30 of the first heat transfer layer 2a. An overlap prevention member 14 is similarly placed in the opposing flow section 20 of the first heat transfer layer 2a. For example, aluminum foil is used for the overlap prevention member 14. This eliminates the need for a mold required for molding. When corrugated heat transfer members 30 are stacked as shown in Figure 5, the contact surface is small, so if misalignment occurs between the heat transfer members 30, overlapping of the corrugated shape may occur, making it impossible to secure the upper and lower gaps. The overlap prevention member 14 is provided to secure the upper and lower gaps. By making the thickness of the overlap prevention member 14 thin, the need to increase the thickness of each heat transfer layer 2 during stacking is suppressed.

[0041] Figure 6 is a cross-sectional view showing the configuration of the heat exchange element 100. This shows a cross-section of the heat exchange element 100 along the first direction D1. As described above, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked alternately in the vertical direction. When the second heat transfer layer 2b is stacked below the first heat transfer layer 2a, the first protrusion 64 of the heat transfer member 30 of the second heat transfer layer 2b and the second protrusion 66 of the heat transfer member 30 of the first heat transfer layer 2a are stacked facing each other. Then, an exhaust air passage 52 is formed between the heat transfer member 30 of the second heat transfer layer 2b and the heat transfer member 30 of the first heat transfer layer 2a.

[0042] When the first heat transfer layer 2a is stacked below the second heat transfer layer 2b, the first protrusion 64 of the heat transfer member 30 of the first heat transfer layer 2a and the second protrusion 66 of the heat transfer member 30 of the second heat transfer layer 2b are stacked facing each other. Then, an air supply passage 50 is formed between the heat transfer member 30 of the first heat transfer layer 2a and the heat transfer member 30 of the second heat transfer layer 2b.

[0043] Here, the shape-retaining member 34 retains a corrugated shape, and the moisture-permeable member 32 is attached to the shape-retaining member 34 by an adhesive 38. When laminating the heat transfer member 30 including the corrugated shape-retaining member 34 and the moisture-permeable member 32 as shown in FIG. 6, it is desirable that the shape-retaining members 34 be laminated adjacent to each other in the vertical direction and the moisture-permeable members 32 be laminated adjacent to each other in the vertical direction. This is to suppress the crushing of the corrugated shape when a force is applied in the pressing direction during lamination.

[0044] When laminating the corrugated shape-retaining members 34, it is desirable to arrange them so that another shape-retaining member 34 is positioned on top of the shape-retaining member 34 in order to maintain the strength during lamination. Also, at this time, it is desirable to arrange the anti-overlap member 14 at the location where the strong corrugated shape-retaining member 34 is positioned in order to maintain the strength.

[0045] Hereinafter, a method for manufacturing the heat exchange element 100 will be described. The method for manufacturing the heat exchange element 100 includes the following steps (1) to (6). (1) Prepare a lattice-shaped shape-retaining member 34 having a plurality of openings 70 as shown in FIG. 3(a). (2) Prepare a rectangular moisture-permeable member 32 as shown in FIG. 3(b). (3) As shown in FIG. 3(c), attach the moisture-permeable member 32 to the shape-retaining member 34 so as to cover the plurality of openings 70 of the shape-retaining member 34. As a result, the heat transfer member 30 is generated. (4) As shown in FIG. 3(d), by bending the heat transfer member 30 into a corrugated shape, the first protrusions 64 and the second protrusions 66 are alternately arranged along the first direction D1. (5) As shown in FIG. 3(e), at the first end 72 in the second direction D2 of the heat transfer member 30, crush the corrugated shape to form the first flat portion 36a. Also, at the second end 74 in the second direction D2 of the heat transfer member 30, crush the corrugated shape to form the second flat portion 36b. A plurality of heat transfer members 30 shown in FIG. 3(e) are prepared.

[0046] (6) As shown in Fig. 2(b), the frame 8 is generated by assembling two first wall members 4a, second wall members 4b, third wall members 4c, first rib members 6a, and second rib members 6b. Among the frame 8, a heat transfer member 30 is attached to the frame of the counterflow portion 20, a first external heat transfer member 40a is attached to the frame of the first crossflow portion 22a, and a second external heat transfer member 40b is attached to the frame of the second crossflow portion 22b. Thereby, the first external heat transfer member 40a is communicated with the first flat portion 36a, and the second external heat transfer member 40b is communicated with the second flat portion 36b. Before or after attaching the heat transfer member 30 to the frame of the counterflow portion 20, an overlap prevention member 14 extending in the first direction D1 is installed on the frame of the counterflow portion 20. Thus, the first heat transfer layer 2a is generated.

[0047] (7) As shown in Fig. 4(b), the frame 8 is generated by assembling two first wall members 4a, fourth wall members 4d, fifth wall members 4e, third rib members 6c, and fourth rib members 6d. Among the frame 8, a heat transfer member 30 is attached to the frame of the counterflow portion 20, a first external heat transfer member 40a is attached to the frame of the first crossflow portion 22a, and a second external heat transfer member 40b is attached to the frame of the second crossflow portion 22b. Thereby, the first external heat transfer member 40a is communicated with the first flat portion 36a, and the second external heat transfer member 40b is communicated with the second flat portion 36b. Before or after attaching the heat transfer member 30 to the frame of the counterflow portion 20, an overlap prevention member 14 extending in the first direction D1 is installed on the frame of the counterflow portion 20. Thus, the second heat transfer layer 2b is generated.

[0048] (8) As shown in Fig. 5, the first heat transfer layer 2a and the second heat transfer layer 2b are laminated while being alternately arranged in the vertical direction. Thereby, in two heat transfer members 30 adjacent in the vertical direction, the two heat transfer members 30 are laminated while the first protrusion 64 of the lower heat transfer member 30 and the second protrusion 66 of the upper heat transfer member 30 face each other. Also, a plurality of first external heat transfer members 40a communicated with the first flat portion 36a are laminated, and a plurality of second external heat transfer members 40b communicated with the second flat portion 36b are laminated.

[0049] The configuration of the heat transfer member 30 is not limited to those shown in Figures 3(a)-(e). To maintain the shape of the corrugated resin film, a shape-retaining member 34 is used in the heat transfer member 30. Conventional shape-retaining members 34 have a grid-like perforation. When manufacturing such a shape-retaining member 34, the perforated portion is removed from the metal film. Since the removed perforated portion is not used, it is difficult to improve the yield of the shape-retaining member 34. In addition, the heat transfer member 30 is required to have an increased efficiency in the exchange of sensible and latent heat. Below, alternative configurations of the heat transfer member 30 to solve these problems will be described as Modification 1 to Modification 3.

[0050] (Modification 1) Figures 7(a)-7(e) show the manufacturing procedure for the heat transfer member 30. Figure 7(a) shows the shape-retaining member 34. As before, the shape-retaining member 34 has a first surface 60 and a second surface 62 facing opposite directions, and is a member for maintaining the corrugated shape of the heat transfer member 30. The shape-retaining member 34 is made of a metal film that can be bent at room temperature and retain its shape. The shape-retaining member 34 includes a plurality of metal pieces in which the length in the first direction D1 is longer than the length in the second direction D2. Specifically, the plurality of metal pieces are arranged in the second direction D2, and by spacing out adjacent metal pieces, the shape-retaining member 34 has a striped shape. The spacing between the spaced metal pieces is shown as an opening 70. That is, the opening 70 may indicate the part between the stripes, or unlike a grid, it may indicate an opening enclosed in two directions (up and down) rather than an opening enclosed in four directions (up, down, left, and right). Figure 7(b) shows the moisture-permeable member 32, which is the same as in Figure 3(b).

[0051] Figure 7(c) shows a configuration in which the moisture-permeable member 32 is attached to the shape-retaining member 34 in a layered manner. In other words, the moisture-permeable member 32 is attached to the shape-retaining member 34 with adhesive so that the moisture-permeable member 32 is exposed at each of the multiple openings 70 of the shape-retaining member 34. The openings 70 of the shape-retaining member 34 are covered by the moisture-permeable member 32. As a result, in the second direction D2, the moisture-permeable member 32 and the shape-retaining member 34 are arranged alternately in a striped pattern.

[0052] In the shape-retaining member 34, the portion where the moisture-permeable member 32 is exposed through multiple openings 70 is responsible for humidity exchange performance. Therefore, the exposed area of ​​the moisture-permeable member 32 should be increased to improve the efficiency of humidity (latent heat) exchange. When the shape-retaining member 34 is in a striped shape, it is easier to reduce the area of ​​the shape-retaining member 34 and increase the exposed area of ​​the moisture-permeable member 32 compared to when the shape-retaining member 34 is in a grid shape.

[0053] Figure 7(d) shows the configuration of the heat transfer member 30 after the process following Figure 7(c). The shape-retaining member 34 to which the moisture-permeable member 32 is attached is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, first protrusions 64 that protrude toward the first surface 60 and second protrusions 66 that protrude toward the second surface 62 are arranged alternately in the first direction D1. As a result, the corrugated shape in the first direction D1 is maintained by the shape-retaining member 34. On the other hand, the shape in the second direction D2 is maintained by the cylindrical shape of the moisture-permeable member 32 and the shape-retaining member 34.

[0054] Figure 7(e) shows the configuration of the heat transfer member 30 after the process following Figure 7(d). A first flat portion 36a is formed at the first end 72 in the second direction D2 of the heat transfer member 30, and a second flat portion 36b is formed at the second end 74 in the second direction D2 of the heat transfer member 30.

[0055] In the first modified example, since the shape-retaining member 34 has a striped shape, less unused portion is generated from the metal film. This improves the yield of the shape-retaining member 34. Also, because the shape-retaining member 34 has a striped shape, the exposed area of ​​the moisture-permeable member 32 is increased. This increases the efficiency of sensible heat and latent heat exchange.

[0056] (Modification 2) Modification 2 relates to a configuration in which the strength of Modification 1 is increased. Figures 8(a)-8(e) show the manufacturing procedure of the heat transfer member 30. Figures 8(a)-8(b) are the same as Figures 7(a)-8(b). Figure 8(c) shows a configuration in which a moisture permeable member 32 is superimposed on and attached to the shape-retaining member 34. Similar to Figure 7(c), the moisture permeable member 32 is attached to the shape-retaining member 34 with adhesive so that the moisture permeable member 32 is exposed at each of the multiple openings 70 of the shape-retaining member 34. The openings 70 of the shape-retaining member 34 are covered by the moisture permeable member 32. As a result, a striped pattern is formed in which the moisture permeable member 32 and the shape-retaining member 34 are arranged alternately in the second direction D2. Furthermore, in Modification 2, an auxiliary retaining member 80, which is a metal piece whose length in the second direction D2 is longer than the length in the first direction D1, is attached with adhesive so as to straddle the alternately arranged moisture permeable member 32 and shape-retaining member 34. The strength in the second direction D2 increases from the auxiliary holding member 80. Here, one auxiliary holding member 80 is attached, but multiple auxiliary holding members 80 may be attached.

[0057] Figure 8(d) shows the configuration of the heat transfer member 30 after the process following Figure 8(c). The shape-retaining member 34 to which the moisture-permeable member 32 is attached is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, first protrusions 64 that project toward the first surface 60 and second protrusions 66 that project toward the second surface 62 are arranged alternately in the first direction D1. In addition, auxiliary retaining members 80 are arranged along the first protrusions 64. When attached in a grid pattern, the shape-retaining member 34 attached along the first direction D1 in Figure 3 is not necessarily placed at the vertices (see Figure 6), but in the modified example 2, the auxiliary retaining members 80 may be placed at the vertices of the first protrusions 64. By placing the auxiliary retaining members 80 at the vertices of the first protrusions 64, it is possible to suppress the heat transfer member 30 from spreading in the first direction D1 and the corrugated shape from collapsing. Furthermore, the placement of the auxiliary holding member 80 at the apex of the first protrusion 64 increases the strength in the first direction D1. Figure 8(e) shows the configuration of the heat transfer member 30 after the process following Figure 8(d). A first flat portion 36a is formed at the first end 72 in the second direction D2 of the heat transfer member 30, and a second flat portion 36b is formed at the second end 74 in the second direction D2 of the heat transfer member 30.

[0058] (Modification 3) Modification 3 also relates to a configuration that increases the strength of Modification 1. Figures 9(a)-(e) show the manufacturing procedure of the heat transfer member 30. Figures 9(a)-(b) are the same as Figures 7(a)-(b). Figure 9(c) shows a configuration in which a moisture permeable member 32 is attached to the shape-retaining member 34 in overlapping layers. Similar to Figure 7(c), the moisture permeable member 32 is attached to the shape-retaining member 34 with adhesive so that the moisture permeable member 32 is exposed at each of the multiple openings 70 of the shape-retaining member 34. The openings 70 of the shape-retaining member 34 are covered by the moisture permeable member 32. As a result, a striped pattern is formed in which the moisture permeable member 32 and the shape-retaining member 34 are arranged alternately in the second direction D2. Furthermore, in Modification 3, an auxiliary retaining member 80 is attached diagonally to the moisture permeable member 32. The auxiliary retaining member 80 increases the strength in the second direction D2. In this example, one auxiliary holding member 80 is attached, but two auxiliary holding members 80 may be attached in an "X" shape.

[0059] Figure 9(d) shows the configuration of the heat transfer member 30 after the process following Figure 9(c). The shape-retaining member 34 to which the moisture-permeable member 32 is attached is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, a first protrusion 64 protruding towards the first surface 60 and a second protrusion 66 protruding towards the second surface 62 are arranged alternately in the first direction D1. Figure 9(e) shows the configuration of the heat transfer member 30 after the process following Figure 9(d). A first flat portion 36a is formed at the first end 72 in the second direction D2 of the heat transfer member 30, and a second flat portion 36b is formed at the second end 74 in the second direction D2 of the heat transfer member 30.

[0060] (Size of Heat Transfer Members 30) The size of the heat transfer members 30 in the heat exchange element 100 of Embodiment 1 will be further described below. Figure 10 is a cross-sectional view showing the configuration of the heat exchange element 100. This is shown in the same way as in Figure 6. As mentioned above, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked alternately in the vertical direction, and a plurality of heat transfer members 30 are stacked in the vertical direction accordingly. Here, the direction in which the plurality of heat transfer members 30 are stacked is defined as the third direction D3. Also, if the side on which the first surface 60 of each heat transfer member 30 is located is defined as the "upper side", then the side on which the second surface 62 of each heat transfer member 30 is located is defined as the "lower side". The upper and lower sides are definitions for convenience, and the upper and lower sides may be reversed. The first heat transfer member 30a and the second heat transfer member 30b of the plurality of heat transfer members 30 are adjacent to each other in the third direction D3. In particular, the first heat transfer member 30a is located on the upper side, and the second heat transfer member 30b is located on the lower side.

[0061] One of the first protrusions 64 of the first heat transfer member 30a is the upper protrusion 90. Two second protrusions 66 sandwiching the upper protrusion 90 in the first direction D1 are the first lower protrusion 92a and the second lower protrusion 92b. For example, the first lower protrusion 92a is located to the left of the upper protrusion 90, and the second lower protrusion 92b is located to the right of the upper protrusion 90. One of the second protrusions 66 of the second heat transfer member 30b is the lower protrusion 94. Two first protrusions 64 sandwiching the lower protrusion 94 in the first direction D1 are the first upper protrusion 96a and the second upper protrusion 96b. For example, the first upper protrusion 96a is located to the left of the lower protrusion 94, and the second upper protrusion 96b is located to the right of the lower protrusion 94.

[0062] In these configurations, the upper projection 90 and the lower projection 94 face each other in the third direction D3, the first lower projection 92a and the first upper projection 96a face each other in D3, and the second lower projection 92b and the second upper projection 96b face each other in the third direction D3. The space enclosed by the first lower projection 92a, the upper projection 90, the second lower projection 92b, the second upper projection 96b, the lower projection 94, and the first upper projection 96a is the air passage 110. The air passage 110 can be said to be part of the supply air passage 50 or the exhaust air passage 52.

[0063] The distance between the first lower protrusion 92a and the second lower protrusion 92b is defined as the first directional airflow width 120. The first directional airflow width 120 may also be the distance between the first upper protrusion 96a and the second upper protrusion 96b. The distance between the upper protrusion 90 and the lower protrusion 94 is defined as the third directional airflow width 122. Here, the ratio obtained by dividing the third directional airflow width 122 by the first directional airflow width 120 is greater than 0.5 and less than or equal to 12.5.

[0064] The wind speed of the airflow through the air passage 110 slows down near the heat transfer member 30 due to friction between the heat transfer member 30 and the wind, and increases as it moves away from the heat transfer member 30. When the width of the air passage in the third direction D3 is the same as the width of the air passage in the first direction D1, the wind speed at the center of the air passage 110 increases, which increases the amount of air flowing through the center. On the other hand, the amount of air flowing near the heat transfer member 30 in the air passage 110 decreases, and the difference in wind speed between the center and the area near the heat transfer member 30 becomes larger, which impairs the transfer of heat or humidity from the wind to the heat transfer member 30.

[0065] Furthermore, although the air passage 110 of the air supply passage 50 and the air passage 110 of the exhaust passage 52 are adjacent, different air flows through them, so the heat transfer member 30 is subjected to a pressure difference between the opposing air, and the heat transfer member 30 may bend slightly. In this case, if the ratio of the third-direction air passage width 122 to the first-direction air passage width 120 becomes large, the effect of the bending of the heat transfer member 30 due to pressure from the first direction D1 becomes greater than the pressure from the third direction D3, making the air passage 110 more likely to become blocked. Taking these factors into consideration, by changing the lengths of the first-direction air passage width 120 and the third-direction air passage width 122, it is possible to avoid the air being concentrated in the center of the air passage 110, improve the transfer of heat or humidity, and obtain a highly efficient element.

[0066] In this embodiment, multiple heat transfer members 30, each having a moisture-permeable member 32 that can pass through moisture and a shape-retaining member 34 for maintaining a corrugated shape, are stacked. This allows for highly efficient exchange of sensible and latent heat while maintaining the shape. Furthermore, by stacking multiple heat transfer members 30, each having a moisture-permeable member 32 that can pass through moisture and a shape-retaining member 34 for maintaining a corrugated shape, the shape-retaining member 34 can maintain the corrugated shape of the low-strength moisture-permeable member 32. In addition, since the shape-retaining member 34 maintains the corrugated shape of the low-strength moisture-permeable member 32, a highly efficient heat exchange element 100 with a large heat transfer area that can exchange not only temperature but also humidity can be realized. Furthermore, since the heat transfer members 30 are bent, the risk of the moisture-permeable member 32 becoming thinner or being affected by heat can be reduced. Also, since bending is performed, the tension or elongation applied during bending can be suppressed.

[0067] Furthermore, since the shape-retaining member 34 has a grid shape and multiple openings 70, it is possible to maintain a framework structure at regular intervals while ensuring a moisture-permeable area. Also, since the corrugated shape-retaining member 34 is arranged perpendicular to the direction of airflow at a constant width, the corrugated shape of the moisture-permeable member 32 can be maintained. In addition, since the shape-retaining member 34 is also arranged at a constant width in the direction of airflow, the parallel positional relationship of the shape-retaining member 34 can be maintained, improving the accuracy of the shape. Moreover, since the area of ​​the moisture-permeable member 32 exposed through the openings 70 of the shape-retaining member 34 is larger than the area of ​​the shape-retaining member 34 excluding the openings 70, the humidity exchange efficiency can be improved.

[0068] Furthermore, since the overlap prevention member 14 is placed between two vertically adjacent heat transfer members 30, the risk of overlap during lamination can be reduced even if the two vertically adjacent heat transfer members 30 are corrugated in shape and are misaligned. Also, since flat portions 36 are provided at both ends of the shape-retaining member 34 in the airflow direction, the airflow between the opposing flow portion 20 and the intersecting flow portion 22 can be made smoother. Also, since the intersecting flow portion 22 is attached to the opposing flow portion 20, airflow can be smoothly introduced between the intersecting flow portions 22 and pressure loss can be suppressed. Also, since the shape-retaining member 34 is attached in a striped pattern, the material yield can be improved. Also, since the shape-retaining member 34 is attached in a striped pattern, the exposed area of ​​the moisture-permeable member 32 can be increased. Also, since the exposed area of ​​the moisture-permeable member 32 is increased, the sensible heat and latent heat efficiency can be improved.

[0069] An outline of one aspect of the present disclosure is as follows: (Item 1) A heat exchange element (100) having a plurality of corrugated heat transfer members (30) stacked together, and an air supply passage (50) through which an air supply flow flows and an exhaust passage (52) through which an exhaust flow flowing in the opposite direction to the air supply flow are arranged opposite to each other, wherein the corrugated heat transfer members (30) have a first surface (60) and a second surface (62) facing opposite directions, and a first projection (64) protruding toward the first surface (60) and a second projection (66) protruding toward the second surface (62) are arranged alternately. The opposing flow section (20) is configured such that the first protrusion (64) of one of the plurality of heat transfer members (30) faces the second protrusion (66) of another heat transfer member (30) adjacent to the first surface (60) of the first heat transfer member (30), with the heat transfer members (30) stacked on top of each other, and each of the plurality of heat transfer members (30) has a moisture-permeable member (32) that can pass through moisture and a shape-retaining member (34) for maintaining a corrugated shape, and the opening of the shape-retaining member (34) is covered by the moisture-permeable member (32), thus forming a heat exchange element (100).

[0070] (Item 2) The heat exchange element (100) according to Item 1, wherein the shape-retaining member (34) has a grid shape, and the shape-retaining member (34) has a plurality of openings (70) in the grid shape.

[0071] (Item 3) The heat exchange element (100) according to Item 1, wherein the shape-retaining member (34) has a striped shape, and the shape-retaining member (34) has a plurality of openings (70) in the striped shape.

[0072] (Item 4) The heat exchange element (100) according to Item 2 or 3, wherein the area of ​​the moisture permeable member (32) exposed from the opening (70) of the shape-retaining member (34) is greater than the area of ​​the shape-retaining member (34) excluding the opening (70).

[0073] (Item 5) The heat exchange element (100) according to Item 1, wherein the opposing flow portion (20) further has overlap prevention members (14) extending in a direction in which the first protrusion (64) and the second protrusion (66) are alternately arranged between one of the heat transfer members (30) and the other heat transfer member (30).

[0074] (Item 6) The heat exchange element (100) according to Item 1, wherein the direction in which the first protrusions (64) and the second protrusions (66) are arranged alternately is defined as the first direction (D1), the direction intersecting the first direction (D1) is defined as the second direction (D2), a first flat portion (36a) formed by flattening a corrugated sheet is arranged at the first end (72) of the heat transfer member (30) in the second direction (D2), and a second flat portion (36b) formed by flattening a corrugated sheet is arranged at the second end (74) of the heat transfer member (30) in the second direction (D2).

[0075] (Item 7) The supply air passage (50) through which the supply airflow flows and the exhaust air passage (52) through which the exhaust airflow flows intersect each other, and the supply air passage (50) has a first intersecting flow section (22a) and a second intersecting flow section (22b), the first intersecting flow section (22a) is installed to communicate with the first flat section (36a) of the heat transfer member (30) and has a flat plate-shaped first external heat transfer member (40a) that constitutes the supply air passage (50) or the exhaust air passage (52), the first intersecting flow section (22a) is made up of multiple stacked first external heat transfer members (40a), the second intersecting flow section (22b) is installed to communicate with the second flat section (36b) of the heat transfer member (30) and has a flat plate-shaped second external heat transfer member (40b) that constitutes the supply air passage (50) or the exhaust air passage (52), The second crossing portion (22b) is a heat exchange element (100) as described in item 6, comprising multiple stacks of the second external heat transfer members (40b).

[0076] (Item 8) When the direction in which the first protrusion (64) and the second protrusion (66) are arranged alternately is defined as the first direction (D1), the direction in which the plurality of heat transfer members (30) are stacked is defined as the third direction (D3), and of the plurality of heat transfer members (30), the first heat transfer member (30a) and the second heat transfer member (30b) are adjacent in the third direction (D3), and one of the first protrusions (64) of the first heat transfer member (30a) is the upper protrusion (90), and the two second protrusions (66) that sandwich the upper protrusion (90) in the first direction (D1) are the first lower protrusion (92a) and the second lower protrusion (92b), One of the second protrusions (66) of the second heat transfer member (30b) is a lower protrusion (94), and the two first protrusions (64) that sandwich the lower protrusion (94) in the first direction (D1) are a first upper protrusion (96a) and a second upper protrusion (96b), the upper protrusion (90) of the first heat transfer member (30a) and the lower protrusion (94) of the second heat transfer member (30b) face each other in the third direction (D3), the first lower protrusion (92a) of the first heat transfer member (30a) and the first upper protrusion (96a) of the second heat transfer member (30b) face each other in the third direction (D3), The second lower projection (92b) of the first heat transfer member (30a) and the second upper projection (96b) of the second heat transfer member (30b) face each other in the third direction (D3), and the space enclosed by the first lower projection (92a), the upper projection (90), and the second lower projection (92b) of the first heat transfer member (30a), and the second upper projection (96b), the lower projection (94), and the first upper projection (96a) of the second heat transfer member (30b) is an air passage (110). The heat exchange element (100) described in item 1, wherein the distance between the first lower projection (92a) and the second lower projection (92b) of the first heat transfer member (30a) is defined as the first directional airflow width (120), the distance between the upper projection (90) of the first heat transfer member (30a) and the lower projection (94) of the second heat transfer member (30b) is defined as the third directional airflow width (122), and the ratio obtained by dividing the third directional airflow width (122) by the first directional airflow width (120) is greater than 0.5 and less than or equal to 12.5.

[0077] (Example 2) Figure 11 is a perspective view showing the configuration of the heat exchange element 100. In the heat exchange element 100, a first heat transfer layer 2a and a second heat transfer layer 2b, collectively referred to as the heat transfer layer 2, are stacked alternately in the vertical direction. The heat transfer layer 2 has a first intersecting flow section 22a, a counter-flow section 20, and a second intersecting flow section 22b arranged in order in the horizontal direction. The first intersecting flow section 22a and the second intersecting flow section 22b are collectively referred to as the intersecting flow section 22. The intersecting flow section 22 includes a wall material 4, a rib material 6, an inlet 10, and an outlet 12, but the arrangement of the wall material 4, rib material 6, inlet 10, and outlet 12 differs between the first heat transfer layer 2a and the second heat transfer layer 2b.

[0078] The opposing flow section 20 is an airflow forming member that creates an airflow path with opposing airflow, and the intersecting flow section 22 is an airflow forming member that creates an airflow path with intersecting airflow. Opposing and intersecting airflow will be described later. In the first heat transfer layer 2a, the direction of air flow from the inlet 10 to the outlet 12 is opposite to the direction of air flow from the inlet 10 to the outlet 12 in the second heat transfer layer 2b, and heat exchange takes place between them. For example, if the air flowing through the first heat transfer layer 2a is the supply airflow, then the air flowing through the second heat transfer layer 2b is the exhaust airflow.

[0079] Figures 12(a) and 12(b) are perspective views showing the configuration of the first heat transfer layer 2a. Here, Figure 12(b) is an exploded perspective view showing the configuration of the first heat transfer layer 2a in Figure 12(a). The frame 8 constitutes the skeleton of the first heat transfer layer 2a, that is, the frame of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b. The frame 8 includes a first wall material 4a, a second wall material 4b, and a third wall material 4c, collectively referred to as wall material 4, and a first rib material 6a and a second rib material 6b, collectively referred to as rib material 6. The first wall material 4a, the second wall material 4b, and the third wall material 4c all have a rectangular prism shape, and the first rib material 6a and the second rib material 6b all have a triangular tubular shape (a triangular cylindrical structure). In other words, the first rib member 6a and the second rib member 6b have a triangular frame shape in plan view and are composed of a base and a pair (two) hypotenuses. Each base that makes up the first rib member 6a and the second rib member 6b constitutes the opposing flow section 20.

[0080] When the two first wall members 4a are assembled with their long sides facing each other and the bottoms of the first rib member 6a and the second rib member 6b facing each other, a rectangular tube shape (a square cylindrical structure) is formed, which serves as the frame for the opposing flow section 20. In other words, one end of the first wall member 4a is connected to one end of the bottom of the first rib member 6a, and the other end of the first wall member 4a is connected to one end of the bottom of the second rib member 6b, thereby forming an opposing flow section 20 that has a frame-like (rectangular) shape in plan view. Furthermore, when the second wall member 4b is assembled so as to overlap one of the hypotenuses of the first rib member 6a, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the first intersecting flow section 22a. Furthermore, when the third wall material 4c is assembled so as to overlap one of the hypotenuses of the second rib material 6b, a triangular tubular shape (a triangular cylindrical structure) is formed, which serves as the frame for the second intersecting flow section 22b. The top and bottom surfaces of each of these rectangular tubular shapes are open.

[0081] The rib material 6 is processed in one piece to the required shape, for example, by vacuum forming a resin sheet. The first rib material 6a and the second rib material 6b may be processed from a single resin sheet. Similarly, the wall material 4 is also formed in one piece by vacuum forming using a single resin sheet, just like the rib material 6. As a result, the frame 8 is assembled from resin sheet molded products that form the vacuum-formed wall material 4 and rib material 6. Different materials may be used for the wall material 4 and the rib material 6. For example, a urethane sheet may be used for the wall material 4, and perforated plastic corrugated cardboard may be used for the rib material 6.

[0082] An opening is provided in the first rib member 6a as an inlet 10. That is, the inlet 10 of the first rib member 6a is provided on the side of the pair of slanted edges that make up the first rib member 6a that is located on the negative side of the first direction D1. An opening is provided in the second rib member 6b as an outlet 12. That is, the outlet 12 of the second rib member 6b is provided on the side of the pair of slanted edges that make up the second rib member 6b that is located on the positive side of the first direction D1. Furthermore, openings are also provided in the portions of the first rib member 6a and the second rib member 6b that are on the opposing flow section 20 side. That is, openings are also provided in the sides of the first rib member 6a and the second rib member 6b that are on the base side of the triangle in a plan view and that make up the opposing flow section 20. As a result, in the first heat transfer layer 2a, the first intersecting flow section 22a penetrates the outside, the first intersecting flow section 22a penetrates the opposing flow section 20 and the second intersecting flow section 22b in sequence, and the second intersecting flow section 22b penetrates the outside. In other words, in the first heat transfer layer 2a, the air introduced from the inlet 10 of the first intersecting flow section 22a flows in the order of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b, and is discharged from the outlet 12 of the second intersecting flow section 22b.

[0083] A heat transfer member 30 is attached to the central part of the frame of the opposing flow section 20. The heat transfer member 30 includes a first flat section 36a and a second flat section 36b, collectively referred to as the flat section 36. The heat transfer member 30 will be described below using Figures 13(a)-(c).

[0084] Figures 13(a)-(c) show the manufacturing procedure for the heat transfer member 30. Figure 13(a) shows the heat transfer member 30. The heat transfer member 30 has a first surface 60 and a second surface 62 facing opposite directions. The heat transfer member 30 is made of a metal film that can be bent at room temperature and retain its shape. Among the metal films, aluminum is used in particular for its thermal conductivity or light weight. As aluminum, aluminum foil with a film thickness of 15 μm to 100 μm is used. If the aluminum foil is thinner than 15 μm, it is too thin and difficult to retain its shape after processing. On the other hand, if the aluminum film thickness is thicker than 100 μm, the force required for bending increases and the heat transfer performance also deteriorates. Therefore, specifically, an aluminum film thickness of about 60 μm is desirable.

[0085] Figure 13(b) shows the configuration of the heat transfer member 30 after the process following Figure 13(a). The heat transfer member 30 is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, first protrusions 64 that project toward the first surface 60 and second protrusions 66 that project toward the second surface 62 are arranged alternately. Here, the direction in which the first protrusions 64 and the second protrusions 66 are arranged alternately is defined as the first direction D1, and the direction that intersects (is perpendicular to) the first direction D1 is defined as the second direction D2. If the aspect ratio of the corrugated shape is 5 or less, bending using rollers can be performed sequentially, resulting in high productivity.

[0086] Figure 13(c) shows the configuration of the heat transfer member 30 after the process following Figure 13(b). The first end portion 72 in the second direction D2 of the heat transfer member 30 is processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a first flat portion 36a by crushing the corrugated shape. The tapered portion provided on the inside of the outermost edge of the press die enables flattening processing that suppresses tearing of the heat transfer member 30. Similarly, the second end portion 74 in the second direction D2 of the heat transfer member 30 is also processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a second flat portion 36b by crushing the corrugated shape. This is done to facilitate the attachment of one end of the rib material 6 for introducing air into the corrugated shape, as shown in Figure 12(b).

[0087] As described above, the heat transfer member 30 has a wave-shaped structure in which first protrusions 64 projecting toward the first surface 60 and second protrusions 66 projecting toward the second surface 62 are arranged alternately. When the direction in which the first protrusions 64 and the second protrusions 66 are arranged alternately is defined as the first direction D1, and the direction intersecting the first direction D1 is defined as the second direction D2, a first flat portion 36a formed by flattening a corrugated sheet is arranged at the first end 72 of the heat transfer member 30 in the second direction D2, and a second flat portion 36b formed by flattening a corrugated sheet is arranged at the second end 74 of the heat transfer member 30 in the second direction D2.

[0088] Returning to Figure 12(b), the heat transfer member 30 is attached to the frame of the opposing flow section 20 from below, with the second direction D2 of the heat transfer member 30 aligned with the direction from the first intersecting flow section 22a toward the second intersecting flow section 22b. A flat plate-shaped first external heat transfer member 40a is attached from below so as to fit into the frame of the first intersecting flow section 22a. As a result, the first external heat transfer member 40a is installed so as to communicate with the first flat portion 36a of the heat transfer member 30. A flat plate-shaped second external heat transfer member 40b is attached from below so as to fit into the frame of the second intersecting flow section 22b. As a result, the second external heat transfer member 40b is installed so as to communicate with the second flat portion 36b of the heat transfer member 30. Here, the first external heat transfer member 40a and the second external heat transfer member 40b are collectively referred to as the external heat transfer member 40. The external heat transfer member 40 is made of the same material as the heat transfer member 30.

[0089] Here, "connecting" means that two members are connected by another member interposed between them, or that the two members are directly connected; in either case, it is sufficient that air or other fluids can flow between the two members.

[0090] When the first heat transfer layer 2a (heat transfer layer 2) is stacked as shown in Figure 11, a gap is secured by the rib material 6, so that an air supply passage 50 is formed within the first heat transfer layer 2a. The air supply passage 50 enters the inlet 10 from the outside, passes through the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b, and in particular passes over the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b, before exiting to the outside from the outlet 12. Therefore, it can be said that the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b constitute the air supply passage 50. Air supply flows through the air supply passage 50.

[0091] In this case, it is desirable that the positions of the first flat portion 36a and the second flat portion 36b in the heat transfer member 30 be located near the center with respect to the height direction of the wave shape. Since the first flat portion 36a and the second flat portion 36b in the heat transfer member 30 are flat, the airflow to the opposing flow portion 20 and the intersecting flow portion 22 is made smooth.

[0092] Figures 14(a) and 14(b) are perspective views showing the configuration of the second heat transfer layer 2b. Here, Figure 14(b) is an exploded perspective view showing the configuration of the second heat transfer layer 2b in Figure 14(a). The frame 8 constitutes the skeleton of the second heat transfer layer 2b, that is, the frame of the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b. The frame 8 includes a first wall material 4a, a fourth wall material 4d, and a fifth wall material 4e, collectively referred to as wall material 4, and a third rib material 6c and a fourth rib material 6d, collectively referred to as rib material 6. The first wall material 4a, the fourth wall material 4d, and the fifth wall material 4e all have a rectangular prism shape, and the third rib material 6c and the fourth rib material 6d all have a triangular tubular shape (a triangular cylindrical structure).

[0093] When the two first wall members 4a are assembled facing each other, and the third rib member 6c and the fourth rib member 6d are assembled facing each other, a rectangular tube shape (a square cylindrical structure) is formed, which serves as the frame for the opposing flow section 20. Furthermore, when the fourth wall member 4d is assembled so as to overlap one of the hypotenuses of the third rib member 6c, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the first intersecting flow section 22a. In addition, when the fifth wall member 4e is assembled so as to overlap one of the hypotenuses of the fourth rib member 6d, a triangular tube shape (a triangular cylindrical structure) is formed, which serves as the frame for the second intersecting flow section 22b. The top and bottom surfaces of each of these rectangular tube shapes are open.

[0094] An opening is provided in the fourth rib member 6d as an inlet 10, and an opening is provided in the third rib member 6c as an outlet 12. Furthermore, openings are also provided in the portions of the third rib member 6c and the fourth rib member 6d on the side facing the opposing flow section 20. As a result, in the second heat transfer layer 2b, the outside and the first intersecting flow section 22a are penetrated, the first intersecting flow section 22a, the opposing flow section 20, and the second intersecting flow section 22b are penetrated in order, and the second intersecting flow section 22b is penetrated to the outside. In other words, in the second heat transfer layer 2b, air introduced from the inlet 10 of the second intersecting flow section 22b flows in the order of the second intersecting flow section 22b, the opposing flow section 20, and the first intersecting flow section 22a, and is discharged from the outlet 12 of the first intersecting flow section 22a.

[0095] As before, the heat transfer member 30 is attached to the frame of the opposing flow section 20 from below, the first external heat transfer member 40a is fitted into the frame of the first intersecting flow section 22a from below, and the second external heat transfer member 40b is fitted into the frame of the second intersecting flow section 22b from below. The exhaust air passage 52 enters the inlet 10 from the outside, passes through the second intersecting flow section 22b, the opposing flow section 20, and the first intersecting flow section 22a, and in particular passes over the second external heat transfer member 40b, over the heat transfer member 30, and over the first external heat transfer member 40a, before exiting to the outside from the outlet 12. Therefore, the first external heat transfer member 40a, the heat transfer member 30, and the second external heat transfer member 40b can be said to constitute the exhaust air passage 52. The supply air flow passes through the exhaust air passage 52. Since the intake air passage 50 and the exhaust air passage 52 are oriented in opposite directions, the exhaust flow flows in the opposite direction to the intake air flow.

[0096] Figure 15 is an exploded perspective view showing the configuration of the heat exchange element 100. The first heat transfer layer 2a and the second heat transfer layer 2b described above are stacked alternately in the vertical direction. In the opposing flow section 20, the first heat transfer layer 2a and the second heat transfer layer 2b are also stacked in the vertical direction, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged along the second direction D2, but they face opposite directions. Therefore, in the opposing flow section 20, the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged opposite each other, but the direction of airflow is opposite. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become opposing flows.

[0097] In the first intersecting flow section 22a, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked vertically, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged to intersect each other. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become intersecting flows.

[0098] In the second intersecting flow section 22b, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked vertically, but the supply air passage 50 in the first heat transfer layer 2a and the exhaust air passage 52 in the second heat transfer layer 2b are arranged to intersect each other. As a result, the supply air flowing through the supply air passage 50 and the exhaust air flowing through the exhaust air passage 52 become intersecting flows.

[0099] As shown in Figure 15, the heat exchange element 100 has multiple corrugated heat transfer members 30 stacked on top of each other. In the opposing flow section 20 of the second heat transfer layer 2b, an overlap prevention member 14 extending in the first direction D1 is placed between the heat transfer member 30 of the second heat transfer layer 2b and the heat transfer member 30 of the first heat transfer layer 2a. An overlap prevention member 14 is similarly placed in the opposing flow section 20 of the first heat transfer layer 2a. For example, aluminum foil is used for the overlap prevention member 14. This eliminates the need for a mold required for molding. When corrugated heat transfer members 30 are stacked as shown in Figure 15, the contact surface is small, so if misalignment occurs between the heat transfer members 30, overlapping of the corrugated shape may occur, making it impossible to secure the upper and lower gaps. The overlap prevention member 14 is provided to secure the upper and lower gaps. By making the thickness of the overlap prevention member 14 thin, the need to increase the thickness of each heat transfer layer 2 during stacking is suppressed.

[0100] Figure 16 is a cross-sectional view showing the configuration of the heat exchange element 100. This shows a cross-section of the heat exchange element 100 along the first direction D1. As described above, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked alternately in the vertical direction. When the second heat transfer layer 2b is stacked below the first heat transfer layer 2a, the first protrusion 64 of the heat transfer member 30 of the second heat transfer layer 2b and the second protrusion 66 of the heat transfer member 30 of the first heat transfer layer 2a are stacked facing each other. Then, an exhaust air passage 52 is formed between the heat transfer member 30 of the second heat transfer layer 2b and the heat transfer member 30 of the first heat transfer layer 2a.

[0101] When the first heat transfer layer 2a is stacked below the second heat transfer layer 2b, the first protrusion 64 of the heat transfer member 30 of the first heat transfer layer 2a and the second protrusion 66 of the heat transfer member 30 of the second heat transfer layer 2b are stacked facing each other. Then, an air supply passage 50 is formed between the heat transfer member 30 of the first heat transfer layer 2a and the heat transfer member 30 of the second heat transfer layer 2b.

[0102] The first protrusion 64 on the heat transfer member 30 of the second heat transfer layer 2b and the second protrusion 66 on the heat transfer member 30 of the first heat transfer layer 2a are stacked facing each other, so that even when a force is applied between them, the first protrusion 64 and the second protrusion 66 remain in contact and the gap is maintained. The same applies to the first protrusion 64 on the heat transfer member 30 of the first heat transfer layer 2a and the second protrusion 66 on the heat transfer member 30 of the second heat transfer layer 2b. On the other hand, if the positions of the first protrusion 64 and the second protrusion 66 become misaligned due to misalignment during stacking, they may sink in the direction of overlap, so an overlap prevention member 14 is provided to prevent this.

[0103] The following describes the manufacturing method of the heat exchange element 100. The manufacturing method of the heat exchange element 100 includes the following steps (1) to (6). (1) A grid-shaped heat transfer member 30 is prepared as shown in Figure 13(a). (2) As shown in Figure 13(b), the heat transfer member 30 is bent into a corrugated shape so that the first protrusions 64 and the second protrusions 66 are arranged alternately along the first direction D1. (3) As shown in Figure 13(c), the corrugated shape is crushed at the first end 72 in the second direction D2 of the heat transfer member 30 to form a first flat portion 36a. Also, the corrugated shape is crushed at the second end 74 in the second direction D2 of the heat transfer member 30 to form a second flat portion 36b. Multiple heat transfer members 30 shown in Figure 13(c) are prepared.

[0104] (4) As shown in Figure 12(b), the frame 8 is generated by assembling two first wall members 4a, a second wall member 4b, a third wall member 4c, a first rib member 6a, and a second rib member 6b. The rib members 6 serve to allow air to pass through as an air intake passage 50 or an exhaust passage 52, and to ensure a vertical gap. For this reason, corrugated plastic with straight through holes inside is used for the rib members 6. The corrugated plastic is cut and used only in the parts necessary to ensure the gap, and cutouts are made so that there is no corrugated plastic in the area where heat exchange takes place with the heat transfer member 30.

[0105] The wall material 4 uses a double-sided adhesive gel sheet that is thicker than the plastic corrugated cardboard of the rib material 6. The gel sheet is easily deformed by pressure, and when pressed after lamination, it is compressed to match the thickness of the rib material 6 and the heat transfer member 30, adjusting the height. The gel sheet is adhesive on both sides, and it adheres the heat transfer member 30 and the rib material 6 on the upper and lower surfaces, suppressing air leakage. For the plastic corrugated cardboard of the intersecting flow section 22, it is desirable to divide the cut-out area so that the airflow is not uneven and the air passages are separated. The plastic corrugated cardboard is also soft and easily deformable, and when pressed after lamination, it absorbs variations in the height direction.

[0106] Of the frame 8, the heat transfer member 30 is attached to the frame of the opposing flow section 20, the first external heat transfer member 40a is attached so as to fit into the frame of the first intersecting flow section 22a, and the second external heat transfer member 40b is attached so as to fit into the frame of the second intersecting flow section 22b. This connects the first external heat transfer member 40a to the first flat section 36a, and the second external heat transfer member 40b to the second flat section 36b. Here, the thickness of the external heat transfer member 40 is made the same as the thickness of the heat transfer member 30. The plastic corrugated cardboard of the rib material 6 and the heat transfer member 30 are bonded together using thin gel double-sided tape. The flat section 36 of the heat transfer member 30 bonded to the rib material 6 is formed by flattening a corrugated shape, so there may be variations in thickness. These variations are absorbed when pressure is applied with the thin gel double-sided tape. Furthermore, the gaps in the plastic corrugated cardboard ribs of the opposing flow section 20 and the intersecting flow section 22 are also bonded with thin gel double-sided tape to suppress air leakage. Before or after attaching the heat transfer member 30 to the frame of the opposing flow section 20, an overlap prevention member 14 extending in the first direction D1 is installed on the frame of the opposing flow section 20. In this way, the first heat transfer layer 2a is generated.

[0107] (5) As shown in Figure 14(b), a frame 8 is generated by assembling two first wall members 4a, a fourth wall member 4d, a fifth wall member 4e, a third rib member 6c, and a fourth rib member 6d. Of the frame 8, the heat transfer member 30 is attached to the frame of the opposing flow section 20, the first external heat transfer member 40a is attached to the frame of the first intersecting flow section 22a, and the second external heat transfer member 40b is attached to the frame of the second intersecting flow section 22b. This connects the first external heat transfer member 40a to the first flat section 36a and the second external heat transfer member 40b to the second flat section 36b. Before or after attaching the heat transfer member 30 to the frame of the opposing flow section 20, an overlap prevention member 14 extending in the first direction D1 is installed on the frame of the opposing flow section 20. In this way, the second heat transfer layer 2b is generated.

[0108] (6) As shown in Figure 15, the first heat transfer layer 2a and the second heat transfer layer 2b are stacked alternately in the vertical direction. As a result, in two heat transfer members 30 adjacent to each other in the vertical direction, the first protrusion 64 of the lower heat transfer member 30 and the second protrusion 66 of the upper heat transfer member 30 are stacked facing each other. In addition, multiple first external heat transfer members 40a connected to the first flat portion 36a are stacked, and multiple second external heat transfer members 40b connected to the second flat portion 36b are also stacked.

[0109] Here, step (2) described above corresponds to the step of "arranging, alternately along the first direction, a first projection protruding from the first surface and a second projection protruding from the second surface by bending a rectangular heat transfer member having a first surface and a second surface facing opposite directions into a corrugated shape."

[0110] Furthermore, step (3) described above corresponds to the steps of the claim, "a step in which a direction intersecting the first direction is defined as the second direction, and a step in which a corrugated shape is crushed to form a first flat portion at the first end of the heat transfer member in the second direction" and "a step in which a corrugated shape is crushed to form a second flat portion at the second end of the heat transfer member in the second direction."

[0111] Furthermore, step (4) described above corresponds to the steps of the claim: "connecting a flat plate-shaped external heat transfer member constituting the air supply passage or the exhaust passage to the first flat portion of the heat transfer member" and "connecting a flat plate-shaped second external heat transfer member constituting the air supply passage or the exhaust passage to the second flat portion of the heat transfer member."

[0112] Furthermore, step (5) described above corresponds to the "step of installing an overlap prevention member extending in the first direction between the one heat transfer member and the other heat transfer member before stacking the one heat transfer member and the other heat transfer member" of the claim.

[0113] Furthermore, step (6) described above corresponds to the "step of preparing a plurality of corrugated heat transfer members having the first flat portion and the second flat portion, and stacking the plurality of heat transfer members by stacking one heat transfer member and the other heat transfer members while facing the first protrusion of one of the plurality of heat transfer members and the second protrusion of another heat transfer member adjacent to the first surface side of the one heat transfer member."

[0114] (Modification 4) In the heat exchange element 100 described above, a metal film, such as an aluminum film, is used for the heat transfer member 30. Therefore, heat is exchanged between adjacent heat transfer layers 2. On the other hand, a total heat exchange element exchanges both heat (sensible heat) and humidity (latent heat). The heat exchange element 100 in the modification is a heat exchange element 100. In order to exchange latent heat, it is necessary to use a resin film that is permeable to water vapor, but if the film thickness is thin or the strength is insufficient, the film alone cannot maintain the bent shape, and the structure of the heat exchange element cannot be realized. Also, if a resin film that is permeable to water vapor is stretched while heat is applied so as to follow the mold, the water vapor permeability characteristics may deteriorate due to the thinning of the film thickness or the effects of heat. In addition, if the amount of stretching in three-dimensional shape processing becomes large, the film may tear.

[0115] Since everything except the heat transfer member 30 is the same as before, a modified heat transfer member 30 will be described here. Figures 3(a) to 3(e) show the manufacturing procedure for the heat transfer member 30. Figure 3(a) shows the shape-retaining member 34. The shape-retaining member 34 has a first surface 60 and a second surface 62 facing opposite directions and is a member for maintaining the corrugated shape of the heat transfer member 30. The shape-retaining member 34 is made of a metal film that can be bent at room temperature and retain its shape. Among the metal films, aluminum is particularly used for its thermal conductivity or light weight. Aluminum tape, which is an aluminum film coated with adhesive, may also be used. Considering processability and shape retention, an aluminum film thickness of about 50 μm is preferred. For example, an aluminum tape with a thickness of 100 μm, made by coating a 50 μm aluminum film with 50 μm of adhesive, is used. The shape-retaining member 34 has a lattice shape, and a plurality of openings 70 are provided in the lattice shape. For example, a lattice-shaped hole is made in the aluminum tape. Details of the lattice shape will be described later.

[0116] Furthermore, a resin sheet may be used instead of a metal film for the shape-retaining member 34. The resin sheet can be formed into a corrugated shape by applying heat and bending, and can retain its shape after cooling.

[0117] Figure 3(b) shows the moisture-permeable member 32. The moisture-permeable member 32, like the shape-retaining member 34, has a first surface 60 and a second surface 62 facing opposite directions, and is a member that can permeate moisture without allowing air to pass through. The moisture-permeable member 32 is, for example, a water vapor-permeable polymer thin film. Polymer thin films are very soft and do not easily maintain their shape even when given a corrugated shape. In other words, the moisture-permeable member 32 does not easily maintain its shape without being combined with a framework made of other materials.

[0118] Figure 3(c) shows a configuration in which the moisture-permeable member 32 is attached to the shape-retaining member 34 in a layered manner. In other words, the moisture-permeable member 32 is attached to the shape-retaining member 34 with adhesive so that the moisture-permeable member 32 is exposed at each of the multiple openings 70 of the shape-retaining member 34. That is, the openings 70 of the shape-retaining member 34 are covered by the moisture-permeable member 32. As a result, even though the moisture-permeable member 32 is thin, soft, and difficult to maintain its shape, the shape-retaining member 34 acts as a framework, making it possible to maintain the corrugated shape.

[0119] In the shape-retaining member 34, the portion of the moisture-permeable member 32 exposed through the multiple openings 70 is responsible for humidity exchange performance. Therefore, to improve the efficiency of humidity (latent heat) exchange, the exposed area of ​​the moisture-permeable member 32 should be increased. For this reason, it is desirable that the area of ​​the multiple openings 70 provided in the shape-retaining member 34 is larger than the area of ​​the shape-retaining member 34 excluding the multiple openings 70. It is required to increase the area of ​​the openings 70 while maintaining the minimum area necessary to maintain the strength of the shape-retaining member 34. In other words, the area of ​​the moisture-permeable member 32 exposed through the openings 70 of the shape-retaining member 34 is larger than the area of ​​the shape-retaining member 34 excluding the openings 70.

[0120] Figure 3(d) shows the configuration of the heat transfer member 30 after the process following Figure 3(c). The shape-retaining member 34 to which the moisture-permeable member 32 is attached is repeatedly bent using a die. As a result, a corrugated heat transfer member 30 is formed. In the corrugated shape, first protrusions 64 that protrude toward the first surface 60 and second protrusions 66 that protrude toward the second surface 62 are arranged alternately. Here, if the aspect ratio of the corrugated shape is 5 or less, bending using rollers can be performed sequentially, which increases productivity.

[0121] In this modified example, the corrugated shape of the heat transfer member 30 is formed from a moisture-permeable member 32 in order to improve the efficiency of total heat exchange. However, as mentioned above, the moisture-permeable member 32 is thin and soft, so it cannot maintain its shape even after being processed into a corrugated shape. Therefore, a shape-retaining member 34 that can maintain its shape even after being formed is used as a framework for maintaining the shape of the moisture-permeable member 32. As shown in Figure 3(d), a cell-type heat exchange element structure with water vapor permeability is realized by first processing the shape-retaining member 34 with holes in a grid pattern, then attaching the moisture-permeable member 32 and bending it into a corrugated shape.

[0122] Here, the grid-like shape of the shape-retaining member 34 is a shape that spans both the first direction D1 and the second direction D2 with a constant width, and is arranged at intervals that can maintain the wave shape of the moisture-permeable member 32. If the span is too narrow, it will be difficult to maintain the shape, and if it is too wide, the exposed area of ​​the moisture-permeable member 32 will be small. Similarly, if the spacing of the grid shape is too wide, it will be difficult to maintain the shape, and if the spacing is too narrow, the exposed area of ​​the moisture-permeable member 32 will be small.

[0123] Figure 3(e) shows the configuration of the heat transfer member 30 after the process following Figure 3(d). The first end portion 72 in the second direction D2 of the heat transfer member 30 is processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a first flat portion 36a by crushing the corrugated shape. The tapered portion provided on the inside of the outermost edge of the press die enables flattening processing that suppresses tearing of the heat transfer member 30. Similarly, the second end portion 74 in the second direction D2 of the heat transfer member 30 is also processed with a press die that has a flat outer edge and a tapered portion on the inside, thereby forming a second flat portion 36b by crushing the corrugated shape. This is done to facilitate the attachment of one end of the rib material 6 for introducing air into the corrugated shape, as shown in Figure 12(b).

[0124] In this embodiment, since flat portions 36 are provided at both ends of the heat transfer member 30, airflow can be transferred from the flat air passage at the entrance of the intersecting flow section 22 to the central corrugated air passage with good airtightness, without any contact interface, using a single member. Furthermore, because the airflow is transferred with good airtightness, airtightness between the heat exchange air passages can be ensured. In addition, since flat portions 36 are provided at both ends of the heat transfer member 30, airflow can be transferred continuously from a flat surface to a corrugated shape without generating an interface. Furthermore, since multiple processed heat transfer members 30 are stacked so that their protrusions face each other, an air passage can be formed between the heat transfer members 30 in a state of continuous airtightness from a flat surface to a corrugated shape. In addition, since bending is performed, tension or elongation applied during bending can be suppressed.

[0125] Furthermore, since the overlap prevention member 14 is placed between two vertically adjacent heat transfer members 30, the risk of overlap during lamination can be reduced even if the two vertically adjacent heat transfer members 30 are corrugated in shape and are misaligned. Also, since the intersecting flow section 22 is attached to the opposing flow section 20, airflow can be smoothly introduced between the intersecting flow sections 22 and the intersecting flow sections 22, thereby suppressing pressure loss. In addition, since the thickness of the external heat transfer member 40 and the thickness of the heat transfer member 30 are the same, steps can be suppressed and airflow can be smoothly introduced from the intersecting flow section 22 to the opposing flow section 20. Furthermore, since the first external heat transfer member 40a and the second external heat transfer member 40b are connected to the heat transfer member 30, lamination can be completed for each air passage. Also, since lamination can be completed for each air passage, lamination can be performed after each air passage has been formed.

[0126] Furthermore, by configuring it as in the modified example, the heat transfer member 30 is generated by the moisture-permeable member 32 and the shape-retaining member 34, so that a heat transfer member 30 capable of exchanging not only heat but also humidity can be realized. In addition, by stacking multiple heat transfer members 30, each having a moisture-permeable member 32 that can pass through moisture and a shape-retaining member 34 for maintaining a corrugated shape, it is possible to maintain the shape while efficiently exchanging sensible heat and latent heat. In addition, by stacking multiple heat transfer members 30, each having a moisture-permeable member 32 that can pass through moisture and a shape-retaining member 34 for maintaining a corrugated shape, the corrugated shape of the low-strength moisture-permeable member 32 can be maintained by the shape-retaining member 34. Furthermore, since the corrugated shape of the low-strength moisture-permeable member 32 is maintained by the shape-retaining member 34, a highly efficient heat exchange element 100 with a large heat transfer area capable of exchanging humidity in addition to temperature can be realized.

[0127] An outline of one aspect of the present disclosure is as follows: (Item 9) A method for manufacturing a heat exchange element (100) having a counterflow section (20) formed by an air intake passage (50) through which an air intake flow flows and an exhaust passage (52) through which an exhaust flow flowing in the opposite direction to the air intake flow flows, comprising the steps of: bending a rectangular heat transfer member (30) having a first surface (60) and a second surface (62) facing opposite directions into a corrugated shape, thereby arranging a first protrusion (64) protruding toward the first surface (60) and a second protrusion (66) protruding toward the second surface (62) alternately along a first direction (D1); defining a second direction (D2) as the direction intersecting the first direction (D1), and forming a first flat section (36a) by crushing the corrugated shape at the first end (72) of the heat transfer member (30) in the second direction (D2); A method for manufacturing a heat exchange element (100), comprising: the step of forming a second flat portion (36b) by crushing the corrugated shape at the second end (74) in the second direction (D2) of the heat transfer member (30); and the step of preparing a plurality of corrugated heat transfer members (30) having the first flat portion (36a) and the second flat portion (36b), and stacking the plurality of heat transfer members (30) by stacking one heat transfer member (30) and the other heat transfer members (30) while facing the first protrusion (64) of one of the plurality of heat transfer members (30) and the second protrusion (66) of another heat transfer member (30) adjacent to the first surface (60) side of the one heat transfer member (30).

[0128] (Item 10) A method for manufacturing a heat exchange element (100) according to Item 9, further comprising the step of installing an overlap prevention member (14) extending in the first direction (D1) between the one heat transfer member (30) and the other heat transfer member (30) before stacking the one heat transfer member (30) and the other heat transfer member (30).

[0129] (Item 11) The heat exchange element (100) further has an intersecting flow section (22) formed by the intersection of the supply air passage (50) through which the supply air flow flows and the exhaust air passage (52) through which the exhaust air flow flows, and further comprises the step of connecting a flat plate-shaped external heat transfer member (40) constituting the supply air passage (50) or the exhaust air passage (52) to the first flat portion (36a) of the heat transfer member (30), wherein the step of stacking the plurality of heat transfer members (30) is to stack a plurality of external heat transfer members (40) that are connected to the first flat portion (36a), the method for manufacturing a heat exchange element (100) according to item 9 or 10.

[0130] (Item 12) The method for manufacturing a heat exchange element (100) as described in Item 11, wherein the thickness of the external heat transfer member (40) is the same as the thickness of the heat transfer member (30).

[0131] (Item 13) When the intersecting flow section (22) is referred to as the first intersecting flow section (22a) and the external heat transfer member (40) is referred to as the first external heat transfer member (40a), the heat exchange element (100) further has a second intersecting flow section (22b) formed by the intersection of the supply air passage (50) through which the supply air flow flows and the exhaust air passage (52) through which the exhaust air flow flows, and further comprises the step of connecting a flat plate-shaped second external heat transfer member (40b) constituting the supply air passage (50) or the exhaust air passage (52) to the second flat portion (36b) of the heat transfer member (30), and the step of stacking the plurality of heat transfer members (30) is to stack a plurality of second external heat transfer members (40b) that are connected to the second flat portion (36b), the method for manufacturing a heat exchange element (100) according to Item 11.

[0132] (Item 14) A method for manufacturing a heat exchange element (100) according to Item 9, further comprising the step of generating the heat transfer element (30) by covering the opening (70) of a shape-retaining member (34) for maintaining a corrugated shape when the heat transfer element (30) is bent into a corrugated shape with a moisture-permeable member (32) that can pass through moisture.

[0133] Although the present disclosure has been explained above based on the examples, it can be easily inferred that the present disclosure is not limited in any way to the above examples, and that various improvements and modifications are possible without departing from the spirit of the present disclosure.

[0134] According to this disclosure, it is possible to exchange sensible and latent heat with high efficiency while maintaining the shape. In addition, airtightness between the heat exchange air passages can be ensured.

[0135] D1 First direction, 2 Heat transfer layer, D2 Second direction, 4 Wall material, 6 Rib material, 8 Frame, 10 Inlet, 12 Outlet, 14 Overlap prevention member, 20 Opposing flow section, 22 Crossing flow section, 30 Heat transfer member, 32 Moisture permeable member, 34 Shape-retaining member, 36 Flat section, 38 Adhesive, 40 External heat transfer member, 50 Air supply passage, 52 Exhaust passage, 60 First surface, 62 Second surface, 64 First protrusion, 66 Second protrusion, 70 Opening, 72 First end, 74 Second end, 100 Heat exchange element.

Claims

1. A heat exchange element having a counter-flow section in which a supply air passage through which a supply airflow flows and an exhaust air passage through which an exhaust airflow flowing in the opposite direction to the supply airflow are arranged opposite to each other, wherein the corrugated heat exchange elements have a first surface and a second surface facing opposite directions, and have alternating first protrusions protruding toward the first surface and second protrusions protruding toward the second surface, the counter-flow section is formed by stacking one heat exchange element and the other heat exchange elements while facing the first protrusion of one of the heat exchange elements and the second protrusion of another heat exchange element adjacent to the first surface of the one heat exchange element, and each of the multiple heat exchange elements has a moisture-permeable member that can pass through moisture and a shape-retaining member for maintaining a corrugated shape, and the opening of the shape-retaining member is covered by the moisture-permeable member.

2. The heat exchange element according to claim 1, wherein the shape-retaining member has a grid shape, and the shape-retaining member has a plurality of openings in the grid shape.

3. The heat exchange element according to claim 1, wherein the shape-retaining member has a striped shape, and the shape-retaining member has a plurality of openings in the striped shape.

4. The heat exchange element according to claim 2 or 3, wherein the area of ​​the moisture-permeable member exposed from the opening of the shape-retaining member is greater than the area of ​​the shape-retaining member excluding the opening.

5. The heat exchange element according to claim 1, wherein the opposing flow portion further comprises overlap prevention members extending in a direction in which the first protrusion and the second protrusion are alternately arranged between one of the heat transfer members and the other heat transfer member.

6. The heat exchange element according to claim 1, wherein the direction in which the first protrusions and the second protrusions are arranged alternately is defined as the first direction, the direction intersecting the first direction is defined as the second direction, a first flat portion formed by flattening a corrugated sheet is arranged at the first end of the heat transfer member in the second direction, and a second flat portion formed by flattening a corrugated sheet is arranged at the second end of the heat transfer member in the second direction.

7. The heat exchange element according to claim 6, comprising a first intersecting flow section and a second intersecting flow section formed by the intersecting of the supply air passage through which the supply air flow flows and the exhaust air passage through which the exhaust air flow flows, wherein the first intersecting flow section has a flat plate-shaped first external heat transfer member installed so as to communicate with the first flat portion of the heat transfer member and constituting the supply air passage or the exhaust air passage, the first intersecting flow section is made up of a plurality of the first external heat transfer members stacked on top of each other, and the second intersecting flow section has a flat plate-shaped second external heat transfer member installed so as to communicate with the second flat portion of the heat transfer member and constituting the supply air passage or the exhaust air passage, the second intersecting flow section is made up of a plurality of the second external heat transfer members stacked on top of each other.

8. When the direction in which the first protrusions and the second protrusions are arranged alternately is defined as the first direction, the direction in which the plurality of heat transfer members are stacked is defined as the third direction, and among the plurality of heat transfer members, the first heat transfer member and the second heat transfer member are adjacent in the third direction, one of the first heat transfer members has an upper protrusion, and the two second protrusions that sandwich the upper protrusion in the first direction are the first lower protrusion and the second lower protrusion, one of the second heat transfer members has a lower protrusion, and the two first protrusions that sandwich the lower protrusion in the first direction are the first upper protrusion and the second upper protrusion, and the upper protrusion of the first heat transfer member and the lower protrusion of the second heat transfer member face each other in the third direction. The heat exchange element according to claim 1, wherein the first lower projection of the first heat transfer member and the first upper projection of the second heat transfer member face each other in the third direction, the second lower projection of the first heat transfer member and the second upper projection of the second heat transfer member face each other in the third direction, the space enclosed by the first lower projection, the upper projection and the second lower projection of the first heat transfer member, and the second upper projection, the lower projection and the first upper projection of the second heat transfer member constitutes an air passage, the distance between the first lower projection and the second lower projection of the first heat transfer member is defined as the first direction air passage width, the distance between the upper projection of the first heat transfer member and the lower projection of the second heat transfer member is defined as the third direction air passage width, and the ratio obtained by dividing the third direction air passage width by the first direction air passage width is greater than 0.5 and less than or equal to 12.

5.

9. A method for manufacturing a heat exchange element having a counterflow section configured such that an air intake passage through which an air intake flow flows and an exhaust passage through which an exhaust flow flowing in the opposite direction to the air intake flow flow face each other, comprising the steps of: bending a rectangular heat transfer member having a first surface and a second surface facing opposite directions into a corrugated shape so that a first projection protruding towards the first surface and a second projection protruding towards the second surface are alternately arranged along a first direction; defining a direction intersecting the first direction as a second direction, and forming a first flat portion by crushing the corrugated shape at the first end of the heat transfer member in the second direction; and forming a second flat portion by crushing the corrugated shape at the second end of the heat transfer member in the second direction. A method for manufacturing a heat exchange element, comprising the steps of: preparing a plurality of corrugated heat transfer members having a first flat portion and a second flat portion; and stacking the plurality of heat transfer members by stacking one heat transfer member and the other heat transfer members while facing the first protrusion of one of the plurality of heat transfer members and the second protrusion of another heat transfer member adjacent to the first surface side of the one heat transfer member.

10. The method for manufacturing a heat exchange element according to claim 9, further comprising the step of installing an overlap prevention member extending in the first direction between the one heat transfer member and the other heat transfer member before stacking the one heat transfer member and the other heat transfer member.

11. The heat exchange element further comprises a cross-flow section formed by the intersection of the supply air passage through which the supply air flow flows and the exhaust air passage through which the exhaust air flow flows, and further comprises the step of connecting a flat plate-shaped external heat transfer member constituting the supply air passage or the exhaust air passage to the first flat portion of the heat transfer member, wherein the step of stacking the plurality of heat transfer members involves stacking the plurality of external heat transfer members connected to the first flat portion.

12. The method for manufacturing a heat exchange element according to claim 11, wherein the thickness of the external heat transfer member is the same as the thickness of the heat transfer member.

13. When the intersecting flow portion is referred to as the first intersecting flow portion and the external heat transfer member is referred to as the first external heat transfer member, the heat exchange element further has a second intersecting flow portion formed by the intersection of the supply air passage through which the supply air flow flows and the exhaust air passage through which the exhaust air flow flows, and further comprises the step of connecting a flat plate-shaped second external heat transfer member constituting the supply air passage or the exhaust air passage to the second flat portion of the heat transfer member, and the step of stacking the plurality of heat transfer members is to stack a plurality of second external heat transfer members connected to the second flat portion, the method for manufacturing a heat exchange element according to claim 11.

14. The method for manufacturing a heat exchange element according to claim 9, further comprising the step of generating the heat exchange element by covering the opening of a shape-retaining member, which maintains the corrugated shape when the heat exchange element is bent into a corrugated shape, with a moisture-permeable member that can pass through moisture.

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