Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DESCRIPTION
TITLE OF THE INVENTION:
HEAT EXCHANGE ELEMENT
Field
[0001] The present disclosure relates to a heat exchange
element of a counterflow type formed by stacking heat
transfer plates.
[0002] As the heat exchange element of a counterflow
type, there is a heat exchange element in which heat
transfer plates formed by resin sheets are stacked. For
example, Patent Literature 1 discloses a heat exchange
element formed in a hexagonal column by stacking heat
transfer plates having a hexagonal shape. In the heat
exchange element of a hexagonal column, a part of a side
surface serves as an inlet/outlet port for air for heat
exchange. In addition, among edge portions of the heat
transfer plates, edge portions other than edge portions
facing the side surfaces serving as the inlet/outlet ports
for air are joined between the heat transfer plates to be
stacked, and leakage of air from the heat exchange element
is prevented. The joining of the edge portions is
performed by thermal welding or bonding using epoxy.
Citation List
Patent Literature
[0003] Patent Literature 1: Japanese Patent Application
Laid-open No. 2004-293862
Summary of Invention
Problem to be solved by the Invention
[0004] In recent years, there is a case where ultrasonic
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welding is used as a method for joining between heat
transfer plates. By using ultrasonic welding, it is
possible to shorten a time for joining between the heat
transfer plates. In ultrasonic welding, ultrasonic
vibration is transmitted to an edge portion through a tool
sandwiching the edge portion. In the joining between the
heat transfer plates using ultrasonic welding, there is a
problem that a position of the heat transfer plate is
deviated due to the ultrasonic vibration.
[0005] The present disclosure has been made in view of
the above, and an object of the present invention is to
provide a heat exchange element capable of accurately and
easily positioning between heat transfer plates without
positional deviation, even when the heat transfer plates
constituting the heat exchange element are fixed with each
other by ultrasonic welding.
Means to Solve the Problem
[0006] To solve the above problems and achieve the
object a heat exchange element according to the present
disclosure is formed by stacking a plurality of heat
transfer plates. Each of the heat transfer plates
includes: a heat exchanger adapted to allow air passing
through one side in a stacking direction of a plurality of
the heat transfer plates and air passing through another
side in the stacking direction to pass through in
directions facing each other to cause heat exchange; a
header provided on one side and another side with the heat
exchanger interposed therebetween when viewed along the
stacking direction; and a joining edge provided along a
side of the heat exchanger that is not in contact with the
header. The joining edge of a plurality of the stacked
heat transfer plates are in contact with each other and
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joined by ultrasonic welding, and the joining edge is
formed with a first convex portion that protrudes along the
stacking direction and a concave portion into which the
first convex portion of an adjacent heat transfer plate
among the heat transfer plates is fitted.
Effects of the Invention
[0007] According to the present disclosure, it is
possible to obtain a heat exchange element capable of
accurately and easily positioning between heat transfer
plates without positional deviation, even when the heat
transfer plates constituting the heat exchange element are
fixed with each other by ultrasonic welding.
Brief Description of Drawings
[0008] FIG. 1 is a perspective view of a heat exchange
element according to a first embodiment.
FIG. 2 is an exploded perspective view of the heat
exchange element according to the first embodiment.
FIG. 3 is a perspective view in which a part of the
heat exchange element according to the first embodiment is
extracted.
FIG. 4 is a plan view of a first heat transfer plate
according to the first embodiment.
FIG. 5 is a plan view of a second heat transfer plate
in the first embodiment.
FIG. 6 is a partially enlarged cross-sectional view in
which a protrusion and a base portion in the heat exchange
element according to the first embodiment are enlarged.
FIG. 7 is a partially enlarged perspective cross-
sectional view in which the protrusion and the base portion
in the heat exchange element according to the first
embodiment are enlarged.
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FIG. 8 is a plan view of the base according to the
first embodiment.
FIG. 9 is a partially enlarged cross-sectional view in
which a cone cover and a cone portion in the heat exchange
element according to the first embodiment are enlarged.
FIG. 10 is a partially enlarged perspective cross-
sectional view in which the cone cover and the cone portion
in the heat exchange element according to the first
embodiment are enlarged.
FIG. 11 is a view illustrating a schematic
configuration of a manufacturing device for the heat
exchange element according to the first embodiment.
FIG. 12 is a perspective cross-sectional view
illustrating a state in which a guide pin illustrated in
FIG. 11 is fitted into the protrusion.
FIG. 13 is a view illustrating a manufacturing process
for the heat exchange element according to the first
embodiment.
FIG. 14 is a view illustrating a manufacturing process
for the heat exchange element according to the first
embodiment.
FIG. 15 is a view illustrating a manufacturing process
for the heat exchange element according to the first
embodiment.
FIG. 16 is a view illustrating a manufacturing process
for the heat exchange element according to the first
embodiment.
Description of Embodiments
[0009] Hereinafter, a heat exchange element according to
an embodiment will be described in detail with reference to
the drawings.
[0010] First Embodiment.
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FIG. 1 is a perspective view of a heat exchange
element according to a first embodiment. FIG. 2 is an
exploded perspective view of the heat exchange element
according to the first embodiment. FIG. 3 is a perspective
5 view in which a part of the heat exchange element according
to the first embodiment is extracted. In a heat exchange
element 50, a first heat transfer plate 1 and a second heat
transfer plate 2 each having a hexagonal shape are
alternately stacked to form a hexagonal column as a whole.
Note that, in the following description, a stacking
direction of the first heat transfer plate 1 and the second
heat transfer plate 2 is simply referred to as a stacking
direction. In addition, a description will be given
assuming that a vertical direction on the page of FIG. 1 is
a vertical direction in the heat exchange element 50.
[0011] In the heat exchange element 50, one of six side
surfaces having a rectangular shape is a first inflow
surface 61 serving as an inflow port of air into the heat
exchange element 50. A side surface facing a direction
opposite to the first inflow surface 61 is a first outflow
surface 71 from which air having flowed in from the first
inflow surface 61 flows out. An air passage 3 connecting
the first inflow surface 61 and the first outflow surface
71 is formed inside the heat exchange element 50.
[0012] One side surface among two side surfaces adjacent
to the first outflow surface 71 is a second inflow surface
62 serving as an inflow port of air into the heat exchange
element 50. A side surface facing a direction opposite to
the second inflow surface 62 is a second outflow surface 72
from which air having flowed in from the second inflow
surface 62 flows out. The first inflow surface 61 and the
second outflow surface 72 are adjacent to each other. An
air passage 4 connecting the second inflow surface 62 and
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the second outflow surface 72 is formed inside the heat
exchange element 50. The air passage 3 and the air passage
4 do not cross each other inside the heat exchange element
50.
[0013] The heat exchange element 50 is provided inside a
ventilator, for example, and allows an exhaust air flow
from inside to outside of a room to pass through the air
passage 3, and allows a supply air flow from outside to
inside of the room to pass through the air passage 4, so
that the heat exchange element 50 can cause heat exchange
between the supply air flow and the exhaust air flow.
[0014] FIG. 4 is a plan view of a first heat transfer
plate according to the first embodiment. The first heat
transfer plate 1 has a hexagonal shape in plan view. By
stacking the first heat transfer plate 1 and the second
heat transfer plate 2, the air passage 3 is formed on one
surface side of the first heat transfer plate 1, and the
air passage 4 is formed on another surface side of the
first heat transfer plate 1. The first heat transfer plate
1 is provided with a heat exchanger 5 that causes heat
exchange between air passing through the air passage 3 and
air passing through the air passage 4. The heat exchanger
5 is formed by a rectangular region having, as short sides,
sides la and lb facing side surfaces on which the first
inflow surface 61, the first outflow surface 71, the second
inflow surface 62, and the second outflow surface 72 are
not formed, among the side surfaces of the heat exchange
element 50. Although a structure will not be described in
detail, the heat exchanger 5 has a corrugated shape having
a plurality of irregularities. In the heat exchanger 5,
air passing through the air passage 3 and air passing
through the air passage 4 pass in parallel and opposite
directions to each other.
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[0015] The first heat transfer plate 1 is provided with
a first header 6a having a triangular shape in plan view.
The first header 6a includes a side lc facing the first
inflow surface 61 and a side id facing the second outflow
surface 72, in the heat exchange element 50.
[0016] The first heat transfer plate 1 is provided with
a second header 6b having a triangular shape in plan view.
The second header 6b includes a side le facing the first
outflow surface 71 and a side if facing the second inflow
surface 62, in the heat exchange element 50. The first
header 6a and the second header 6b are provided on one side
and another side with the heat exchanger 5 interposed
therebetween. The sides la and lb of the first heat
transfer plate 1 are sides that are not in contact with the
first header 6a and the second header 6b.
[0017] In the first header 6a and the second header 6b,
ribs 8 are formed. The rib 8 formed in the first header 6a
extends from the side lc toward the heat exchanger 5. The
rib 8 formed in the first header 6a extends substantially
parallel to the side id, and allows air having flowed in
from the first inflow surface 61, that is, the side lc
side, to smoothly pass toward the heat exchanger 5.
[0018] The rib 8 formed in the second header 6b extends
from the side le toward the heat exchanger 5. The rib 8
formed in the second header 6b extends substantially
parallel to the side if, and allows air from the heat
exchanger 5 to smoothly pass toward the side le.
[0019] On an outer edge of the first header 6a, a belt-
shaped flat portion 21 is provided, which is a belt-shaped
flat region extending along the side lc. On an outer edge
of the first header 6a, a belt-shaped flat portion 22 is
provided, which is a belt-shaped flat region extending
along the side id. In the first heat transfer plate 1, a
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step 41 along the stacking direction is provided between
the belt-shaped flat portion 21 and the belt-shaped flat
portion 22, in order to allow inflow of air from the side
lc and prevent inflow of air from the side ld. More
specifically, the belt-shaped flat portion 21 is formed at
a position below a region where the rib 8 is formed, and
the belt-shaped flat portion 22 is formed at a position
above the belt-shaped flat portion 21. Note that the belt-
shaped flat portion 21 and the region where the rib 8 is
formed may be formed on one surface.
[0020] On an outer edge of the second header 6b, a belt-
shaped flat portion 23 is provided, which is a belt-shaped
flat region extending along the side le. On an outer edge
of the second header 6b, a belt-shaped flat portion 24 is
provided, which is a belt-shaped flat region extending
along the side if. In the first heat transfer plate 1, a
step 42 along the stacking direction is provided between
the belt-shaped flat portion 23 and the belt-shaped flat
portion 24, in order to allow outflow of air from the side
le and prevent outflow of air from the side if. More
specifically, the belt-shaped flat portion 23 is formed at
a position below a region where the rib 8 is formed, and
the belt-shaped flat portion 24 is formed at a position
above the belt-shaped flat portion 23. Note that the belt-
shaped flat portion 23 and the region where the rib 8 is
formed may be formed on one flat surface.
[0021] On an outer edge of the heat exchanger 5, belt-
shaped flat portions 25 and 26 are provided, which are
belt-shaped flat regions extending along the side la. The
belt-shaped flat portion 25 and the belt-shaped flat
portion 26 are formed provided with a step 43 at an
intermediate portion in between in a direction along the
side la. The belt-shaped flat portion 26 is formed above
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the belt-shaped flat portion 25.
[0022] On an outer edge of the heat exchanger 5, belt-
shaped flat portions 27 and 28 are provided, which are
belt-shaped flat regions extending along the side lb. The
belt-shaped flat portion 27 and the belt-shaped flat
portion 28 are formed provided with a step 44 at an
intermediate portion in between in a direction along the
side lb. The belt-shaped flat portion 28 is formed above
the belt-shaped flat portion 27. The first heat transfer
plate 1 has a point symmetrical shape centered on a center
position of the hexagonal shape in plan view.
[0023] FIG. 5 is a plan view of a second heat transfer
plate according to the first embodiment. The second heat
transfer plate 2 has a hexagonal shape in plan view.
Configurations similar to those of the first heat transfer
plate 1 are denoted by identical reference numerals, and a
detailed description thereof will be omitted. The second
heat transfer plate 2 is in a mirror image relationship
with the first heat transfer plate 1.
[0024] By stacking the first heat transfer plate 1 and
the second heat transfer plate 2, the air passage 4 is
formed on one surface side of the second heat transfer
plate 2, and the air passage 3 is formed on another surface
side of the second heat transfer plate 2. The second heat
transfer plate 2 is provided with the heat exchanger 5 that
causes heat exchange between air passing through the air
passage 3 and air passing through the air passage 4. In
the second heat transfer plate 2, the heat exchanger 5 is
formed by a rectangular region having, as short sides,
sides 2a and 2b facing side surfaces on which the first
inflow surface 61, the first outflow surface 71, the second
inflow surface 62, and the second outflow surface 72 are
not formed, among the side surfaces of the heat exchange
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element 50.
[0025] The second heat transfer plate 2 is provided with
a third header 6c having a triangular shape in plan view.
The third header 6c includes a side 2c facing the first
5 inflow surface 61 and a side 2d facing the second outflow
surface 72, in the heat exchange element 50.
[0026] The second heat transfer plate 2 is provided with
a fourth header 6d having a triangular shape in plan view.
The fourth header 6d includes a side 2e facing the first
10 outflow surface 71 and a side 2f facing the second inflow
surface 62, in the heat exchange element 50. The third
header 6c and the fourth header 6d are provided on one side
and another side with the heat exchanger 5 interposed
therebetween. The sides 2a and 2b of the second heat
transfer plate 2 are sides not in contact with the third
header 6c and the fourth header 6d.
[0027] In the third header 6c and the fourth header 6d,
the ribs 8 are formed. The rib 8 formed in the third
header 6c extends from the side 2d toward the heat
exchanger 5. The rib 8 formed in the third header 6c
extends substantially parallel to the side 2c, and allows
air from the heat exchanger 5 to smoothly pass toward the
side 2d.
[0028] The rib 8 formed in the fourth header 6d extends
from the side 2f toward the heat exchanger 5. The rib 8
formed in the fourth header 6d extends substantially
parallel to the side 2e, and allows air having flowed in
from the second inflow surface 62, that is, the side 2f
side, to smoothly pass toward the heat exchanger 5.
[0029] On an outer edge of the third header 6c, a belt-
shaped flat portion 31 is provided, which is a belt-shaped
flat region extending along the side 2c. On an outer edge
of the third header 6c, a belt-shaped flat portion 32 is
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provided, which is a belt-shaped flat region extending
along the side 2d. In the second heat transfer plate 2, a
step 51 along the stacking direction is provided between
the belt-shaped flat portion 31 and the belt-shaped flat
portion 32, in order to allow outflow of air from the side
2d and prevent outflow of air from the side 2c. More
specifically, the belt-shaped flat portion 32 is formed at
a position below the region where the rib 8 is formed, and
the belt-shaped flat portion 31 is formed at a position
above the belt-shaped flat portion 32. Note that the belt-
shaped flat portion 32 and the region where the rib 8 is
formed may be formed on one flat surface.
[0030] On an outer edge of the fourth header 6d, a belt-
shaped flat portion 33 is provided, which is a belt-shaped
flat region extending along the side 2e. On an outer edge
of the fourth header 6d, a belt-shaped flat portion 34 is
provided, which is a belt-shaped flat region extending
along the side 2f. In the second heat transfer plate 2, a
step 52 along the stacking direction is provided between
the belt-shaped flat portion 33 and the belt-shaped flat
portion 34, in order to allow inflow of air from the side
2f and prevent inflow of air from the side 2e. More
specifically, the belt-shaped flat portion 34 is formed at
a position below the region where the rib 8 is formed, and
the belt-shaped flat portion 33 is formed at a position
above the belt-shaped flat portion 34. Note that the belt-
shaped flat portion 34 and the region where the rib 8 is
formed may be formed on one flat surface.
[0031] On an outer edge of the heat exchanger 5, belt-
shaped flat portions 35 and 36 are provided, which are
belt-shaped flat regions extending along the side 2a. The
belt-shaped flat portion 35 and the belt-shaped flat
portion 36 are formed provided with a step 53 at an
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intermediate portion in between in a direction along the
side 2a. The belt-shaped flat portion 35 is formed above
the belt-shaped flat portion 36.
[0032] On an outer edge of the heat exchanger 5, belt-
shaped flat portions 37 and 38 are provided, which are
belt-shaped flat regions extending along the side 2b. The
belt-shaped flat portion 37 and the belt-shaped flat
portion 38 are formed provided with a step 54 at an
intermediate portion in between in a direction along the
side 2b. The belt-shaped flat portion 37 is formed above
the belt-shaped flat portion 38. The second heat transfer
plate 2 has a point symmetrical shape centered on a center
position of the hexagonal shape in plan view.
[0033] Next, a protrusion 13, a base 14, a cone cover
15, and a cone 16 formed on the first heat transfer plate 1
and the second heat transfer plate 2 will be described.
[0034] The protrusion 13 and the base 14 are formed on
the headers 6a, 6b, 6c, and 6d. FIG. 6 is a partially
enlarged cross-sectional view in which a protrusion and a
base portion in the heat exchange element according to the
first embodiment are enlarged. FIG. 7 is a partially
enlarged perspective cross-sectional view in which the
protrusion and the base portion in the heat exchange
element according to the first embodiment are enlarged.
FIG. 8 is a plan view of the base according to the first
embodiment.
[0035] The protrusion 13 is formed so as to protrude
downward. The protrusion 13 is a second convex portion. A
back surface of the protrusion 13 is a recess. Returning
to FIGS. 4 and 5, a plurality of protrusions 13 are formed
along the sides lc, le, 2d, and 2f serving as inlet/outlet
ports for air. The plurality of protrusions 13 are formed
for each of the sides lc, le, 2d, and 2f. The protrusions
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13 are formed at positions where lengths of the sides lc,
le, 2d, and 2f are divided at equal intervals. A ratio of
a height of the protrusion 13 to a diameter at a root of
the protrusion 13 is 1 or less. With this ratio, when the
heat transfer plates 1 and 2 are formed by vacuum molding,
it is possible to prevent a material from becoming too thin
and forming a hole.
[0036] As illustrated in FIGS. 6 and 7, the base 14 is
formed so as to protrude upward. A cross-sectional shape
of the base 14 is trapezoidal shape. A flat region is
provided at a top portion of the base 14, and a recess 14a
recessed downward is formed in the flat region. As
illustrated in FIG. 8, a planar shape of the base 14 is a
rhombus shape. The recess 14a has an elongated hole shape
whose longitudinal direction is a direction toward a center
of the heat transfer plates 1 and 2 in plan view. A width
along a short direction of the recess 14a is a width in
which the protrusion 13 is fitted.
[0037] The base 14 is provided such that a longer
diagonal line among two diagonal lines of the rhombus is
parallel to the sides id, if, 2c, and 2e with which the
base 14 is along. That is, it suffices that the base 14 is
provided such that the longer diagonal line among the two
diagonal lines of the rhombus is along an air flow
direction. The base 14 is provided as close as possible to
the belt-shaped flat portions 22, 24, 31, and 33, at a
position away to such an extent that the base 14 does not
overlap with the belt-shaped flat portions 22, 24, 31, and
33 with a gap provided in between, on a straight line
substantially parallel to the air flow direction. Note
that, in the present embodiment, it can also be said that
the base 14 is disposed on a straight line substantially
parallel to the belt-shaped flat portions 22, 24, 31, and
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33.
[0038] The protrusion 13 and the base 14 are formed at
positions overlapping with each other in plan view when the
first heat transfer plate 1 and the second heat transfer
plate 2 are stacked. As illustrated in FIGS. 6 and 7, when
the heat transfer plates 1 and 2 are stacked, a region
serving as a flat surface of a top portion of the base 14
abuts on the heat transfer plates 1 and 2 stacked above.
Further, the protrusion 13 is fitted into the recess 14a of
the base 14. The protrusion 13 is fitted into the recess
14a and thus is not exposed to the air passages 3 and 4.
Note that the protrusion 13 may protrude upward, and the
base 14 may protrude downward.
[0039] As illustrated in FIGS. 4 and 5, the cone cover
15 is formed on the belt-shaped flat portions 25, 27, 36,
and 38 of the heat transfer plates 1 and 2. A plurality of
cone covers 15 are formed for each of the belt-shaped flat
portions 25, 27, 36, and 38. The cone covers 15 are formed
at positions where lengths of the belt-shaped flat portions
25, 27, 36, and 38 are divided at equal intervals. The
cone covers 15 are formed at positions closer to the heat
exchanger 5 than a center in a width direction of each of
the belt-shaped flat portions 25, 27, 36, and 38.
[0040] FIG. 9 is a partially enlarged cross-sectional
view in which a cone cover and a cone portion in the heat
exchange element according to the first embodiment are
enlarged. FIG. 10 is a partially enlarged perspective
cross-sectional view in which the cone cover and the cone
portion in the heat exchange element according to the first
embodiment are enlarged. The cone cover 15 is a concave
portion recessed upward from below. The cone cover 15
protrudes on a back surface side of the concave portion.
The cone cover 15 is formed in a conical shape whose tip
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end has a flat shape. A ratio of a height of the cone
cover 15 to a gap distance between the heat exchanger 5 and
the cone cover 15 is 1 or less. With this ratio, when the
heat transfer plates 1 and 2 are formed by vacuum molding,
5 it is possible to prevent a material from becoming too thin
and forming a hole. The concave portion of the cone cover
15 has an elongated hole shape extending in a length
direction of each of the belt-shaped flat portions 25, 27,
36, and 38.
10 [0041] As illustrated in FIGS. 4 and 5, the cone 16 is
formed on the belt-shaped flat portions 26, 28, 35, and 37
of the heat transfer plates 1 and 2. A plurality of cones
16 are formed for each of the belt-shaped flat portions 26,
28, 35, and 37. The cones 16 are formed at positions where
15 lengths of the belt-shaped flat portions 26, 28, 35, and 37
are divided at equal intervals. The cones 16 are formed at
positions closer to the heat exchanger 5 than a center in a
width direction of each of the belt-shaped flat portions
26, 28, 35, and 37. A ratio of a height of the cone 16 to
a gap distance between the heat exchanger 5 and the cone 16
is 1 or less. With this ratio, when the heat transfer
plates 1 and 2 are formed by vacuum molding, it is possible
to prevent a material from becoming too thin and forming a
hole.
[0042] As illustrated in FIGS. 9 and 10, the cone 16 is
a first convex portion protruding upward. The cone 16 is
formed in a conical shape whose tip end has a curved
surface.
[0043] When the heat transfer plates 1 and 2 are
stacked, the belt-shaped flat portion 21 abuts on the belt-
shaped flat portion 31 below. The belt-shaped flat portion
22 abuts on the belt-shaped flat portion 32 above. The
belt-shaped flat portion 23 abuts on the belt-shaped flat
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portion 33 below. The belt-shaped flat portion 24 abuts on
the belt-shaped flat portion 34 above. The belt-shaped
flat portion 25 abuts on the belt-shaped flat portion 35
below. The belt-shaped flat portion 26 abuts on the belt-
shaped flat portion 36 above. The belt-shaped flat portion
27 abuts on the belt-shaped flat portion 37 below. The
belt-shaped flat portion 28 abuts on the belt-shaped flat
portion 38 above. As will be described in detail later,
the abutting belt-shaped flat portions 21, 22, 23, 24, 25,
26, 27, 28, 31, 32, 33, 34, 35, 36, 37, and 38 serve as
joining edge joined by ultrasonic welding.
[0044] The cone cover 15 and the cone 16 are formed at
positions overlapping with each other in plan view when the
heat transfer plates 1 and 2 are stacked. As illustrated
in FIGS. 9 and 10, when the heat transfer plates 1 and 2
are stacked, the cone 16 fits into the concave portion of
the cone cover 15. Note that the concave portion of the
cone cover 15 may be recessed downward, and the cone 16 may
be protruded downward.
[0045] Next, a manufacturing process for the heat
exchange element will be described. FIG. 11 is a view
illustrating a schematic configuration of a manufacturing
device for the heat exchange element according to the first
embodiment. The manufacturing device includes a receiving
base 17 on which the heat transfer plates 1 and 2 are
placed. The receiving base 17 has a function of holding
the heat transfer plates 1 and 2 by a method such as
suction, and is provided with a hole (not illustrated) for
positioning at a location identical to a position of the
protrusion 13. Furthermore, on an upper side of the
manufacturing device, a guide pin 18 and a guide pin 19 are
included at locations identical to positions of the
protrusion 13. FIG. 12 is a perspective cross-sectional
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view illustrating a state in which a guide pin illustrated
in FIG. 11 is fitted into the protrusion. The guide pin 18
is movable up and down, and a tip end thereof is inserted
into a recess on a back surface of the protrusion 13 as
illustrated in FIG. 12 when the guide pin 18 moves
downward. This similarly applies to the guide pin 19.
[0046] In the manufacturing process for the heat
exchange element 50, stacking and fixing of the first heat
transfer plate 1 and the second heat transfer plate 2 are
repeated. FIGS. 13 to 16 are views illustrating a
manufacturing process for the heat exchange element
according to the first embodiment.
[0047] In the manufacturing process of the heat exchange
element 50, as illustrated in FIG. 13, first, the first
heat transfer plate 1, which is the first piece of
stacking, is placed on the receiving base 17. At this
time, the protrusion 13 is aligned with the hole of the
receiving base 17, so that the protrusion 13 is fitted into
the hole of the receiving base 17 to perform positioning.
[0048] Next, as illustrated in FIG. 14, a tip end of the
guide pin 18 is fitted into the concave portion on the back
surface of the protrusion 13 of the second heat transfer
plate 2 to be stacked next, and then, as illustrated in
FIG. 15, the second heat transfer plate 2 is stacked. By
doing in this manner, the abutting belt-shaped flat
portions 22, 24, 26, 28, 32, 34, 36, and 38 are fixed with
one another by ultrasonic welding in a state where both the
heat transfer plates 1 and 2 of the upper layer and the
lower layer are positioned by the manufacturing device.
Next, as illustrated in FIG. 16, stacking is performed
while positioning is performed using the guide pins 19 with
respect to the first heat transfer plates 1 to be stacked
next. In this manner, the first heat transfer plate 1 and
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the second heat transfer plate 2 are stacked up to any
height by alternately repeatedly stacking and fixing. As
can be seen from the description of the manufacturing
process, the guide pin 18 is used for positioning the
second heat transfer plate 2, and the guide pin 19 is used
for positioning the first heat transfer plate 1.
[0049] Further, the tip ends of the guide pins 18 and 19
are fitted into the concave portions on the back surfaces
of the protrusions 13, and the heat transfer plates 1 and 2
on the upper layer are pressed against the heat transfer
plates 1 and 2 below. Therefore, frictional resistance is
generated between the flat portion of the base 14 in which
the protrusion 13 is fitted and the region of the headers
6a, 6b, 6c, and 6d that abuts on the flat portion of the
base 14. As a result, reliability of ultrasonic welding is
improved, and a yield is improved.
[0050] According to the heat exchange element 50
described above, the protrusion 13, the base 14, the cone
cover 15, and the cone 16 formed on the heat transfer
plates 1 and 2 are less likely to cause positional
deviation in a stacked state. Therefore, even by
ultrasonic welding that applies vibration to the heat
transfer plates 1 and 2, positional deviation is less
likely to occur in the heat transfer plates 1 and 2. In
addition, since the protrusion 13 is fitted into the recess
14a of the base 14 and the cone 16 is fitted into the cone
cover 15 only by stacking the heat transfer plates 1 and 2,
positioning can be performed accurately and easily. In
addition, if the protrusion 13 is tightly fitted into the
recess 14a of the base 14 and the cone 16 is tightly fitted
into the cone cover 15, it is possible to further reduce
occurrence of positional deviation. In addition, the heat
transfer plates 1 and 2 contract toward a center thereof
Date Recue/Date Received 2024-01-03
CA 03226203 2024-01-03
19
after molding. Since the recess 14a has an elongated hole
shape whose longitudinal direction is a direction toward a
center of the heat transfer plates 1 and 2 in plan view,
the protrusion 13 is easily fitted into the recess 14a even
when the position of the base 14 is deviated due to
contraction toward the center of the heat transfer plates 1
and 2. In addition, by the protrusions 13 abutting on the
recesses 14a, the heat transfer plates 1 and 2 are
prevented from being deviated from each other in a
direction different from the direction toward the center of
the heat transfer plates 1 and 2, so that positioning
accuracy is also improved.
[0051] Further, the protrusion 13 and the base 14 are at
positions close to the belt-shaped flat portions 22, 24,
31, and 33 even in the regions of the headers 6a, 6b, 6c,
and 6d, and the cone cover 15 and the cone 16 are also at
the belt-shaped flat portions 25, 26, 27, 28, 35, 36, 37,
and 38. Therefore, even when a force for deviating the
heat transfer plates 1 and 2 acts by ultrasonic welding, a
bending stress generated in the heat transfer plates 1 and
2 remains in a short distance range, so that it is possible
to make the heat transfer plates less likely to be bent.
[0052] In addition, since the plurality of protrusions
13, the plurality of bases 14, the plurality of cone covers
15, and the plurality of cones 16 are formed for each of
the belt-shaped flat portions 21, 22, 23, 24, 25, 26, 27,
28, 31, 32, 33, 34, 35, 36, 37, and 38, positional
deviation is further less likely to occur.
[0053] Further, since the protrusion 13 has a tapered
shape, the cone cover 15 has a conical shape, and the cone
16 has a conical shape, it is easy to perform centering
when the heat transfer plates 1 and 2 are positioned with
each other or the heat transfer plate and the manufacturing
Date Recue/Date Received 2024-01-03
CA 03226203 2024-01-03
device are positioned with each other, and the heat
transfer plates 1 and 2 can be easily positioned with each
other.
[0054] In addition, by performing ultrasonic welding in
5 a state where accurate positioning is made, a range to be
welded is less likely to reach other ranges, or a portion
having a welding defect is less likely to occur.
Accordingly, clogging due to excessive welding and leakage
of air from the heat exchange element 50 can be prevented.
10 [0055] In addition, since the base 14 is provided such
that the longer diagonal line among the two diagonal lines
of the rhombus is along the air flow direction, and the top
portion of the base 14 abuts on the adjacent heat transfer
plate 1 or 2, the base 14 is less likely to obstruct an air
15 flow. In addition, by providing a gap between the base 14
and the belt-shaped flat portions 22, 24, 31, and 33, it is
possible to reduce disturbance of a wind flow around the
base 14 and the sides 1d, if, 2c, and 2e and to suppress
occurrence of a pressure loss, as compared with a case
20 where no gap is provided. Further, by disposing the bases
14 linearly in the air flow direction, it is possible to
similarly reduce disturbance of the flow and suppress
occurrence of a pressure loss. In addition, by disposing
the base 14 as close as possible to the sides 1d, if, 2c,
and 2e with the gap interposed therebetween, a distance
between the welding point and the base 14 becomes as short
as possible, and the positioning can be more effectively
performed at the time of welding.
[0056] Further, since the base 14 is provided on the
headers 6a, 6b, 6c, and 6d, a width of the belt-shaped flat
portions 21, 22, 23, 24, 31, 32, 33, and 34 can be narrowed
as compared with a case where the base 14 is provided on
the belt-shaped flat portions 21, 22, 23, 24, 31, 32, 33,
Date Recue/Date Received 2024-01-03
CA 03226203 2024-01-03
21
and 34. If the heat transfer plates 1 and 2 have equal
sizes, the headers 6a, 6b, 6c, and 6d can be widened as the
widths of the belt-shaped flat portions 21, 22, 23, 24, 31,
32, 33, and 34 are narrower. Although the base 14 is to be
provided in the flow path, by widening the headers 6a, 6b,
6c, and 6d, a pressure loss of the heat exchange element 50
can be reduced as compared with a case where the base 14 is
provided in the belt-shaped flat portions 21, 22, 23, 24,
31, 32, 33, and 34.
[0057] The configuration described in the above
embodiment is an example of the contents of the present
disclosure. The configuration of the embodiment can be
combined with another known technique. A part of the
configuration of the embodiment can be omitted or changed
without departing from the gist of the present disclosure.
Reference Signs List
[0058] 1 first heat transfer plate; la, lb, lc, id, le,
if side; 2 second heat transfer plate; 2a, 2b, 2c, 2d,
2e, 2f side; 3, 4 air passage; 5 heat exchanger; 6a
first header; 6b second header; 6c third header; 6d
fourth header; 8 rib; 13 protrusion; 14 base; 14a
recess; 15 cone cover; 16 cone; 17 receiving base; 18, 19
guide pin; 21, 22, 23, 24, 25, 26, 27, 28, 31, 32, 33, 34,
35, 36, 37, 38 belt-shaped flat portion; 41, 42, 43, 44,
51, 52, 53, 54 step; 50 heat exchange element; 61 first
inflow surface; 62 second inflow surface; 71 first
outflow surface; 72 second outflow surface.
Date Recue/Date Received 2024-01-03
