U.S. patent application number 11/982213 was filed with the patent office on 2008-05-08 for cooling heat exchanger.
This patent application is currently assigned to DENSO Corporation. Invention is credited to Taichi Asano, Yoshiki Katoh.
Application Number | 20080105416 11/982213 |
Document ID | / |
Family ID | 39358754 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080105416 |
Kind Code |
A1 |
Katoh; Yoshiki ; et
al. |
May 8, 2008 |
Cooling heat exchanger
Abstract
A cooling heat exchanger has first and second heat transfer
plates joined to each other. Each of the first and second heat
transfer plates has protrusions protruding from a base portion
thereof for defining internal fluid passages, a fin portion
projecting from the base portion in the same direction as the
protrusions and defining a fin inner space, and an aperture on the
base portion at a position corresponding to the fin portion. The
fin portion includes an offset wall that is offset from the base
portion and connected to the base portion at two positions. The
aperture of the first heat transfer plate is displaced from the
aperture of the second heat transfer plate with respect to a
longitudinal direction of the protrusions so that a communication
channel that allows communication between the fin inner spaces of
the first and second heat transfer plates is provided for draining
condensation.
Inventors: |
Katoh; Yoshiki; (Chita-gun,
JP) ; Asano; Taichi; (Kariya-city, JP) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
DENSO Corporation
Kariya-city
JP
|
Family ID: |
39358754 |
Appl. No.: |
11/982213 |
Filed: |
November 1, 2007 |
Current U.S.
Class: |
165/151 |
Current CPC
Class: |
F25B 2309/061 20130101;
F25B 39/00 20130101; F28F 3/04 20130101; F28F 17/005 20130101; F28D
1/0417 20130101; F28D 1/0333 20130101 |
Class at
Publication: |
165/151 |
International
Class: |
F28D 1/03 20060101
F28D001/03 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 2, 2006 |
JP |
2006-298691 |
Claims
1. A heat exchanger for performing heat exchange between air
flowing outside thereof and an internal fluid flowing inside
thereof, thereby cooling the air, comprising: a first heat transfer
plate; and a second heat transfer plate, wherein each of the first
and second heat transfer plates includes a base portion defining a
plane in a flow direction of the air and a plurality of protrusions
protruding from the base portion and extending in a direction that
intersects with the flow direction of the air, the protrusions
defining internal fluid passages therein for allowing the internal
fluid to flow, the first and second heat transfer plates are joined
to each other such that the base portions are in contact with each
other, the protrusions of the first heat transfer plate protrude in
one direction and the protrusions of the second heat transfer plate
protrude in an opposite direction, each of the first and second
heat transfer plates further includes a fin portion projecting from
the base portion in the same direction as the protrusions thereof
and an aperture on the base portion at a position corresponding to
the fin portion, the fin portion includes an offset wall that is
offset from the base portion and defines a fin inner space therein,
the offset wall is connected to the base portion at two locations
that are spaced in a direction parallel to a longitudinal direction
of the protrusions, and the aperture of the first heat transfer
plate is displaced from the aperture of the second heat transfer
plate with respect to the longitudinal direction of the
protrusions, and the fin inner space of the first heat transfer
plate is in communication with the fin inner space of the second
heat transfer plate through the apertures, such that a
communication channel for draining condensation is provided between
the first and second heat transfer plates.
2. The heat exchanger according to claim 1, wherein the fin portion
has a fin height in a direction perpendicular to the plane of the
base portion, the fin height being equal to or greater than 0.35
mm.
3. The heat exchanger according to claim 1, wherein each of the
first and second heat transfer plates has a plurality of fin
portions including the fin portion, the plurality of fin portions
is disposed in the flow direction of the air such that a plurality
of communication channels including the communication channel is
disposed in the flow direction of the air.
4. A heat exchanger for performing heat exchange between air
flowing outside thereof and an internal fluid flowing inside
thereof, thereby cooling the air, the heat exchanger comprising: a
first heat transfer plate including a base portion that defines a
plane in a flow direction of the air, a plurality of protrusions
that protrudes from the base portion and extends in a direction
intersecting with the flow direction of the air, a fin portion that
projects from the base portion in a same direction as the
protrusions and defines a fin inner space therein, and a first
aperture on the base wall at a position corresponding to the fin
portion, the fin portion including an offset wall that is offset
from the base portion, the offset wall connected to the base
portion at two locations that are separated in a longitudinal
direction of the protrusions; and a second heat transfer plate
including a base portion that defines a plane in the flow direction
of the air, a plurality of protrusions that protrudes from the base
portion and extends in a direction intersecting with the flow
direction of the air, and a second aperture, wherein the first heat
transfer plate and the second heat transfer plate are joined to
each other such that the base portions thereof are in contact with
each other, the protrusions of the first heat transfer plate
protrude in one direction and the protrusions of the second heat
transfer plate protrude in an opposite direction, the protrusions
of the first and second heat transfer plates define internal fluid
passages therein for allowing the internal fluid to flow, and the
first aperture and the second aperture overlap at least at a
part.
5. The heat exchanger according to claim 4, wherein the first heat
transfer plate includes a plurality of fin portions including the
fin portion and a plurality of first apertures including the first
aperture, the plurality of fin portions being disposed in the
longitudinal direction of the protrusions, the plurality of first
apertures being disposed in the longitudinal direction of the
protrusions, and the second heat transfer plate includes a
plurality of second apertures including the second aperture, the
plurality of second apertures being disposed in the longitudinal
direction of the protrusions.
6. The heat exchanger according to claim 4, wherein a dimension of
the second aperture in the longitudinal direction of the
protrusions is equal to or greater than a width of the fin portion
in the flow direction of the air.
7. The heat exchanger according to claim 4, wherein a dimension of
the second aperture in the flow direction of the air is equal to or
greater than a width of the fin portion in the flow direction of
the air.
8. The heat exchanger according to claim 4, wherein the second
aperture is disposed such that a lower end thereof is located lower
than a lower end of the first aperture.
9. The heat exchanger according to claim 4, wherein the first heat
transfer plate includes a plurality of fin portions including the
fin portion and a plurality of first apertures including the first
aperture, the plurality of fin portions being disposed in the flow
direction of the air, the plurality of first apertures being
disposed in the flow direction of the air, the second heat transfer
plate includes a plurality of second apertures including the second
aperture, the plurality of second apertures being disposed in the
flow direction of the air, and each of the plurality of first
apertures overlaps with a corresponding one of the plurality of
second apertures, at least, at a part.
10. The heat exchanger according to claim 3, wherein the plurality
of fin portions is spaced in the flow direction of the air, and a
distance between adjacent two fin portions is equal to or greater
than 0.4 mm.
11. The heat exchanger according to claim 1, wherein a dimension of
each aperture in the longitudinal direction of the protrusions is
equal to or greater than 5 mm.
12. The heat exchanger according to claim 1, wherein the offset
wall is parallel to the plane of the base portion.
13. The heat exchanger according to claim 1, wherein the offset
wall is inclined relative to the plane of the base portion such
that a distance between the offset wall and the plane of the base
portion reduces toward a lower position.
14. The heat exchanger according to claim 1, wherein each of the
protrusions includes a curved outer surface, the fin portion is
disposed downstream of one of the protrusions with respect to the
flow direction of the air, the offset wall is inclined relative to
the plane of the base portion such that a distance between the
offset wall and the plane of the base portion reduces toward a
downstream position with respect to the flow direction of the
air.
15. The heat exchanger according to claim 1, wherein each of the
protrusions includes a curved outer surface, the fin portion is
disposed between two of the protrusions that are disposed in the
flow direction of the air, and the offset wall is curved toward the
plane of the base portion such that a distance between the offset
wall and the plane of the base portion reduces toward a middle
position with respect to the flow direction of the air.
16. The heat exchanger according to claim 1, wherein the fin
portion includes a first connecting wall that connects an upper end
of the offset wall to the base portion and a second connecting wall
that connects a lower end of the offset wall to the base
portion.
17. The heat exchanger according to claim 16, wherein the first
connecting wall and the second connecting wall are respectively
inclined relative to the plane of the base portion, and an angle of
inclination of each of the first connecting wall and the second
connecting wall is at least 30 degrees and at most 60 degrees.
18. The heat exchanger according to claim 16, wherein the upper end
of the offset wall and the first connecting wall form a rounded
corner therebetween, and the lower end of the offset wall and the
second connecting wall form a rounded corner therebetween.
19. The heat exchanger according to claim 1, wherein the offset
wall has a semi-circular shape in a cross-section defined in the
longitudinal direction of the protrusions, and ends of the offset
wall connect to the base portion.
20. The heat exchanger according to claim 1, wherein the fin
portion has a width equal to or greater than 0.2 mm with respect to
the flow direction of the air.
21. The heat exchanger according to claim 20, wherein the base
portion includes side sections on opposite sides of the fin portion
with respect to the flow direction of the air, and a width of each
of the side sections with respect to the air flow direction is
equal to or greater than 0.15 mm.
22. The heat exchanger according to claim 1, wherein the
protrusions of the first heat transfer plate and the protrusions of
the second heat transfer plate are disposed at the same positions
with respect to the flow direction of the air such that each of the
internal fluid passages is provided by one of the protrusions of
the first heat transfer plate and one of the protrusions of the
second heat transfer plate.
23. The heat exchanger according to claim 1, further comprising: a
plurality of first heat transfer plates including the first heat
transfer plate; and a plurality of second heat transfer plates
including the second heat transfer plate, wherein the plurality of
first heat transfer plates and the plurality of second heat
transfer plates are disposed in pairs, and the pairs of the first
and second heat transfer plates are stacked in a direction
perpendicular to the planes of the base portions such that
clearances for allowing the air to flow are provided between the
adjacent pairs of the first and second heat transfer plates.
24. The heat exchanger according to claim 23, wherein a dimension
of each clearance at a position between the offset wall of one heat
transfer plate and a surface of another heat transfer plate that is
opposed to the one heat transfer plate across the clearance is
equal to or greater than 0.15 mm.
25. The heat exchanger according to claim 1, wherein the fin
portion is disposed upstream of an end protrusion with respect to
the flow direction of the air, the end protrusion being one of the
plurality of protrusions and located at a downstream-most position
in the plurality of protrusions with respect to the flow direction
of the air.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No.
2006-298691 filed on Nov. 2, 2006, the disclosure of which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a cooling heat exchanger
having heat transfer plates on which fin portions are integrally
formed.
BACKGROUND OF THE INVENTION
[0003] For example, Unexamined Japanese Patent Publication No.
2002-147983 describes a plate-type cooling heat exchanger, such as
an evaporator, which is constructed of heat transfer plates without
using separate fin members. The heat transfer plates include base
portions, which are generally flat, and protrusions protruding from
the base portions for defining internal fluid passages therein
through which an internal fluid, such as a refrigerant, flows. The
protrusions are formed by pressing, such as projecting. The heat
transfer plates further have slit fins on the base portions and
between the protrusions.
[0004] In the disclosed heat exchanger, heat exchange is performed
between an external fluid, such as air, flowing outside thereof and
the internal fluid. At this time, a flow of air is disturbed by the
protrusions. Namely, since the protrusions serve as turbulent
members for causing turbulent flows, a coefficient of heat transfer
of the air improves. Further, efficiency of heat transfer improves.
Also, the fins have substantially U-shaped cross-sections, and thus
the air can flow inside of the fins. Because a heat transfer area
for the air increases due to configuration of the fins, the
efficiency of heat transfer further improves.
[0005] Although such a plate-type heat exchanger does not have the
fin members, such as corrugated fins, which are generally used in a
fin and tube type heat exchanger, the efficiency of heat transfer
is improved by the slit fins. The plate-type heat exchanger is
simply formed by brazing the heat transfer plates, which are formed
by pressing.
[0006] In a cooling heat exchanger, condensation is generated due
to cooling of the air. Condensation generated on the surfaces of
heat transfer plates tends to accumulate in the inside of slit
fins. In this case, because water exists between inner surfaces of
the slit fins and the air passing through the slit fins, thermal
resistance due to the water is likely to increase. As a result, the
efficiency of heat transfer reduces. Also, the accumulated
condensation will be scattered toward downstream positions with
respect to the air flow due to air pressure. Namely, in a cooling
heat exchanger, it is required to effectively discharge or drain
condensation from the fin portions.
SUMMARY OF THE INVENTION
[0007] The present invention is made in view of the foregoing
matter, and it is an object of the present invention to provide a
cooling heat exchanger capable of improving drainage of
condensation.
[0008] According to an aspect of the present invention, a heat
exchanger for cooling air, which flows outside thereof, includes a
first heat transfer plate and a second heat transfer plate. Each of
the first and second heat transfer plates includes a base portion
that defines a plane in a flow direction of the air and protrusions
that protrude from the base portion and extend in a direction that
intersects with the air flow direction. The first and second heat
transfer plates are joined to each other such that the base
portions thereof are in contact with each other. Also, the
protrusions of the first heat transfer plate protrude in one
direction and the protrusions of the second heat transfer plate
protrude in an opposite direction. The protrusions provide internal
fluid passages therein for allowing the internal fluid to flow.
Each of the first and second heat transfer plates further includes
a fin portion that projects from the base portion in the same
direction as the respective protrusions for defining a fin inner
space therein and an aperture on the base portion at a position
corresponding to the fin portion. Each of the fin portions includes
an offset wall offset from the base portion. The offset wall is
connected to the base portion at two locations that are spaced in a
direction parallel to a longitudinal direction of the protrusions.
The aperture of the first heat transfer plate is displaced from the
aperture of the second heat transfer plate with respect to the
longitudinal direction of the protrusions, and the fin inner space
of the first heat transfer plate is in communication with the fin
inner space of the second heat transfer plate, such that a
communication channel for draining condensation is provided between
the first and second heat transfer plates.
[0009] Accordingly, condensation in the fin inner spaces is
smoothly discharged through the communication channel.
[0010] According to another aspect of the present invention, a heat
exchanger for cooling air includes a first heat transfer plate and
a second heat transfer plate. The first heat transfer plate
includes a base portion that defines a plane in a flow direction of
the air, a plurality of protrusions that protrudes from the base
portion, a fin portion that projects from the base portion in the
same direction as the plurality of protrusions such that a fin
inner space is defined inside of the fin portion, and a first
aperture on the base portion at a position corresponding to the fin
portion. The protrusions extend in a direction that intersects with
a flow direction of the air and define internal fluid passages
therein for allowing the internal fluid to flow. The fin portion
includes an offset wall that is offset from the base portion. The
offset wall is connected to the base portion at two locations that
are separated in a longitudinal direction of the protrusions. The
second heat transfer plate includes a base portion that defines a
plane in the flow direction of the air, a plurality of protrusions
protruding from the base portion, and a second aperture. The
protrusions of the second heat transfer plate extend in a direction
intersecting with the flow direction of the air and define internal
fluid passages therein for allowing the internal fluid to flow. The
first heat transfer plate and the second heat transfer plate are
joined to each other such that the base portions thereof are in
contact with each other. The protrusions of the first heat transfer
plate protrude in one direction and the protrusions of the second
heat transfer plate protrude in an opposite direction. The first
aperture and the second aperture overlap at least at a part with
respect to the longitudinal direction of the protrusions.
[0011] Accordingly, since the fin inner space is in communication
with outside of the first and second heat transfer plates through
the first and second apertures, condensation will be discharged
from the fin inner space through the first and second apertures. As
such, condensation is effectively drained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other objects, features and advantages of the present
invention will become more apparent from the following detailed
description made with reference to the accompanying drawings, in
which like parts are designated by like reference numbers and in
which:
[0013] FIG. 1 is an exploded perspective view of an evaporator
according to a first embodiment of the present invention;
[0014] FIG. 2 is an exploded perspective view of the evaporator,
for explaining a general flow of a refrigerant therein, according
to the first embodiment;
[0015] FIG. 3 is a cross-sectional view of the evaporator taken
along a line III-III in FIG. 1;
[0016] FIG. 4 is a perspective view of a part of a heat transfer
plate of the evaporator according to the first embodiment;
[0017] FIG. 5 is a cross-sectional view of the heat transfer plates
taken along a line V-V in FIG. 4;
[0018] FIG. 6 is a schematic cross-sectional view of heat transfer
plates as a comparative example;
[0019] FIG. 7A is a graph showing the amount of accumulation of
condensation per fin of the comparative example;
[0020] FIG. 7B is a graph showing the amount of accumulation of
condensation per fin of the evaporator according to the first
embodiment;
[0021] FIG. 8 is a graph showing a relationship between a fin
height and the amount of accumulation of condensation per fin
according to the first embodiment and the comparative example;
[0022] FIG. 9 is a schematic cross-sectional view of a part of heat
transfer plates of an evaporator according to a second embodiment
of the present invention;
[0023] FIG. 10 is a schematic cross-sectional view of a part of
heat transfer plates of an evaporator according to a third
embodiment of the present invention;
[0024] FIG. 11 is a schematic cross-sectional view of a part of
heat transfer plates of an evaporator according to a fourth
embodiment of the present invention;
[0025] FIG. 12 is a schematic cross-sectional view of a part of
heat transfer plates of an evaporator according to a fifth
embodiment of the present invention;
[0026] FIG. 13 is a schematic cross-sectional view of a part of
heat transfer plates of an evaporator according to a sixth
embodiment of the present invention; and
[0027] FIG. 14 is a schematic cross-sectional view of a part of
heat transfer plates of an evaporator according to a seventh
embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0028] First to seventh embodiments of the present invention will
now be described with reference to the accompanying drawings. In
the second to seventh embodiments, components similar to those of
the first embodiment will be indicated by the same reference
numerals and will not be described further.
First Embodiment
[0029] Referring to FIGS. 1 to 8, a heat exchanger of the first
embodiment is exemplarily employed as an evaporator 10 for a
vehicular air conditioner. A general structure of the evaporator 10
can be similar to a heat exchanger described in U.S. Pat. No.
6,047,769 (Japanese Unexamined Patent Publication No. 11-287580).
The evaporator 10 generally includes a plurality of heat transfer
plates 12.
[0030] In the drawings, arrows A1 denote a general flow direction
of air for an air conditioning operation as an external fluid, and
arrows B denote a general flow direction of an internal fluid, such
as a refrigerant, flowing in internal fluid passages formed in heat
transfer plates. The flow direction B of the refrigerant intersects
the flow direction A1 of the air. In the illustrated example, the
evaporator 10 is constructed as a perpendicularly countercurrent
heat exchanger in which the flow direction A1 of the air is
substantially perpendicular to the flow direction B of the
refrigerant. Also, the evaporator 10 is constructed such that
refrigerant upstream passages, which are in communication with a
refrigerant inlet, is located downstream of refrigerant downstream
passages, which are in communication with a refrigerant outlet,
with respect to the flow direction A1 of the air.
[0031] The evaporator has a core part 11 for performing heat
exchange between the air and the refrigerant. The core part 11 is
constructed by stacking a plurality of heat transfer plates 12 in a
direction substantially perpendicular to the air flow direction A1.
The heat transfer plates 12 include tank parts 20 to 23 at upper
and bottom ends thereof. Because the air does not pass through the
tank parts 20 to 23, the core part 11 is constructed of middle
portions of the heat transfer plates 12 other than the tank parts
20 to 23.
[0032] Each of the heat transfer plates 12 is formed by pressing a
thin metallic plate member. The plate member is, for example, a
clad plate member that has a base material made of A3000 aluminum,
and both surfaces of which are clad with a A4000 aluminum brazing
material. The heat transfer plate 12 is a very thin plate, and has
a thickness t, as shown in FIG. 3. In the present embodiment, for
example, the thickness t of the heat transfer plate 12 is 0.2 mm.
The heat transfer plate 12 has a generally rectangular plate shape.
All of the heat transfer plates 12 generally have the same outer
dimensions.
[0033] As shown in FIG. 3, each of the heat transfer plates 12 has
substantially flat base portions 13, which share a plane, and
protrusions 14 protruding from the base portions 13. The
protrusions 14 are, for example, formed by pressing, such as
embossing or projecting. The protrusions 14 are formed as ribs and
continuously extend in parallel to a longitudinal direction of the
heat transfer plate 12.
[0034] In an example shown in FIG. 3, each of the protrusions 14
has a generally semi-circular shaped cross-section. However, the
protrusion 14 can have any other cross-sectional shapes such as a
substantially trapezoidal shape having rounded corners or the
like.
[0035] The protrusion 14 forms a passage space therein for allowing
the refrigerant to flow. In the present embodiment, the protrusions
14 form refrigerant passages 15, 16 through which a low pressure
refrigerant that has passed through a decompressing device, such as
an expansion valve, of a refrigerant cycle flows.
[0036] For example, the evaporator 10 is disposed such that the
longitudinal direction of the heat transfer plates 12 corresponds
to a direction of gravitational force when in use, that is, in an
up and down direction. Therefore, the protrusions 14 extend in the
up and down direction. In other words, the protrusions 14 extend
perpendicular to the air flow direction A1.
[0037] The heat transfer plates 12 are disposed in pairs. In each
of the pairs, one heat transfer plate (hereafter, a first heat
transfer plate) 12 and the other heat transfer plate (hereafter, a
second heat transfer plate) 12 have the protrusions 14 at the same
positions with respect to the air flow direction A1. The first and
second heat transfer plates 12 are disposed such that the
protrusions 14 thereof protrude outwardly. The base portions 13 of
the first and second heat transfer plates 12 are in contact with
and joined to each other. Thus, both sides of the protrusions 14
with respect to the air flow direction A1 are sealed by the base
portions 13.
[0038] The refrigerant passages 15, 16 are formed by the spaces
defined by the opposed protrusions 14 of the first and second heat
transfer plates 12. In the present embodiment, the refrigerant
passages 15 are located at a downstream side of the heat transfer
plates 12 with respect to the air flow direction A1, and the
refrigerant passages 16 are located at an upstream side of the heat
transfer plates 12 with respect to the air flow direction A1.
Therefore, the refrigerant passages 15 are also referred to as
air-downstream-side refrigerant passages 15 and the refrigerant
passages 16 are also referred to as air-upstream-side refrigerant
passages 16.
[0039] The heat transfer plates 12 are integrally formed with fin
portions (hereafter, simply referred to as the fins) 17. The fins
17 are formed on the base portions 13 that are in contact with each
other in the pair of heat transfer plates 12. The fins 17 are
formed between the protrusions 14 with respect to the air flow
direction A1, as shown in FIGS. 3 and 4. In the present embodiment,
the fins 17 of the first heat transfer plate 12 are located at the
same positions as the fins 17 of the second heat transfer plate 12
with respect to the air flow direction A1.
[0040] Also, the fins 17 are arranged at predetermined intervals in
the up and down direction. In the example shown in FIGS. 3 and 4,
the fins 17 are formed in one row in the up and down direction,
between two of the adjacent protrusions 14. However, the fins 17
can be formed in plural rows or staggered manner between two of the
adjacent protrusions 14.
[0041] The fins 17 are formed as slit fins, each of which has an
offset wall 17a that is spaced from the plane or a surface of the
base portions 13 by a predetermined distance, as shown in FIG. 4.
In the slit fin, an opening is provided between the offset wall 17a
and the base portion 13 such that the air can pass through, and the
offset wall 17a is physically connected to the base portions 13 at
least two or more locations.
[0042] In the example shown in FIG. 4, each offset wall 17a is
parallel to the plane of the base portions 13. The upper and lower
ends of the offset fin 17a are connected to the base portions 13
through side walls 17b, 17c. Thus, each fin 17 has a substantially
U-shape.
[0043] As shown in FIG. 3, a projecting height of the offset wall
17a, that is, a fin height Fh of the fin 17 is substantially the
same as a rib height Rh of the protrusion 14 or slightly smaller
than the rib height Rh, for example.
[0044] Also, the fin 17 has a fin inner dimension Fhi that is
defined by subtracting the thickness t of the heat transfer plate
12 from the fin height Fh (i.e., Fhi=Fh-t). The fin inner dimension
Fhi corresponds to a width of the space defined between the plane
of the base portions 13 and the offset wall 17a for allowing the
air to pass through, that is, a dimension between the inner surface
of the offset wall 17a and the plane of the base portions 13 in a
direction perpendicular to the plane of the base portions 13. The
fin 17 has a fin width Fw with respect to the air flow direction
A1.
[0045] For example, each of the fins 17 is made in the following
manner. First, two slits are formed on the base portion 13 with an
interval corresponding to the fin width Fw. Then, a portion between
the two slits is projected. Thus, the fin 17 has a substantially
U-shape.
[0046] In this case, the portion is projected such that each of the
side walls 17b, 17c is inclined by a predetermined angle 0 with
respect to the surface of the base portion 13. Also, each of the
side walls 17b, 17c has rounded corners, which is so-called
R-shapes, with the base portion 13 and the offset wall 17a.
Therefore, the fins 17 has a smooth projected shape. That is, the
formation of the fins 17 is improved.
[0047] In view of the formation of the fins 17, for example, the
fin width Fw is equal to or greater than 0.2 mm, and a fin distance
Fd between the adjacent two fins 17 with respect to the air flow
direction A1 is equal to or greater than 0.4 mm.
[0048] The substantially U-shape of the fin 17, that is, the shape
of the slit fin corresponds to a cut and moved shape that provides
a cut-out or opening on the base portion 13. That is, a cut-out
opening (hereafter, simply referred to as the aperture) 17d is
formed on the base portion 13 at a position corresponding to the
fin 17 by forming the fin 17.
[0049] In the present embodiment, for example, a length G of the
aperture 17d, that is, a dimension of the aperture 17d in the up
and down direction is equal to or greater than 5 mm. Here, the
dimension G of the aperture 17d includes dimensions of the rounded
corners formed between the base portion 13 and the side walls 17b,
17c, as shown in FIG. 5.
[0050] The fins 17 are formed on the base portions 13, that is, at
positions where the first and second heat transfer plates 12 are in
contact with each other. Therefore, the formation of the apertures
17d will not cause leakage of the refrigerant from the refrigerant
passages 15, 16.
[0051] However, if corrosion of the base portions 13 advances, the
refrigerant will leak from the fin 17. To restrict the leakage of
the refrigerant due to the corrosion, a difference of a dimension
Bw of the base portion 13 with respect to the air flow direction A1
and the fin width Fw is equal to or greater than 0.3 mm (i.e.,
Bw-Fw.gtoreq.0.3 mm).
[0052] In other words, when the dimension of the base portion 13 on
each side of the fin 17 with respect to the air flow direction A1
(i.e., a width of each of side sections of the base portion 13 on
opposite sides of the fin 17) is equal to or greater than 0.15 mm
as a margin for corrosion, the leakage of refrigerant due to
corrosion of the base portions 13 is sufficiently reduced.
[0053] Also, to sufficiently maintain brazing of the base portion
13, the difference of the dimension Bw of the base portion 13 and
the fin width Fw is equal to or greater than 1.0 mm, for example.
That is, when the overlapping dimension (e.g., contact dimension or
a margin for brazing) of the base portions 13 on each side of the
fin 17 with respect to the air flow direction A1 is equal to or
greater than 0.5 mm, the base portions 13 are sufficiently
brazed.
[0054] In the present embodiment, the length of the fin 17, that
is, a dimension of the fin 17 with respect to the up and down
direction is greater than the fin width Fw with respect to the air
flow direction A1. That is, the fins 17 have the length in the up
and down direction.
[0055] As shown in FIG. 5, the positions of the fins 17 are
displaced or staggered between the first and second heat transfer
plates 12 with respect to the up and down direction such that the
apertures 17d of the first heat transfer plate 12 partly overlap
with the apertures 17d of the second heat transfer plate 12. That
is, the apertures 17d of the first heat transfer plate 12 are
partly in communication with the apertures 17d of the second heat
transfer plate 12.
[0056] Due to mutual overlapping of the apertures 17d of the first
and second heat transfer plates 12, a communication channel P that
allows continuous communication between the inner spaces of the
fins 17 in the up and down direction is formed. In the example
shown in FIG. 5, the communication channel P is continuously formed
in the up and down direction. However, it is not always necessary
that the communication channel P is continuous across the length of
the heat transfer plates 12. The communication space P may be
suitably separated in the up and down direction.
[0057] In FIGS. 1 and 2, the fins 17 are not illustrated for the
sake of simplification of the illustration. In the example shown in
FIGS. 1 to 3, each of the heat transfer plates 12 as five
protrusions 14. However, the number of the protrusions 14 of each
heat transfer plate 12, that is, the number of the refrigerant
passages 15, 16 can be modified according to conditions in use,
such as a required performance, an outer shape, and the like.
[0058] Also, each of the heat transfer plates 12 has two upper tank
parts 20, 22 at the upper end and two lower tank parts 21, 23 at
the lower end. The upper tank parts 20, 22 are aligned generally in
the air flow direction A1. Likewise, the lower tank parts 21, 23
are aligned generally in the air flow direction A1. The upper tank
parts 20, 22 and the lower tank parts 21, 23 are separated in the
refrigerant flow direction B. Hereafter, the upper tank part 20 is
also referred to as the air-downstream-side upper tank part 20, the
lower tank part 21 is also referred to as the air-downstream-side
lower tank part 21, the upper tank part 22 is also referred to as
the air-upstream-side upper tank part 22, and the lower tank part
23 is also referred to as the air-upstream-side lower tank part
23.
[0059] The tank parts 20 to 23 are formed such as by projecting.
The tank parts 20 to 23 project in the same direction as the
protrusions 14. A projection height of the tank parts 20 to 23,
that is, a dimension of the tank parts 20 to 23 in a direction
perpendicular to the plane of the base portions 13 is half of tube
pitch Tp. Thus, when the pairs of the heat transfer plates 12 are
stacked, ends of the tank parts 20 to 23 of one heat transfer plate
12 are in contact with ends of the tank parts 20 to 23 of opposed
heat transfer plate 12 of the adjacent pair of heat transfer plates
12. The adjacent pairs of heat transfer plates 12 can be joined to
each other at the ends of the tank parts 20 to 23.
[0060] Here, the projection height of the tank parts 20 to 23
includes the thickness t of the heat transfer plate 12. As shown in
FIG. 3, the tube pitch Tp is arrangement intervals of the pairs of
the heat transfer plates 12. Also, a space pitch Sp is a value that
is defined by subtracting the thicknesses t of two heat transfer
plates 12 from the tube pitch Tp (i.e., Sp=Tp-2t).
[0061] In FIG. 3, the rib height Rh of the protrusions 14 is
smaller than a half of the tube pitch Tp, that is, smaller than the
projection height of the tank parts 20 to 23, as an example.
However, the rib height Rh can be modified. For example, the rib
height Rh of the protrusions 14 can be substantially equal to or
slightly larger than the projection height of the tank parts 20 to
23.
[0062] The tank parts 20 to 23 project in the same direction as the
protrusions 14, and define spaces therein. Also, the longitudinal
ends, such as upper and lower ends, of the protrusions 14 connect
to the tank parts 20 to 23. That is, the spaces defined by the
protrusions 14 are in communication with the spaces defined by the
tank parts 20 to 23. Therefore, the ends of the air-upstream-side
refrigerant passage 16 are in communication with the spaces defined
by the air-upstream-side upper and lower tank parts 22, 23,
respectively. Likewise, the ends of the air-downstream-side
refrigerant passage 15 are in communication with the spaces defined
by the air-downstream-side upper and lower tank parts 20, 21,
respectively.
[0063] The spaces defined by the air-upstream-side upper tank part
22 and the air-downstream-side upper tank part 20 are separated
from each other. Namely, the air-upstream-side upper tank part 22
and the air-downstream-side upper tank part 20 provide portions of
the refrigerant passages separately. Likewise, the spaces defined
by the air-upstream-side lower tank part 23 and the
air-downstream-side lower tank part 21 are separated from each
other. Namely, the air-upstream-side lower tank part 23 and the
air-downstream-side lower tank part 21 provide portions of the
refrigerant passages separately.
[0064] Each of the tank parts 20 to 23 is formed with a
communication opening 20a to 23a at a substantially middle portion
thereof. When the pairs of the heat transfer plates 12 are stacked
such that the ends of the tank parts 20 to 23 are in contact with
each other between the adjacent pairs of the heat transfer plates
12, the spaces defined by the respective tank parts 20 to 23 are
communicated with each other through the openings 20a to 23a.
[0065] Therefore, the refrigerant passages defined by the tank
parts 20 to 23 are communicated with each other between the
adjacent heat transfer plates 12 with respect to the plate stacking
direction, such as, a substantially right and left direction of
FIGS. 1 and 2. In other words, four tank spaces are provided by the
tank parts 20 to 23 in the plate stacking direction,
respectively.
[0066] Also, as shown in FIG. 3, the positions of the protrusions
14 are staggered in the air flow direction A1 between the adjacent
pairs of the heat transfer plates 12. Therefore, the protrusions 14
of one of the pairs of the heat transfer plates 12 are opposed to
the base portions 13 of the adjacent pair of the heat transfer
plates 12. In the example shown in FIG. 3, the protrusions 14 of
one pair of the heat transfer plates 12 are located to correspond
to middle positions of the base portions 13 of the adjacent pair of
the heat transfer plates 12. That is, the protrusions 14 of one
pair of the heat transfer plates 12 are located to correspond to
the center of the rib pitch Rp of the adjacent pair of the heat
transfer plates 12.
[0067] As described above, the rib height Rh of the protrusions 14
is generally half of the tube pitch Tp. Therefore, a clearance is
provided between top portions of the protrusions 14 of one pair of
the heat transfer plates 12 and the base portions 13 of the
adjacent pair of heat transfer plates 12, in the plate stacking
direction.
[0068] As such, an air passage 18 is provided between the adjacent
pairs of the heat transfer plates 12 continuously across the width
of the heat transfer plates 12 in the air flow direction A1. As
shown by an arrow A2 in FIG. 3, the air can flow through the air
passage 18 in a meandering or serpentine manner. The fins 17 are
located adjacent to the protrusions 14, within the air passage
18.
[0069] In the example shown in FIG. 3, the fins 17 are located at
the center of the rib pitch Rp of the base portions 13, that is,
located at middle portions between the protrusions 14 adjacent in
the air flow direction A1. Therefore, an outer surface of the
offset wall 17a of each fin 17 is opposed to the outer surface of
the protrusion 14, which is adjacent to the offset wall 17a across
the air passage 18, across a predetermined distance X.
[0070] Although not illustrated, the heat transfer plates 12 have
contact ribs that project from the base portions 13 toward the
adjacent heat transfer plates 12 across the air passages 18. The
contact ribs are in the form of small projection having smooth
semi-circular shapes, and project from the base portions 13 and at
positions between the fins 17.
[0071] The contact ribs have a projection height that is
substantially the same as the rib height Rh of the protrusions 14.
The contact ribs of one heat transfer plate 12 are in contact with
the tops of the protrusions 14 of another heat transfer plates 12
that is adjacent across the air passage 18. The evaporator 10 is
integrally brazed in the condition that the contact ribs are in
contact with the tops of the protrusion 14 of the adjacent heat
transfer plates and a pressing force is exerted to the contact
portions between the contact ribs and the protrusions 14 in the
plate stacking direction.
[0072] Since the brazing is performed in a condition that the
adjacent heat transfer plates 12 contact at the middle portions
where the refrigerant passages 15, 16 are formed, in addition to
the tank parts 20 to 23, the base portions 13 are sufficiently
brazed. Since the heat transfer plates 12 are sufficiently brazed,
it is less likely that the refrigerant will leak from the
refrigerant passages 15, 16 due to insufficient brazing.
[0073] To sufficiently contact the base portions 13 of the heat
transfer plates 12, the contact ribs are formed separately and at
plural locations in the longitudinal direction of the heat transfer
plates 12.
[0074] Next, structures of inlet and outlet parts of the
refrigerant will be described. As shown in FIGS. 1 and 2, the
evaporator 10 has first and second end plates 24, 25 at the ends of
the stacked heat transfer plates 12. The first and second end
plates 24, 25 have the same size as the heat transfer plates 12.
Each of the first and second end plates 24, 25 has a generally flat
plate shape. The first and second end plates 24, 25 are joined to
the end heat transfer plates 12 such that inner surfaces thereof
contacts the surfaces of the first and second end plates 24, 25 on
which the tank parts 20 to 23 are formed.
[0075] The first end plate 24, which is disposed on a left end in
FIG. 1, has openings adjacent to its upper end. A refrigerant inlet
pipe 24a and a refrigerant outlet pipe 24b are coupled to and
joined to the openings of the first end plate 24. The refrigerant
inlet pipe 24a is disposed on a downstream side of the refrigerant
outlet pipe 24b with respect to the air flow direction A1. The
refrigerant inlet pipe 24a is in communication with the opening 20a
of the air-downstream-side upper tank part 20 of the leftmost heat
transfer plate 12, which is located at the left end in FIG. 1. The
refrigerant outlet pipe 24b is in communication with the opening
22a of the air-upstream-side upper tank part 22 of the leftmost
heat transfer plate 12.
[0076] The first end plate 24 is made of an aluminum clad plate,
both surfaces of which are clad with the brazing material, similar
to the heat transfer plates 12. Thus, the first end plate 24 is
joined to the refrigerant inlet and outlet pipes 24a, 24b and the
heat transfer plate 12 by brazing. On the other hand, the second
end plate 25 is made of a clad plate in which only one surface to
be joined with the heat transfer plate 12 is clad with the brazing
material.
[0077] A gas and liquid two-phase, low pressure refrigerant, which
has been decompressed by the decompressing device (not show), flows
in the refrigerant inlet pipe 24a. On the other hand, the
refrigerant outlet pipe 24b is in communication with a suction side
of a compressor (not shown). Thus, a gas phase refrigerant, which
has been evaporated in the evaporator 10, is introduced to the
compressor from the refrigerant outlet pipe 24b.
[0078] The air-downstream-side refrigerant passages 15, which are
defined between the protrusions 14 of the paired heat transfer
plates 12, are in communication with the refrigerant inlet pipe
24a. The refrigerant flows in the air-downstream-side refrigerant
passages 15 from the refrigerant inlet pipe 24a. Thus, the
air-downstream-side refrigerant passages 15 provide inlet-side
refrigerant passages in the whole of the evaporator 10.
[0079] On the other hand, the air-upstream-side refrigerant
passages 16 are in communication with the refrigerant outlet pipe
24b. The refrigerant that has passed through the
air-downstream-side refrigerant passages 15, that is, the
inlet-side refrigerant passages, flows in the air-upstream-side
refrigerant passages 16, and then flows out from the evaporator 10
from the refrigerant outlet pipe 24b. Therefore, the
air-upstream-side refrigerant passages 16 provide outlet-side
refrigerant passages.
[0080] The refrigerant generally flows through the evaporator 10 as
shown by arrows Pa through Pk in FIG. 2. In this case, the
air-downstream-side upper tank parts 20 provide a refrigerant
inlet-side upper tank space, and the air-downstream-side lower tank
parts 21 provide a refrigerant inlet-side lower tank space. Also,
the air-upstream-side upper tank parts 22 provide a refrigerant
outlet-side upper tank space, and the air-upstream-side lower tank
parts 23 provide a refrigerant outlet-side lower tank space.
[0081] Although not illustrated, a separation part is provided at a
middle portion of the stack of the heat transfer plates 12 such
that the stack of the heat transfer plates 12 is generally divided
into a left section (first section) Y1 and a right section (second
section) Y2. Thus, the refrigerant inlet-side upper tank space,
which is provided by the air-downstream-side upper tank parts 20,
is separated into a left passage space and a right passage space by
the separation part. Likewise, the refrigerant outlet-side tank
space, which is provided by the air-upstream-side upper tank parts
22, is separated into a left passage space and a right passage
space by the separation part.
[0082] For example, the separation part is constructed by closing
the openings 20a, 22a of the middle heat transfer plate 12 that is
located at the middle of the stack of the heat transfer plates
12.
[0083] In the evaporator 10, first, the gas and liquid two-phase
refrigerant flows in the refrigerant inlet-side tank space from the
refrigerant inlet pipe 24a, as shown by the arrow Pa. Since the
refrigerant inlet-side tank space is separated into the left
passage space and the right passage space by the separation part,
the refrigerant only flows in the left passage space of the
refrigerant inlet-side tank space.
[0084] Then, the refrigerant flows through the inlet-side
refrigerant passages 15 of the left section Y1 in a downward
direction as shown by the arrow Pb, and flows in the refrigerant
inlet-side lower tank space, which is provided by the
air-downstream-side lower tank parts 21. In the refrigerant
inlet-side lower tank space, the refrigerant flows in a rightward
direction, that is, toward the right section Y2, as shown by the
arrow Pc.
[0085] Then, the refrigerant flows through the inlet-side
refrigerant passages 15 of the right section Y2 in an upward
direction as shown by the arrow Pd, and flows in the right passage
space of the refrigerant inlet-side upper tank space. The opening
20a of the air-downstream-side upper tank part 20 of the rightmost
heat transfer plate 12 is in communication with the opening 22a of
the air-upstream side upper tank part 22 through a communication
passage (not shown) formed on an upper portion of the second end
plate 25.
[0086] Therefore, the refrigerant flows in the rightward direction
in the right passage space of the refrigerant inlet-side upper tank
space as shown by the arrow Pe, and then flows in the right passage
space of the refrigerant outlet-side upper tank space through the
communication passage of the right end plate 25 as shown by the
arrow Pf.
[0087] Since the refrigerant outlet-side upper tank space is
separated into the left passage space and the right passage space
by the separation part, the refrigerant only flows in the right
passage space of the refrigerant outlet-side upper tank space from
the communication passage, as shown by the arrow Pg. Then, the
refrigerant flows through the outlet-side refrigerant passages 16
of the right section Y2 in the downward direction as shown by the
arrow Ph. The refrigerant flows in the refrigerant outlet-side
lower tank space and moves in the rightward direction as shown by
the arrow Pi.
[0088] Thereafter, the refrigerant flows through the outlet-side
refrigerant passages 16 of the left section Y1 in the upward
direction as shown by the arrow Pj, and flows in the left passage
space of the refrigerant outlet-side upper tank space. The
refrigerant flows toward the refrigerant outlet pipes 24b as shown
by the arrow Pk, and flows out from the evaporator 10.
[0089] In manufacturing the evaporator 10, the component parts,
such as the heat transfer plates, 12, the first and second end
plates 24, 25 and the refrigerant inlet and outlet pipes 24a, 24b,
are assembled to make contact at predetermined portions thereof.
The assembled component parts are held in the above condition by
predetermined jigs and placed in a furnace. When the assembled
component parts are heated to a melting point of the brazing
material, the component parts are integrally brazed. Thus, the
evaporator 10 is integrally brazed.
[0090] Next, an operation of the evaporator 10 will be described.
For example, the evaporator 10 is housed in an air conditioning
unit case (not shown) such that the up and down direction in FIGS.
1 and 2, that is, the longitudinal direction of the heat transfer
plates 12 corresponds to the vertical direction. When a blower (not
shown) for the air conditioning operation is operated, the air
passes through the evaporator as shown by the arrow A1.
[0091] When the compressor of the refrigerant cycle is operated,
the gas and liquid two-phase refrigerant is introduced to the
evaporator 10 from the decompression device, such as the expansion
valve. Thus, the refrigerant passes through the evaporator 10 as
shown by the arrows Pa through Pk.
[0092] Since the air passages 18 are formed between the heat
transfer plates 12, the air blown by the blower flows through the
air passages 18 in the meandering manner, as shown by the arrow A2.
At this time, the refrigerant is evaporated by receiving latent
heat of evaporation from the air, and the air is cooled.
[0093] In this case, the inlet-side refrigerant passages 15 are
disposed downstream of the outlet-side refrigerant passages 16 with
respect to the air flow direction A1. Therefore, the arrangement of
the inlet and outlet of the refrigerant is opposed to the flow of
the air. Namely, the general flow direction of the refrigerant is
opposed to the general air flow direction.
[0094] The air flow direction A1 is substantially perpendicular to
the longitudinal direction of the protrusions 14. The protrusions
14 provide heat transfer surfaces protruding from the base portions
13 and intersecting with the air flow direction A1. Thus, the flow
of the air is obstructed and disturbed by the protrusions 14.
Accordingly, a coefficient of heat transfer of the air is improved
on the heat transfer surfaces of the protrusions 14.
[0095] In a plate-type heat exchanger in which a core part is
constructed of heat transfer plates, heat transfer surfaces of air
are smaller than that of a fin and tube-type heat exchanger in
which a core part is constructed of tubes and fins. Therefore, it
is generally difficult to sufficiently maintain a necessary heat
transfer performance.
[0096] In the evaporator 10 of the present embodiment, the fins 17
are formed on the heat transfer plates 12. The fins 17 have the
substantially U-shapes and disposed between the adjacent
protrusions 14 and in the air passages 18. Since the air flows
along both inner surfaces and outer surfaces of the offset walls
17a, the heat transfer surface area increases, as compared with a
plate-type heat exchanger without having the fins.
[0097] Further, the coefficient of heat transfer of the air is
improved at the base portions 13 due to the fins 17. For example,
in the case where the fins are not formed on the base portions 13,
a temperature boundary layer progresses and becomes thick toward
downstream positions with respect to the air flow direction A1.
Thus, the coefficient of heat transfer of the air on the base
portions 13 is likely to reduce.
[0098] On the other hand, in the present embodiment, since the fins
17 are formed on the base portions 13 between the adjacent
protrusions 14, the thickness of the temperature boundary layer on
the flat surfaces of the base portions 13 is reduced. Therefore,
the coefficient of heat transfer of the air at the base portions 13
improves, as compared with the base portions 13 without having the
fins 17.
[0099] Accordingly, even in the plate-type heat exchanger, the heat
transfer efficiency is effectively improved while suppressing an
increase in resistance to flow of the air.
[0100] In the present embodiment, the side walls 17b, 17c of the
fins 17 are inclined at predetermined angles .theta. relative to
the plane of the base portions 13 so as to ease the formation of
the fins 17. However, the length FL of the offset wall 17a in the
up and down direction is reduced, as compared with a case in which
the side walls of the fin are perpendicular to the base portion.
Therefore, the heat transfer efficiency will be reduced due to the
decrease of the length FL of the offset wall 17a.
[0101] Thus, to improve the formation of the fins 17 as well as to
improve the heat transfer efficiency, for example, the
predetermined angle .theta. of the inclination of each side wall
17b, 17c can be set in a range between equal to or greater than 30
degrees and equal to or less than 60 degrees.
[0102] Here, the length FL of the offset wall 17a is a dimension of
a flat portion of the inner surface of the offset wall 17a in the
up and down direction. That is, the length FL of the offset wall
17a does not include the dimensions of the rounded corners formed
between the offset wall 17a and the side walls 17b, 17c.
[0103] Next, an effect of draining condensation of the evaporator
10 will be described. In the evaporator 10, moisture in the air is
condensed due to a cooling effect, and hence condensation is
generated. The condensation tends to accumulate on an inner portion
of the fin 17, in particular, an inner area of the lower side walls
17c, as shown by an area M in FIG. 5.
[0104] FIG. 6 shows a comparative example in which the fins 17 of
the first and second heat transfer plates 12 are disposed at the
same positions with respect to the up and down direction. In the
comparative example, the condensation is blocked by the lower side
walls 17c. Thus, the drainage of the condensation is restricted. In
other words, the condensation is received by the lower side walls
17c.
[0105] In the present embodiment shown in FIG. 5, on the other
hand, the positions of the fins 17 are staggered between the paired
heat transfer plates 12 in the up and down direction such that the
continuous communication channel P is formed within the fins 17.
Therefore, the condensation generated on the inner side of the fins
17 smoothly flows downwardly as shown by the arrow N through the
communication channel P, without being blocked by the lower side
walls 17c. In other words, a drainage channel for draining the
condensation is provided by the communication channel P.
Accordingly, the condensation is effectively discharged.
[0106] Further, in a case that the dimension G of the aperture 17d
of the fin 17 is 5 mm or more in the up and down direction, the
condensation is more effectively discharged.
[0107] Since the side walls 17b, 17c and the base portions 13 form
the rounded corners, the communication space P is formed into a
smoothly curved shape. Therefore, the condensation is smoothly
discharged.
[0108] FIG. 7A is a graph showing the amount of accumulation of
condensation per fin of the comparative example. FIG. 7B is a graph
showing the amount of accumulation of condensation per fin of the
present embodiment. As shown in FIGS. 7A and 7B, the amount of
accumulation of condensation per fin of the present embodiment is
generally half of or one-third of that of the comparative
example.
[0109] FIG. 8 is a graph showing a relationship between the fin
height Fh and the amount of accumulation of condensation per fin. A
horizontal axis represents the fin height Fh and a vertical axis
represents the amount of accumulation of condensation per fin. In
this case, the fin width Fw is 1.5 mm.
[0110] As shown by two curves of FIG. 8, when the fin height Fh is
smaller than 0.35 mm, the amount of accumulation of condensation
per fin 17 of the present embodiment is larger than that of the
comparative example. This is caused by the following reasons.
[0111] In the present embodiment, a width of the communication
channel P defined between the base portion 13 and the offset wall
17a, that is, a dimension of the communication channel P in the
direction perpendicular to the plane of the base portion 13, is
substantially equal to the fin height Fh, as shown in FIG. 5. In
the comparative example, on the other hand, a width of a space
defined between the fins 17, that is, a space where the
condensation stays (hereafter, condensation accumulating space) in
the direction perpendicular to the plane of the base portion 13 is
twice of the fin height Fh, as shown in FIG. 6.
[0112] In the present embodiment, if the fin height Fh is smaller
than necessary, the condensation cannot easily flow through the
communication channel P. As a result, the flow of the condensation
will be stagnated throughout the communication channel P, although
the condensation will not accumulated only at the uppermost portion
of the communication channel P.
[0113] In the comparative example, since the width of the
condensation accumulating space is larger than the width of the
communication channel P of the present embodiment. Therefore, the
condensation does not accumulate at the upper portion of each
condensation accumulating space. As a result, the amount of
accumulation of condensation per fin of the comparative example is
relatively smaller than that of the present embodiment.
[0114] Therefore, when the fin height Fh is smaller than 0.35 mm,
the amount of accumulation of condensation per fin of the present
embodiment is larger than that of the comparative example. On the
other hand, when the fin height Fh is equal to or greater than 0.35
mm, the amount of accumulation of condensation per fin of the
present embodiment is smaller than that of the comparative example.
Thus, the draining effect of the present embodiment is
improved.
[0115] In the present embodiment, the thickness t of the heat
transfer plates 12 is 0.2 mm. Therefore, when the fin height Fh is
0.35 mm or more, the fin inner height Fhi is equal to or greater
than 0.15 mm. In other words, when the width of the space defined
between the offset wall 17a and the base portion 13 is equal to or
greater than 0.15 mm, the amount of accumulation of condensation
per fin of the present embodiment is smaller than that of the
comparative example. Thus, the draining effect is improved.
[0116] The above idea can be applied to set the clearance between
the offset wall 17a of the fin 17 and the surface of the heat
transfer plate 12. For example when the distance X between the
outer surface of the offset wall 17a and the outer surface of the
protrusion 14 that is opposed to the fin 17 across the air passage
18 is equal to or greater than 0.15 mm, the amount of accumulation
of condensation in the clearance will be reduced. As such, the
draining effect is improved.
[0117] In FIGS. 7A, 7B and 8, the amount of accumulation of
condensation is measured in the following conditions.
[0118] (1) Outer size of the evaporator of the present embodiment
and the comparative example: width is 260 mm; height is 215 mm; and
depth is 38 mm. Here, the width is a dimension in the plate
stacking direction, as shown by an arrow W in FIG. 2. The height is
a dimension as shown by an arrow H in FIG. 2. Also, the depth is a
dimension in the air flow direction A1, as shown by an arrow D in
FIG. 2.
[0119] (2) The volume of air is 500 m.sup.3/h. Resistance of air
flow at the core part is equal between the evaporator of the
present embodiment and the comparative example.
[0120] (3) Regarding the comparative example, the thickness t of
the heat transfer plate is 0.15 mm; the space pitch Sp is 2.6 mm;
the rib pitch Rh is 7.1 mm; and the protrusion height Rh is 1.45
mm.
[0121] (4) Regarding the evaporator of the present embodiment, the
thickness t of the heat transfer plate 12 is 0.15 mm; the space
pitch Sp is 3.0 mm; the rib pitch Rp is 7.1 mm; the protrusion
height Rh is 1.45 mm, the fin height Fh is 1.0 mm; and the fin
width Fw is 0.8 mm. Here, the fin pitch Fp is a half of the rib
pitch Rp.
[0122] In the example shown in FIG. 3, the heat transfer plates 12
have the fins 17 downstream of the most downstream protrusions 14
with respect to the air flow direction A1. However, it is not
always necessary to have the fin 17 downstream of the most
downstream protrusion 14 with respect to the air flow direction
A1.
[0123] In a case that the fins 17 are not provided downstream of
the most downstream protrusions 14 with respect to the air flow
direction A1, even if the condensation in the fins 17 is blown by
the air pressure, the blown condensation will adhere to the
protrusion 14 that is located downstream of the fins 17 and
discharged along the protrusions 14 in the downward direction.
Therefore, scattering of the condensation in the fins 17 will be
reduced.
[0124] In the present embodiment, the heat transfer plate 12 has a
basically flat shape and the protrusions 14, the fins 7, the tank
parts 20 to 23 and the like are formed to project from the flat
wall. That is, the base portions 13 are coplanar. However, it is
not always necessary that the base portions 13 are coplanar.
Alternatively, the middle portions of the heat transfer plates 12
other than the tank parts 20 to 23, that is, portions of the heat
transfer plates 12 forming the core part 11 may have the wave
shape, which includes smoothly curves walls, instead of the flat
wall. Also in this case, the similar effects as the present
embodiment will be provided.
Second Embodiment
[0125] The evaporator 10 according to the second embodiment is
similar to the evaporator 10 of the first embodiment except a
configuration of the offset wall 17a. In the first embodiment, the
offset walls 17a are parallel to the plane of the base portions 13.
In the second embodiment, on the other hand, the offset walls 17a
are inclined relative to the plane of the base portions 13, with
respect to the up and down direction.
[0126] As shown in FIG. 9, each of the offset walls 17a is inclined
at a predetermined angle .theta.a relative to the plane of the base
portion 13 such that a distance between the offset wall 17a and the
plane of the base portion 13 increases toward an upper position. As
such, the condensation in the fin 17 of one heat transfer plate 12
is smoothly introduced into the fin 17 of the opposite heat
transfer plate 12, as shown by the arrow N. Accordingly, the
condensation is further smoothly drained.
Third Embodiment
[0127] The evaporator 10 according to the third embodiment is
similar to the evaporator 10 of the first embodiment except a
configuration of the offset wall 17a. In the third embodiment, the
offset walls 17a are inclined relative to the plane of the base
portions 13, with respect to the air flow direction A1, as shown in
FIG. 10.
[0128] For example, each of the offset walls 17a is inclined in the
same direction as a downstream side curved wall of the
semi-circular-shaped protrusion 14. In other words, the off set
wall 17a is inclined toward a downstream position with respect to
the air flow direction A1. Specifically, the offset wall 17a forms
an angle .theta.b of inclination relative to the plane of the base
portion 13 such that a distance between the offset wall 17a and the
plane of the base portion 13 increases toward an upstream position
with respect to the air flow direction A1.
[0129] In this case, the flow of the air is aligned along the
downstream side curved wall of the protrusion 14 due to a guide
effect of the inclined offset walls 17a. Therefore, separation of
the air flow from the surface of the heat transfer plate 12 at a
position downstream of the protrusion 14 is reduced, as shown by an
arrow Q1 in FIG. 10. Namely, a decrease of the coefficient of heat
transfer due to the separation of the air flow is reduced.
Accordingly, the heat transfer efficiency further improves. Also in
this case, the offset wall 17a can be further inclined with respect
to the up and down direction, in a manner similar to the second
embodiment.
Fourth Embodiment
[0130] The evaporator 10 according to the fourth embodiment is
similar to the evaporator 10 of the third embodiment, but is
different because the offset wall 17a has a curved shape to align
the air flow along the meandering shape of the air passage 18.
[0131] As shown in FIG. 11, the offset wall 17a is curved inwardly
such that a distance between the offset wall 17a and the plane of
the base portion 13 reduces toward a middle portion with respect to
the air flow direction A1. Therefore, the air flow can be aligned
along the curved surfaces of the protrusions 14 due to a guide
effect of the curved shape of the offset wall 17a, as shown by the
arrow A2. Therefore, it is less likely that the air flow will be
separated from the surface of the heat transfer plate 12 at the
upstream and downstream positions of the protrusions 14 with
respect to the air flow direction A1, as shown by arrows Q1, Q2.
Accordingly, the decrease of the coefficient of heat transfer due
to the separation of the air flow is further reduced than that of
the third embodiment. Therefore, the heat transfer efficiency
further improves.
Fifth Embodiment
[0132] The evaporator according to the fifth embodiment 10 is
similar to the evaporator 10 of the first embodiment except the
shape of the fins 17. The shape of the fins 17 is not limited to
the substantially U-shape as illustrated in FIG. 5, but may be
modified.
[0133] For example, the fin 17 is formed to project in a smoothly
curved shape, as shown in FIG. 12. In this case, the offset wall
17a is a curved wall projecting from the base portion 13 in the
form of a substantially semi-circular or semi-elliptical shape.
Both ends of the curved wall connects to the base portions 13.
Since the shape of the fin 17 is smooth or gentle, the formation of
the fin 17 by projecting improves.
Sixth Embodiment
[0134] The evaporator 10 according to the sixth embodiment is
similar to the evaporator 10 of the first embodiment except the
following structures. In the first embodiment, both the first and
second heat transfer plates 12 have the fins 17. Alternatively, in
the sixth embodiment, only one of the first and second heat
transfer plates 12 has the fins 17.
[0135] For example, as shown in FIG. 13, the first heat transfer
plate (left heat transfer plate) 12 has the fins 17. However, the
second heat transfer plate (right heat transfer plate) 12, which is
paired with the first heat transfer plate 12, does have the fins
17. Instead, the second heat transfer plate 12 is formed with
apertures 13a at the positions corresponding to the fins 17 of the
first heat transfer plate 12. The apertures 13a is, for example,
formed by punching. Also in this case, the fins 17 and the
apertures 13a are disposed at plural locations in the up and down
direction.
[0136] In the example shown in FIG. 13, the aperture 13a is located
within an area of the aperture 17d of the fin 17 with respect to
the up and down direction. In other words, the aperture 17d and the
aperture 13a are disposed to overlap at least at a part between the
first and second heat transfer plates 12.
[0137] As such, the inner space of the fin 17 of the first heat
transfer plate 12 is in communication with an outer space of the
heat transfer plates 12 through the aperture 13a. Therefore, the
condensation in the inner space of the fin 17 can be introduced to
the outside of the heat transfer plates 12. The condensation will
further flows in the downward direction, as shown by an arrow T. In
other words, a drainage channel for draining the condensation can
be provided by the inner spaces of the fins 17. Accordingly, the
condensation will be effectively discharged.
[0138] For example, in a case that the dimension G of the aperture
17d of the fin 17 in the up and down direction is equal to or
greater than 5, the condensation is further effectively drained. In
a case that a dimension K of the aperture 13a in the up and down
direction is equal to or grater than the fin width Fw of the fin
17, the condensation can be effectively discharged to the outside
of the heat transfer plates 12 through the apertures 13a.
Therefore, the draining effect further improves. Further, in a case
that a dimension of the aperture 13a with respect to the air flow
direction A1 is equal to or greater than the fin width Fw of the
fin 17, the draining effect further improves.
Seventh Embodiment
[0139] The evaporator 10 according to the seventh embodiment is
similar to the evaporator 10 of the sixth embodiment, but positions
of the apertures 13a and the fins 17 are modified.
[0140] As shown in FIG. 14, the respective aperture 13a is located
slightly lower than the corresponding apertures 17d of the fin 17.
Specifically, a lower end 13b of each aperture 13a is located lower
than a lower end 17e of the corresponding aperture 17d, with
respect to the up and down direction.
[0141] Since the lower end 17e of the aperture 17d overlaps with
the aperture 13a, the condensation can be smoothly discharged from
the lower end 17e of the fin 17 to the outside of the heat transfer
plates 12 through the aperture 13a. As such, the condensation will
be effectively drained.
[0142] In the example shown in FIG. 14, an upper end 13c of the
aperture 13a is located lower than an upper end 17f of the aperture
17d, with respect to the up and down direction. Alternatively, the
upper end 13c of the aperture 13a can be at the same height as the
upper end 17f of the aperture 17d or located higher than the upper
end 17f of the aperture 17d.
[0143] (Modifications)
[0144] In the above embodiments, the protrusions 14 are located at
the same positions between the paired heat transfer plates 12 with
respect to the air flow direction A1. Alternatively, the
protrusions 14 can be located at different positions with respect
to the air flow direction A1 between the paired heat transfer
plates 12. For example, the protrusions 14 can be disposed in a
staggered manner between the paired heat transfer plates 12 with
respect to the air flow direction A1.
[0145] In the above embodiments, the protrusions 14 extend in the
up and down direction, that is, in the direction of gravitational
force. Here, "the up and down direction" and "the direction of
gravitational force" should not mean exactly a direction of
gravitational force, but may be slightly inclined. That is, the
meaning of "the up and down direction" and "the direction of
gravitational force" include directions that are slightly inclined
from the exact direction of the gravitational force.
[0146] In the above embodiments, the protrusions 14 extend to the
up and down direction. However, it is not always necessary that the
longitudinal direction of the protrusions 14 correspond to the up
and down direction. The protrusions 14 can extend in a direction
that intersect with the air flow direction A1. For example, the
protrusions 14 can extend diagonally with respect to the up and
down direction.
[0147] In the second embodiment shown in FIG. 9, the offset wall
17a is inclined relative to the plane of the base portion 13, with
respect to the up and down direction. In the third embodiment shown
in FIG. 10, the offset wall 17a is inclined relative to the plane
of the base portion 13, with respect to the air flow direction A1.
Alternatively, the offset wall 17a can be configured by combination
of the structures of the second and third embodiments. That is, the
offset wall 17a can be inclined with respect to the up and down
direction and the air flow direction A1.
[0148] In the fourth embodiment, the offset wall 17a has the curved
shape to align the air flow along the serpentine shape of the air
passage 18. Alternatively, the offset wall 17a can have a shape
combined with the shape of the second embodiment and the shape of
the fourth embodiment.
[0149] In the above embodiments, the core part 11 and the tank
spaces are integrally formed by the stack of the heat transfer
plates 12. Alternatively, the core part 11 can be formed by the
stack of the heat transfer plates 12 and the tank spaces can be
formed separately from the core part 11.
[0150] In the above embodiments, two separate heat transfer plates
12 are paired and joined to each other, and the refrigerant
passages 15, 16 are formed inside of the protrusions 14 of the heat
transfer plates 12. Alternatively, the pair of heat transfer plates
12 can be formed by folding a single plate member on which
protrusions for the refrigerant passages are formed into two and
joining the folded plate at the base portions, in a manner similar
to the plates shown in FIG. 36 of U.S. Pat. No. 6,401,804 (Japanese
Unexamined Patent Publication No. 2001-41678).
[0151] Further, the pairs of the heat transfer plates 12 can be
connected through connecting members, in a similar manner as a
structure shown in FIG. 35 of U.S. Pat. No. 6,401,804.
[0152] In the above embodiments, "the pair of heat transfer plates
12" and "the paired heat transfer plates 12" include both the case
in which two separate plates 12 are joined and the case in which a
single plate is folded and joined at predetermined portions.
[0153] In the sixth and seventh embodiments, the fins 17 are formed
on the first heat transfer plate 12 and the apertures 13a are
formed on the second heat transfer plate 12. However, the fins 17a
and the apertures 13a can be formed on both of the first and second
heat transfer plates 12. For example, the fins 17 and the apertures
13a are formed on the first heat transfer plate 12 alternately in
rows, and the fins 17 and the apertures 13a are formed on the
second heat transfer plate 12 alternately in rows. The first and
second heat transfer plates 12 are joined such that the rows of the
fins 17 and the rows of the apertures 13a of the first heat
transfer plate 12 respectively correspond to the rows of the
apertures 13a and the rows of the fins 17 of the second heat
transfer plate 12. Also in this case, the similar effects are
provided.
[0154] In the sixth and seventh embodiments, the fins 17 can have
any shapes and arrangement structures as those of the fins 17 of
the first to fifth embodiments.
[0155] In the above embodiments, the heat exchanger 10 is
exemplarily employed to the evaporator in which a low pressure, low
temperature refrigerant of the refrigerant cycle flows through the
refrigerant passages 15. However, the fluid flowing through the
refrigerant passages (internal fluid passages) are not limited to
the refrigerant, but may be any other cooling fluid, such as a cool
water or the like. Namely, the heat exchanger of the above
embodiments can be employed as any cooling heat exchangers used for
any other purposes.
[0156] Additional advantages and modifications will readily occur
to those skilled in the art. The invention in its broader term is
therefore not limited to the specific details, representative
apparatus, and illustrative examples shown and described.
* * * * *