BACKGROUND
1. Technical Field
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The present disclosure relates to a heat exchanger and an air conditioner having the heat exchanger.
2. Description of the Related Art
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Conventionally, there has been known a heat exchanger which includes a plurality of flat tubes which are arranged in a first direction and through which a refrigerant flows, and a plurality of fins which are arranged in a second direction intersecting the first direction, and in which the plurality of flat tubes and the plurality of fins intersect in a lattice shape (see PTL 1).
Citation List
Patent Literature
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PTL 1:
Japanese Patent No. 6233540 SUMMARY
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In the case of the heat exchanger described in PTL 1, each of the plurality of fins includes a plurality of spacer portions protruding toward and in contact with another adjacent fan. Specifically, each of the plurality of fins is provided with a plurality of cutout portions through which the plurality of flat tubes pass. A plurality of spacer portions are provided on both sides of the cutout portion. When the spacer portion comes into contact with another adjacent fin, the plurality of fins are stacked in parallel with each other and at intervals.
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When several hundred fins are stacked in order to produce a heat exchanger, an excessive weight may be applied to some spacer portions of a certain fin. Originally, weight is equally applied to each of the plurality of spacer portions of one fin. However, there is a case where height of the plurality of spacer portions varies due to variation in manufacturing of the fin, and weight is excessively applied to one spacer portion.
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Further, the fin is formed by press molding a metal thin plate. Furthermore, since a place where the plurality of spacer portions are provided is limited to both sides of the cutout portion, each of the spacer portions is small. Therefore, when excessive weight is applied, the spacer portion is easily deformed. When the spacer portion is deformed, a gap between adjacent fins formed by the spacer portion becomes small, and airflow resistance of the gap increases. As a result, heat exchange performance of the heat exchanger is deteriorated.
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In view of the above, the present disclosure provides a heat exchanger, in which a plurality of spacer portions provided in each fin come into contact with another adjacent fin to form a gap between the fins, the heat exchanger being capable of suppressing deformation of the spacer portion, and an air conditioner.
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A heat exchanger according to one aspect of the present disclosure includes a plurality of flat tubes arranged in a first direction, and a plurality of fins arranged in a second direction intersecting the first direction. Each of the plurality of fins includes a plurality of cutout portions provided at one end in a third direction intersecting the first direction and the second direction and through which the plurality of flat tubes pass, and a plurality of collar portions provided along at least a portion of an edge of the plurality of cutout portions and holding the plurality of flat tubes. Each of the plurality of collar portions includes a first spacer portion, a second spacer portion, and a third spacer portion that protrude in the second direction and are in contact with another adjacent fin. The first spacer portion is located on one side portion in the first direction of the collar portion, and the second spacer portion and the third spacer portion are located on the other side portion in the first direction of the collar portion such that the first spacer portion is located between the second spacer portion and the third spacer portion as viewed in the first direction. The sum of sizes of the first spacer portion, the second spacer portion, and the third spacer portion in the third direction is more than or equal to 1/2 of size in the third direction of the fin.
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Further, an air conditioner according to another aspect of the present disclosure includes the heat exchanger described above and a fan that generates flow of air passing through the heat exchanger in the third direction.
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According to the present disclosure, a heat exchanger, in which a plurality of spacer portions provided in each fin come into contact with another adjacent fin to form a gap between the fins, the heat exchanger being capable of suppressing deformation of the spacer portion, and an air conditioner can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
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- Fig. 1 is a schematic view of an air conditioner according to an exemplary embodiment of the present disclosure;
- Fig. 2 is a schematic perspective view of a part of a heat exchanger;
- Fig. 3 is a top view of a part of a fin;
- Fig. 4 is a perspective view illustrating a collar portion in the fin;
- Fig. 5 is a sectional view of a plurality of the fins taken along line A-A of Fig. 3;
- Fig. 6 is a sectional view of a plurality of the fins taken along line B-B of Fig. 3;
- Fig. 7 is a sectional view of a plurality of the fins taken along line C-C of Fig. 3; and
- Fig. 8 is a sectional view of a plurality of the fins taken along line D-D of Fig. 3.
DETAILED DESCRIPTIONS
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A heat exchanger according to one aspect of the present disclosure includes a plurality of flat tubes arranged in a first direction, and a plurality of fins arranged in a second direction intersecting the first direction. Each of the plurality of fins includes a plurality of cutout portions provided at one end in a third direction intersecting the first direction and the second direction and through which the plurality of flat tubes pass, and a plurality of collar portions provided along at least a portion of an edge of the plurality of cutout portions and holding the plurality of flat tubes. Further, each of the plurality of collar portions includes a first spacer portion, a second spacer portion, and a third spacer portion that protrude in the second direction and are in contact with another adjacent fin. Furthermore, the first spacer portion is located on one side portion in the first direction of the collar portion, and the second spacer portion and the third spacer portion are located on the other side portion in the first direction of the collar portion such that the first spacer portion is located between the second spacer portion and the third spacer portion as viewed in the first direction. Then, the sum of sizes of the first spacer portion, the second spacer portion, and the third spacer portion in the third direction is more than or equal to 1/2 of size in the third direction of the fin.
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According to such an aspect, it is possible to suppress deformation of the spacer portions in the heat exchanger in which the plurality of spacer portions provided in each of the fins come into contact with another adjacent fin to form a gap between the fins.
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For example, size in the third direction of the first spacer portion may be larger than sizes in the third direction of the second spacer portion and the third spacer portion, and may be smaller than sum of sizes in the third direction of the second spacer portion and the third spacer portion.
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For example, the second spacer portion is preferably closer to one end in the third direction of the fin provided with the cutout portion than the third spacer portion, and size in the third direction of the third spacer portion is preferably larger than size in the third direction of the second spacer portion.
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An air conditioner according to another aspect of the present disclosure includes the heat exchanger described above and a fan that generates flow of air passing through the heat exchanger in the third direction.
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According to such another aspect, it is possible to suppress deformation of the spacer portions in the air conditioner including the heat exchanger in which the plurality of spacer portions provided in each of the fins come into contact with another adjacent fin to form a gap between the fins.
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Hereinafter, one exemplary embodiment of the present disclosure will be described with reference to the drawings.
(First exemplary embodiment)
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Fig. 1 is a schematic view of air conditioner 10 according to a first exemplary embodiment of the present disclosure.
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As illustrated in Fig. 1, air conditioner 10 according to the first exemplary embodiment includes indoor unit 12 disposed indoors and outdoor unit 14 disposed outdoors.
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As illustrated in Fig. 1, indoor unit 12 includes housing 16 disposed indoors, heat exchanger 18 that is disposed inside housing 16 and exchanges heat with indoor air, and cross flow fan 20 that generates an indoor air flow to cause indoor air to pass through heat exchanger 18. When cross flow fan 20 rotates, indoor air flows into housing 16 and passes through heat exchanger 18. Air that has passed through heat exchanger 18 is blown from housing 16 into an indoor space.
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As illustrated in Fig. 1, the outdoor unit 14 is mounted with heat exchanger 22 that exchanges heat with outdoor air, axial fan 24 that generates a flow of outdoor air so that the outdoor air passes through heat exchanger 22, and compressor 26 that sends out a refrigerant (first fluid) passing through heat exchangers 18 and 22. Heat exchanger 18, heat exchanger 22, and compressor 26 are connected via refrigerant pipe 28. Expansion valve 30 that decompresses the refrigerant and four-way valve 32 that changes a flow direction of the refrigerant are disposed on refrigerant pipe 28.
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During a cooling operation, the refrigerant is sent out from compressor 26, passes through four-way valve 32, heat exchanger 22 of outdoor unit 14, expansion valve 30, and heat exchanger 18 of indoor unit 12 in this order, and returns to compressor 26. During a heating operation, the refrigerant is sent out from compressor 26, passes through four-way valve 32, heat exchanger 18 of indoor unit 12, expansion valve 30, and heat exchanger 22 of outdoor unit 14 in this order, and returns to compressor 26. Four-way valve 32 switches flow of the refrigerant between flow during the cooling operation and flow during the heating operation.
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Fig. 2 is a perspective view schematically illustrating a part of heat exchanger 22. Note that X-Y-Z orthogonal coordinate system illustrated in the drawing is for facilitating understanding of the exemplary embodiment, and does not limit the exemplary embodiment. Further, in Fig. 2, hollow arrow G indicates a flow direction of air passing through heat exchanger 22, that is, a blowing direction of axial fan 24. Furthermore, hollow arrow R indicates a flow direction of the refrigerant.
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As illustrated in Fig. 2, heat exchanger 22 includes a plurality of flat tubes 40 arranged at intervals in the first direction (X-axis direction) and through which the refrigerant flows, and a plurality of fins 42 arranged at intervals in the second direction (Y-axis direction) intersecting the first direction and thermally connected to the plurality of flat tubes 40. That is, the plurality of flat tubes 40 and the plurality of fins 42 intersect in a lattice shape as viewed in the third direction (Z-axis direction) intersecting both the first and second directions. Axial fan 24 generates flow of air so that the air passes through heat exchanger 22 in the third direction. Note that axial fan 24 corresponds to an example of "fan". As described above, air conditioner 10 includes heat exchanger 22 and axial fan 24 that generates flow of air so that air passes through heat exchanger 22 in the third direction (Z-axis direction).
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Each of the plurality of flat tubes 40 is a tubular member having a flat cross-sectional shape elongated in a flow direction (Z-axis direction) of air passing through heat exchanger 22 and through which the refrigerant flows. The plurality of flat tubes 40 extend in parallel to each other in the stacking direction (Y-axis direction) of the plurality of fins 42.
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Each of the plurality of fins 42 has a thin plate shape and has a substantially rectangular shape as viewed in the stacking direction (Y-axis direction). Specifically, each of fins 42 has a shape that is relatively long in a parallel direction (X-axis direction) of the plurality of flat tubes 40 and relatively short in the flow direction (Z-axis direction) of air passing through heat exchanger 22.
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Further, in the case of the present exemplary embodiment, each of the plurality of fins 42 is produced by processing, for example, pressing, a metal thin plate having brazing material layers on both surfaces, that is, a brazing plate. The brazing plate is produced by forming an aluminum-silicon alloy layer as a brazing material on both surfaces of a thin plate made from an aluminum alloy, for example.
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A more feature of fin 42 will be described with reference to Figs. 3 to 8. Fig. 3 is a top view of a portion of fin 42. Further, Fig. 4 is a perspective view illustrating collar portion 44 in fin 42. Furthermore, Figs. 5 to 8 are sectional views of the plurality of fins 42 taken along lines A-A, B-B, C-C, and D-D illustrated in Fig. 3, respectively.
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As illustrated in Fig. 3, each of the plurality of fins 42 includes a plurality of cutout portions 42a through which the plurality of flat tubes 40 pass. In the case of the present exemplary embodiment, the plurality of cutout portions 42a extend in the lateral direction from one end 42b in the lateral direction (Z-axis direction) in parallel at intervals. That is, the plurality of cutout portions 42a are provided at one end 42b (one end) in the third direction (Z-axis direction). In other words, in the case of the present exemplary embodiment, the plurality of cutout portions 42a extend from the upstream side toward the downstream side in the flow direction (hollow arrow G) of air passing through heat exchanger 22.
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As illustrated in Fig. 4, collar portion 44 for holding flat tube 40 is integrally provided in each of the plurality of cutout portions 42a of fin 42. Collar portion 44 is produced by press molding, for example. Further, collar portion 44 is a wall-shaped portion having a "U" shape provided along an edge of cutout portion 42a and standing in the stacking direction (Y-axis direction) of the plurality of fins 42. An outer peripheral surface of flat tube 40 is in contact with inner peripheral surface 44a of collar portion 44. As a result, each of fins 42 is thermally connected to flat tubes 40 while holding the plurality of flat tubes 40 passing through each of cutout portions 42a via the plurality of collar portions 44.
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Further, as illustrated in Fig. 4, collar portion 44 of each of fins 42 includes first spacer portion 46, second spacer portion 48, and third spacer portion 50 for forming, with another adjacent fin 42, a gap through which air flows.
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As illustrated in Fig. 4, first to third spacer portions 46 to 50 are portions protruding in the stacking direction (Y-axis direction) of the plurality of fins 42 as compared with other portions of collar portion 44, and are in contact with other adjacent fins 42. Specifically, first to third spacer portions 46 to 50 respectively include rising portions 46a, 48a, 50a extending in the stacking direction (Y-axis direction) of the plurality of fins 42, and flare portions 46b, 48b, 50b provided at distal ends of rising portions 46a, 48a, 50a and in contact with another adjacent fin 42. Flare portions 46b, 48b, 50b respectively include contact surfaces 46c, 48c, 50c in contact with another adjacent fin 42.
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Further, first to third spacer portions 46 to 50 are provided separately on both sides of cutout portion 42a. Specifically, first spacer portion 46 is provided on one side of cutout portion 42a, that is, one side portion 44b of collar portion 44 facing each other in the longitudinal direction (X-axis direction) of fin 42. Further, second spacer portion 48 and third spacer portion 50 are provided on the other side of cutout portion 42a, that is, another side portion 44c of collar portion 44.
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Furthermore, as illustrated in Fig. 4, as viewed in the longitudinal direction (X-axis direction) of fin 42, first spacer portion 46 is located between second spacer portion 48 and third spacer portion 50.
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Moreover, as illustrated in Fig. 3, in the lateral direction (Z-axis direction) of fin 42, the sum of size L1 of first spacer portion 46, size L2 of second spacer portion 48, and size L3 of third spacer portion 50 is more than or equal to 1/2 of size W of fin 42. That is, the sum of sizes L1 to L3 of contact surfaces 46c to 50c of first to third spacer portions 46 to 50 is more than or equal to 1/2 of size W of fin 42.
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Note that, according to such first to third spacer portions 46 to 50, extension length Lc of cutout portion 42a is at least 1/2 of size W of fin 42. This is because first spacer portion 46 is located between second spacer portion 48 and third spacer portion 50 as viewed in the longitudinal direction (X-axis direction) of fin 42, and the sum of sizes L1 to L3 of first to third spacer portions 46 to 50 is more than or equal to 1/2 of size W of fin 42.
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Hereinafter, a method of producing heat exchanger 22 will be described.
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First, a plurality of fins 42 are stacked. Specifically, the plurality of fins 42 are stacked such that the stacking direction (Y-axis direction) is the vertical direction. For example, in order to produce one heat exchanger 22, several hundred fins 42 are stacked. At this time, lower fin 42 supports upper fin 42 from below via first to third spacer portions 46 to 50 provided along an edge of each of a plurality of cutout portions 42a of lower fin 42. That is, weight of upper fin 42 is applied to first to third spacer portions 46 to 50 of lower fin 42.
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In the case of the present exemplary embodiment, a total of three first to third spacer portions 46 to 50 are provided on both sides of cutout portion 42a of fin 42. Therefore, size of each of first to third spacer portions 46 to 50 (contact surfaces 46c to 50c) is larger than size of a spacer portion in a case where a total of four or more spacer portions are provided on both sides of cutout portion 42a. For this reason, load bearing capacity of each of three first to third spacer portions 46 to 50 is high. As a result, when a plurality of fins 42 are stacked, even if weight of upper fin 42 is applied, first to third spacer portions 46 to 50 are hardly deformed.
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Specifically, in practice, when another fin 42 is stacked on one fin 42, there is a case where another fin 42 is not in contact with each of first to third spacer portions 46 to 50 of one fin 42 at the same time due to deflection of fin 42 or the like. That is, in practice, another fin 42 first comes into contact with any one of first to third spacer portions 46 to 50. At this time, a large load is applied to a spacer portion with which another fin 42 first comes into contact. However, in the case of the present exemplary embodiment, a spacer portion with which another fin 42 first comes into contact has high load bearing characteristic, and is prevented from being deformed.
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Further, in the case of the present exemplary embodiment, one spacer portion (first spacer portion 46) is provided on one side of cutout portion 42a, and two spacer portions (second and third spacer portions 48 and 50) are provided on the other side. Then, as illustrated in Fig. 4, first spacer portion 46 is located between second spacer portion 48 and third spacer portion 50 as viewed in the longitudinal direction (X-axis direction) of fin 42. By this, in the lateral direction (Z-axis direction) of fin 42, a position of a concentrated load applied to one side of cutout portion 42a and a position of a concentrated load applied to the other side are substantially the same. That is, a concentrated load is applied to first spacer portion 46 on one side, and a concentrated load is applied between second and third spacer portions 48 and 50 on the other side. As a result, deformation of fin 42 is suppressed.
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In contrast, for example, in a case where there is one spacer portion on each of both sides of cutout portion 42a and these spacer portions do not face each other in the longitudinal direction (X-axis direction) of fin 42 (for example, in a case where second spacer portion 48 does not exist), or in a case where first spacer portion 46 is not located between second spacer portion 48 and third spacer portion 50 as viewed in the longitudinal direction of fin 42, a position of a concentrated load applied to one side of cutout portion 42a and a position of a concentrated load applied to the other side are greatly different in the lateral direction (Z-axis direction) of fin 42. In this case, there is a possibility that fin 42 is twisted and deformed in a manner that both sides of cutout portion 42a do not face each other.
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Further, in the lateral direction (Z-axis direction) of fin 42, the sum of size L1 of first spacer portion 46, size L2 of second spacer portion 48, and size L3 of third spacer portion 50 is more than or equal to 1/2 of size W of fin 42. For this reason, upper fin 42 is placed on first to third spacer portions 46 to 50 of lower fin 42 in a state of being substantially parallel to lower fin 42. Therefore, a plurality of fins 42 are stacked in parallel with each other in a state where a predetermined gap is formed between the fins.
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In a case different from this, since a position in the lateral direction (Z-axis direction) of the center of gravity of each of fins 42 is close to another end 42c in the lateral direction without cutout portion 42a, upper fin 42 placed on first to third spacer portions 46 to 50 of lower fin 42 is likely to tilt. Note that the center of gravity of fin 42 is located on another end 42c side where cutout portion 42a is not provided with respect to lateral center line Cw illustrated in Fig. 3.
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When a plurality of fins 42 are stacked, a plurality of flat tubes 40 are inserted into each of a plurality of cutout portions 42a of each of the plurality of fins 42. That is, one flat tube 40 is simultaneously inserted into cutout portion 42a of each of the plurality of fins 42. As a result, a plurality of flat tubes 40 and a plurality of fins 42 intersect in a lattice shape. By heating a plurality of fins 42 into which a plurality of flat tubes 40 are inserted, a brazing material layer on a surface of each of fins 42 is melted. After that, when cooled, the plurality of flat tubes 40 and the plurality of fins 42 are fixed to each other by the solidified brazing material.
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Note that, as in the present exemplary embodiment, as illustrated in Fig. 3, in the lateral direction (Z-axis direction) of fin 42, size L1 of first spacer portion 46 is preferably larger than sizes L2, L3 of second spacer portion 48 and third spacer portion 50, respectively. Further, size L1 is preferably smaller than the sum of sizes L2 and L3. By this, it is possible to reduce a difference in weight applied from upper fin 42 to both sides of cutout portion 42a via first to third spacer portions 46 to 50. By the above, when a plurality of fins 42 are stacked, deformation of cutout portion 42a in each of fins 42 is suppressed. When cutout portion 42a is deformed, it becomes difficult to insert flat tube 40 into cutout portion 42a. Further, inner peripheral surface 44a of collar portion 44 provided in cutout portion 42a and an outer peripheral surface of flat tube 40 cannot appropriately make surface contact, and heat transfer efficiency between flat tube 40 and fin 42 is lowered.
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Further, as in the present exemplary embodiment, as illustrated in Fig. 3, with respect to second and third spacer portions 48 and 50 located at the same side with respect to cutout portion 42a, size L3 of third spacer portion 50 is preferably larger than size L2 of second spacer portion 48.
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The reason is that second spacer portion 48 is closer to one end 42b provided with cutout portion 42a than third spacer portion 50. For this reason, in the lateral direction (Z-axis direction) of fin 42, third spacer portion 50 is closer to the center of gravity of fin 42 than second spacer portion 48. Therefore, in a case where weights applied to second spacer portion 48 and third spacer portion 50 from upper fin 42 when a plurality of fins 42 are stacked are compared, the weight of third spacer portion 50 closer to the center of gravity is larger than the weight of second spacer portion 48. Therefore, size L3 of third spacer portion 50 is preferably larger than size L2 of second spacer portion 48 so as to withstand a larger weight.
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According to the present exemplary embodiment as described above, it is possible to suppress deformation of spacer portions 46 to 50 in heat exchanger 22 in which a plurality of spacer portions 46 to 50 provided in each of fins 42 come into contact with another adjacent fin 42 to form a gap between fins 42.
(Other exemplary embodiments)
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Although the present disclosure is described above with reference to the exemplary embodiment described above, the present disclosure is not limited to the exemplary embodiment described above.
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For example, in the case of the above-described exemplary embodiment, collar portion 44 of each of fins 42 is formed integrally with fin 42, that is, as a part of fin 42. However, the exemplary embodiment of the present disclosure is not limited to this. The collar portion according to the exemplary embodiment of the present disclosure may be formed as a component separate from the fin and joined to the fin. Further, a plurality of collar portions according to the exemplary embodiment of the present disclosure may be provided along at least a portion of an edge of a plurality of cutout portions.
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For example, in the case of the above-described first exemplary embodiment, heat exchanger 22 according to the exemplary embodiment of the present disclosure is mounted in outdoor unit 14 of air conditioner 10, but may be mounted in indoor unit 12. Further, the heat exchanger according to the exemplary embodiment of the present disclosure can also be used for applications other than an air conditioner.
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That is, in a broad sense, the heat exchanger according to the exemplary embodiment of the present disclosure includes a plurality of flat tubes arranged in the first direction and a plurality of fins arranged in the second direction intersecting the first direction. Each of the plurality of fins includes a plurality of cutout portions provided at one end in a third direction intersecting the first direction and the second direction and through which the plurality of flat tubes pass, and a plurality of collar portions provided along at least a portion of an edge of the plurality of cutout portions and holding the plurality of flat tubes. Each of the plurality of collar portions includes a first spacer portion, a second spacer portion, and a third spacer portion that protrude in the second direction and are in contact with another adjacent fin. The first spacer portion is located on one side portion in the first direction of the collar portion, and the second spacer portion and the third spacer portion are located on the other side portion in the first direction of the collar portion such that the first spacer portion is located between the second spacer portion and the third spacer portion as viewed in the first direction. The sum of sizes of the first spacer portion, the second spacer portion, and the third spacer portion in the third direction is more than or equal to 1/2 of size in the third direction of the fin.
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The present disclosure is applicable to a heat exchanger in which a plurality of spacer portions provided in a fin are in contact with another adjacent fin to form a gap between the fins.