Heat exchanger

Description

[0001] The present invention relates to a heat exchanger which has an inner fin that is placed in a stream of flowing medium to cool or warm an object, and it also relates to a heat exchanger manufacturing method thereof.

[0002] A conventional heat exchanger is disclosed in Japanese Patent Application Laid-Open Publication No. 2002 - 170915. This conventional heat exchanger is used for cooling silicon-controlled rectifiers, various electric power condensers and others, and it includes a pan-like casing, a base plate attached to the casing, a corrugated inner fin inserted into an inner space of the casing and the base plate, and a partition plate holding the fin. The case and the fin are formed by using press working, and they assembled, then being integrally formed by brazing.

[0003] Another conventional heat exchanger is disclosed in Japanese Patent Application Laid-Open Publication No. 2007 - 202309. This heat exchanger is used for cooling an inverter, which converts direct current power into alternate current power, and others of a hybrid electric vehicle, and it has an aluminum body formed therein with a plurality of fins as one unit and a cover plate attached to the body. The body is formed by using die casting and fins are formed by means of machining the body.

[0004] US 2004/0035555 A1 discloses a counter-stream-mode oscillating-flow heat transport apparatus, where turning portions of serpentine flow paths are disposed to face an upper surface of heat-generating element. The flow paths are stacked in multiple layers in the direction from the heat-generating element to the flow paths, and a plurality of flow paths are disposed adjacent to the heat-generating element in the direction of fluid oscillation.

[0005] The above know conventional heat exchangers, however, encounter a problem in that they are expensive due to long manufacturing time.

[0006] It is, therefore, an object of the present invention to provide a heat exchanger which overcomes at least one of the drawbacks of the prior art and preferably which can decrease manufacturing cost, ensuring a necessary heat transfer efficiency and water tightness thereof.

[0007] It is another object of the present invention to seek to provide a heat exchanger manufacturing method which overcomes the foregoing drawbacks and can decrease manufacturing cost, ensuring a necessary heat transfer efficiency and water tightness thereof.

[0008] According to a first aspect of the present invention there is provided a heat exchanger as described in claim 1.

[0009] Therefore, the heat exchanger of embodiments of the present invention can decrease manufacturing cost, ensuring a necessary heat transfer efficiency and water tightness thereof.

[0010] According to a second aspect of the present invention there is provided a heat exchanger manufacturing method as described in claim 17.

[0011] Therefore, the heat exchanger manufacturing method can provide a heat exchanger which can decrease manufacturing cost, ensuring a necessary heat transfer efficiency and water tightness thereof.

[0012] The objects, features and advantages of the present invention will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a plan view showing a heat exchanger useful in understanding the present invention;

FIG. 2 is a front view of the heat exchanger of FIG.1;

FIG. 3 is a cross sectional side view of the heat exchanger of FIG. 1 , taken along a line S3 - S3 in FIG. 1;

FIG. 4 is a plan view of an upper case of the heat exchanger of FIG. 1;

FIG. 5 is a front view of the upper case shown in FIG. 4;

FIG. 6 is a front view of the upper case where a plurality of fin portions are formed thereon as one unit by using an extrusion process method, before their unnecessary parts are not cut off;

FIG. 7 is a front view of the upper case shown in FIG. 6;

FIG. 8 is a plan view of a lower case of the heat exchanger of FIG.1;

FIG. 9 is a front view showing the lower case shown in FIG. 8;

FIG. 10 is a cross sectional view showing a heat exchanger consisting of two sets of the heat exchangers shown in FIGS. 1 to 5, being formed as one unit, and being provided with a power module to be cooled;

FIG. 11 is an exploded view of the heat exchanger shown in FIG. 10;

FIG. 12 is a plan view of an upper case of a heat exchanger of a first embodiment according to the present invention;

FIG. 13 is a front view of the heat exchanger shown in FIG. 12;

FIG. 14 is a cross sectional side view of the heat exchanger shown in FIGS. 12 and 13, taken along a line S13 - S13 in FIG. 12;

FIG. 15 is a partial cross sectional view of the heat exchanger shown FIGS. 12 to 14, taken along a line S15 - S15;

FIG. 16 is a plan view showing a first turning portion of an upper case of a heat exchanger of a second embodiment according to the present invention;

FIG. 17 is a plan view showing a modification of the first turning portion of the upper case of the heat exchanger of the second embodiment;

FIG. 18 is a partial cross sectional view showing a first modification of a heat-transfer accelerating part formed on the upper cases of the first and second embodiments;

FIG. 19 is a partial cross sectional view showing a second modification of the heat-transfer accelerating part;

FIG. 20 is a partial cross sectional view showing a third modification of the heat-transfer accelerating part;

FIG. 21 is a partial cross sectional view showing a fourth modification of the heat-transfer accelerating part;

FIG. 22 is a partial cross sectional view showing a fifth modification of the heat-transfer accelerating part;

FIG. 23 is a plan view showing a heat exchanger of a third embodiment according to the present invention;

FIG. 24 is a front view of the heat exchanger of the third embodiment;

FIG. 25 is a cross sectional side view of the heat exchanger of the third embodiment, being provided with a power module thereon;

FIG. 26 is a plan view of an upper case of the heat exchanger of the third embodiment;

FIG. 27 is a front view of the upper case shown in FIG. 26;

FIG. 28 is a plan view of a lower case of the heat exchanger of the third embodiment;

FIG. 29 is a front view of the lower case shown in FIG. 28;

FIG. 30 is an enlarged partial cross sectional view of the lower case, shown in FIGS. 28 and 29, with a second turn portion;

FIG. 31 is an enlarged perspective schematic view showing a flow of cooling water in the second turn portion shown in FIG. 30;

FIG. 32 is a plan view showing a heat exchanger of a fourth embodiment according to the present invention;

FIG. 33 is a front view of the heat exchanger of the fourth embodiment;

FIG. 34 is a cross sectional side view of the heat exchanger of the fourth embodiment, taken along a line S34 - S34 in FIG. 32;

FIG. 35 is an enlarged perspective schematic view showing a flow of cooling water in a third turn portion of the heat exchanger of the fourth embodiment; and

FIG. 36 is a plain view showing a lower case used in a heat exchanger of a fifth embodiment of the present invention;

FIG. 37 is a front view showing the lower case shown in FIG. 36;

FIG. 38 is a bottom view showing the lower case shown in FIGS. 36 and 37;

FIG. 39 is a cross sectional side view of the lower case shown in FIGS. 36 to 38, taken along a line S39 - S39 in FIG. 36:

FIG. 40 is a cross sectional side view of the lower case shown in FIGS. 36 to 38, taken along a line S40 - S40 in FIG. 36:

FIG. 41 is a front view showing an upper case used in the heat exchanger of the fifth embodiment;

FIG. 42 is a bottom view showing the upper case shown in FIG. 41; and

FIG. 43 is a bottom view showing the upper case shown in FIGS. 41 and 42 before a part of fin portions formed on a main body of the upper case is cut off.

[0013] Throughout the following detailed description, similar reference characters and numbers refer to similar elements in all figures of the drawings, and their descriptions are omitted for eliminating duplication.

[0014] As defined herein, the terms upper, lower, upwards, downwards, side, etc. are provided for ease of reference with regard to various relative positions of features. The terms may be considered to relate to the heat exchanger when it is mounted and in use.

[0015] Referring to FIG. 1 to FIG. 3 of the drawings, there is shown a heat exchanger useful in understanding the present invention. The heat exchanger 2 is used for cooling a power module with an inverter for supplying electric power to an electric motor of an electric vehicle or a hybrid electric vehicle.

[0016] The heat exchanger 2 includes an upper case 4 and a lower case 5, where the upper case 4 is formed with a plurality of radiation fin portions 3 as one unit, and the upper 4 is coupled with the lower case 5 to form a flow channel 21 for flowing cooling water therein. The upper case 4 corresponds to a first case of an embodiment of the present invention, the lower case 5 corresponds to a second case of an embodiment of the present invention, and the cooling water corresponds to a flowing medium of an embodiment of the present invention.

[0017] As shown in FIG. 4 and FIG. 5, the upper case 4 is made of aluminum, having a main body 4a shaped like a rectangular plate. The radiation fin portions 3 are formed on a lower surface of the main body 4a of the upper case 4 as one unit so that they are projected downward therefrom. The fin portions 3 are provided so as to extend strait in a longitudinal direction of the upper case 4 and be arranged in multi rows at predetermined intervals in a lateral direction thereof. An outer peripheral portion and some portions of the fin portions 3 are removed from the upper case 4, which will be later described.

[0018] The fin portions 3 form side wall portions of the flow channel 21, and a part of bottom surface of the main body 4a form an upper wall portion of the flow channel 21. Consequently, the side and upper wall portions of the flow channel 21 provide wide surfaces through which heat is capable of effectively transferring, which can enhance heat transfer also because the fin portions 3 and the main body 4a of the upper case 4 are formed as one unit made of aluminum with a high heat transfer property.

[0019] These fin portions 3 are formed from the upper case 4 as one unit by using an extrusion process method.

[0020] As shown in FIG. 5 and FIG. 6, in a first process, the upper case 4 shaped in a rectangular plate is formed from an aluminum block to have a plurality of protruded fin portions 3 over the lower surface of the main body 4a by using the extrusion process method, so that the fin portions 3 have a thin rectangular cross-section, projecting downward and extending straight in the longitudinal directions from one edge portion to the other edge portion of the main body 4a. The fin portions 3 are arranged at even intervals in the lateral direction. These shapes and arrangement of the pre-formed fin portions 3 are simple, so that they can be easily formed by using a simple-shaped and inexpensive die.

[0021] In a next process, unnecessary portions of the fin portions 3 are removed therefrom by a machining process so that the fin portions 3 are formed as shown in FIG. 4 and FIG. 5. The unnecessary portions of the fin portions 3 include, for example, the outer peripheral portion, center portions, portions that are not capable of being inserted in the flow channel 21 and portions corresponding to turning portions 522a to 522c of the flow channel 21.

[0022] On the other hand, as shown in FIG. 8 and FIG. 9, the lower case 5 is shaped like a rectangular block provided with a recess 5a which is divided formed downward from an upper surface, as a reference plane 51. The recess 5a is divided by first to third wall portions 511, 512 and 513 of the lower case 5 to form first to fourth straight line portions 521 a to 521d arranged parallel to each other and first to third turn portions 522a to 522c as a part of the flow channel 21.

[0023] Specifically, the first wall portion 511 extends in a longitudinal direction of the lower case 5 from a one side portion of the lower case toward the other side portion thereof to have a clearance between an end portion of the first wall portion 511 and the other side portion, where the first turn portion 522a is formed to fluidically communicate the first and second straight line portions 521a and 521b with each other. The second wall portion 512 extends in the longitudinal direction from the other side portion toward the one side portion to have a clearance between an end portion of the second wall portion 512 and the one side portion, where the second turn portion 522b is formed to fluidically communicate the second and third straight line portions 521b and 521c with each other. The second wall portion 512 is offset in a lateral direction of the lower case 5 at its intermediate portion which is gradually slanted along the longitudinal direction so that cooling water can smoothly change its flow volumes and flow speed. The third wall portion 513 extends in the longitudinal direction from the one side portion toward the other side portion to have a clearance between an end portion of the third wall portion 513 and the other side portion, where the third turn portion 522c is formed to fluidically communicate the third and fourth straight line portions 521c and 521d with each other.

[0024] An inlet port 53 and an outlet port 54 are provided on the one side portion of the lower case 5 to be fluidically communicated with the first straight line portion 521a and the fourth straight line portion 521 d, respectively.

[0025] The lower surface of on the main body 4a of the upper case 4 and the upper surface of the lower case 5 are fitted to each other, the fin portions 3 of the upper case 4 being inserted into the recess 5a of the lower case 5. Then, they are watertightly joined with each other by using a friction stir welding method. The friction stir welding method is shown in Japanese Patent Application Laid-Open Publication No. 2002 - 210570 for example, and it is used for joining metals without fusion and filler materials, original metal characteristics remaining unchanged as possible. A cylindrical, shouldered tool with a profiled probe is moved, being rotated and plunged, along portions to be joined. This generates frictional heating and mechanical deformation to weld the portions.

[0026] For example, thus manufactured heat exchanger 2 is used for cooling a power module 1 having two inverters, on the upper surface of the upper case 4, on as shown in FIG. 10 and FIG. 11.

[0027] Therefore, in FIGS. 10 and 11, the heat exchanger 2 shown in FIGS. 1 to 3 is slightly modified in such a way that two heat exchangers 2 are formed as one unit. Specifically, the lower case 5 is formed with a large rectangular recess 5b at an upper surface side thereof to receive the upper case 4. The rectangular recess 5b continuously connected with two recesses 5a for receiving the fin portions 3 formed on the upper case 4.

[0028] The upper case 4 is fitted into the rectangular recess 5b of the lower case 5, and then the fitted portions 22 shown in FIG. 10, which do not form the flow channel 21, of the upper and lower cases 4 and 5 are joined together by using the friction stir welding method.

[0029] On the other hand, the lower case 5 is provided a plurality of bolt-holes 55 and 55c on a peripheral portion and a center portion of the lower case 5, respectively. The upper case 4 is provided with a bolt-hole at its center position corresponding to the center bolt-hole 55c. The power module 1 is provided a plurality of bolt-holes 11 and 11c on a peripheral portion and a center portion of the upper case 4. After joining the upper and lower cases 4 and 5, bolts 6 are screw-cramped into the bolt-holes 55 and 55c through the bolt-holes 11, 11c and 41, so that the power module 1, the upper case 4 and the lower case 5 are integrally joined so that a bottom surface of the power module 1 directly contacts with the upper surface of the upper case 4 of the heat exchanger 2.

[0030] The operation and the advantages of the heat exchanger 2 will be described.

[0031] In the heat exchanger 2 attached with the power module 1, the cooling water is supplied through the inlet port 53 to the flow channel 21, and it runs through the flow channel 21 formed in the heat exchanger 2, then being discharged through the outlet port 54. The cooling water is supplied from and returns to a not-shown air-conditioning system or other cooling system so as to circulate between the heat exchanger 2 and the system.

[0032] Specifically, the cooling water flows in the first straight line portion 521a, where heat transfer between the power module 1 and the cooling water is accelerated through the fin portion 3 disposed therein because of its wide surfaces. In the straight line portion 521a, the fin portion 3 therein has a plurality of narrow straight channels extending along the longitudinal direction and parallel to each other, providing wider heat-transfer surfaces. There are small amount of the cooling water that flows cross the narrow straight channels.

[0033] When the cooling water reaches the other end portion of the upper and lower cases 4 and 5, it changes its flow direction to turn 180 degrees around to face due to the first turn portions 522a and the center wall portion, then flowing in the second straight line portion 521b. In the first turn portion 522a, there is no fin portion because of cutting-off of the fin portions 3 corresponding thereto, which enables the cooling water to easily and effectively turn. Thus, the heat transfer between the power module 1 and the cooling water flowing through the second to fourth straight line portions 521 b to 521d is accelerated, and the second and third turn portions 522b and 522c easily and effectively turn the directions of the cooling water to the next straight line portion. Therefore, the power module 1 is effectively cooled down due to the wide surfaces of the fin portions 3 and the wall portions of the upper and lower cases 4 and 5 and also due to a large flow amount of the cooling water.

[0034] In this cooling operation, the power module 1 directly contacts with the heat exchanger 1 on the upper surface of the upper case 4, thereby its cooling efficiency being improved. In addition, since the fin portions 3 are formed on the upper case 4 as one unit by using the extrusion process method, its thermal conductivity is superior to an aluminum casting formed therewith, due to material properties. This enables the fin portions 3 to be simple in shapes thereof to ensure heat radiation performance, decreasing flow resistance of the cooling water running in the flow channel 21.

[0035] The fin portions 3 are formed on the main body 4a of the upper case 4 by using the extrusion process method, which enables the fin portions 3 to be formed thinner and to have closer intervals between the adjacent fin portions, compared to the aluminum casting. This decreases the flow resistance of the cooling water running in the flow channel 21, ensuring the radiation performance thereof.

[0036] In the heat exchanger 2 the upper case 4 and the lower case 5 are joined with each other by using the friction stir welding method, so that good water-tightness of the heat exchanger 2 can be obtained without troubles such as a crack caused at high temperature, an expansion and/or burst due to blowhole in a welding process, even when at least one of the upper case 4 and the lower case 5 is an aluminum casting. Incidentally, aluminum castings are obtained at low manufacturing costs and at a high productivity rate.

[0037] By using the friction stir welding method, joining and sealing can be obtained at the same time, which removes bolts and a seal member such as a packing, an O-ring or a liquid gasket, thereby decreasing parts and manufacturing man-hour. In addition, the friction stir welding method can suppress a temperature generated in a joining process and decrease portions exposed to a high temperature generated in the joining process. This can decrease thermal deformation to a negligible extend.

[0038] Next, a heat exchanger of a first embodiment according to the present invention will be described.

[0039] As shown in FIGS. 12 to 15, in the heat exchanger 2 of the first embodiment, fin portions 3 are provided on a main body 4a as one unit, extending in first to fourth straight line portions 521a to 521d and further partially in first to third turn portions 522a to 522c. In addition, the lower case 5 has first to third downward projecting portions 5c to 5e projecting from a lower surface of the lower case 5 at positions corresponding to the first to third turn portions 522a to 522c, respectively. The first to third downward projecting portions 5c to 5e correspond to a projecting turn portion of the present invention.

[0040] The first downward projecting portion 5c is located at the other side portion of the lower case 5, being provided therein with a first downward turn portion 523a as a part of the flow channel 21. The second downward projecting portion 5d is located at the one side portion, being provided therein with a second downward turn portion 523b as a part of the flow channel 21. The third downward projecting portion 5e is located at the other side portion, being provided therein with a third downward turn portion 523c as a part of the flow channel 21. The first to third downward turn portions 523a to 523c correspond to an enlarged turn portion of the present invention.

[0041] The bottom surfaces of the first to third downward turn portions 523a to 523c are lower than those of the first to fourth straight line portions 521 a to 521d.

[0042] The fin portions 3 have the same heights at the first to third turn portions 522a to 522c as those at first to fourth straight line portions 521 a to 521d. As shown in FIGS. 14 and 15, the heights "h" of the fin portions 3 is set to be smaller than the heights "H" between a lower surface of a main body 4a of an upper case 4 and a bottom surface of a lower case 5 so that parts of a flow channel 21 are formed between clearances therebetween to flow and turn the cooling water to the next straight line portion. The bottom surfaces are formed in such a way that it is gradually slanted downwardly at the first straight line portion side, being flat at an intermediate portion thereof, then being gradually slanted upward. Bottom surfaces of the second and third turn portions 522b and 522c are formed similarly to that of the first turn portion 522a.

[0043] The other parts and portions are similar to those previously described.

[0044] The operation and the advantages of the heat exchanger 2 of the first embodiment will be described.

[0045] The cooling water is supplied through an inlet port 53 into the first straight line portion 521 a, then to the first straight line portion 522a. The fin portions 3 are provided in the first straight line portion 521a and the first turn portion 522a, so that wider heat-transfer surface areas can be obtained to improve a cooling efficiency of the heat exchanger 2. Through the bottom side clearances, namely the first to third downward turn portions 523a to 523c, of the first to third turn portions 522a to 522c, a sufficient amount of the cooling water can flow downward and then upward to the next straight line portion, thereby improving the cooling efficiency. Therefore, the heat exchanger 2 of the first embodiment can improve the cooling efficiency due to the wider heat-transfer surface area and the bottom side surfaces of the first to the third turn portions 522a to 522c, in addition to the advantages of heat exchanger previously described.

[0046] Next, a heat exchanger of a second embodiment according to the present invention will be described.

[0047] As shown in FIGS. 16 and 17, in the heat exchanger of the second embodiment, a main body 4a of an upper case 4 is provided at its lower surface with a plurality of heat radiation portions at its portions corresponding to first to third turn portions 522a to 522c.

[0048] The heat radiation portions consist of first radiation portions 311 and second radiation portions 312 shaped in a plate as shown in FIG. 16, or alternatively they consist of circular column portions 321 as shown in FIG. 17. Incidentally, the first and second radiation portions 311 and 312 and the circular column portions 321 correspond to projecting pieces of the present invention.

[0049] In the former, the first and second radiation portions 311 and 312 are arranged to be inclined against a flow direction of the cooling water, and they are also arranged substantially perpendicular to each other, being offset in longitudinal and lateral directions of the upper case 4. The first and second radiation portions 311 and 312 are arranged in lines at predetermined intervals as indicted by lines 313 and 314. In the latter, the circular column portions 321 are arranged in lines at predetermined intervals as indicated by lines 323 and 324, being offset in the longitudinal and lateral directions. The other parts and portions are similar to those previously described

[0050] The operation and advantages of the second embodiment will be described.

[0051] In the heat exchanger 2 having the heat radiation portions shown in FIG. 16, a cooling water entering an inlet port flows through a first straight portion, being heat-transferred through fin portions therein, and then it enters a first turn portion, where some of the cooling water flows straight, namely in the longitudinal direction, between the lines 313 and 314 and between other lines and the other flow in the lateral direction. This enables the cooling water to turn and also to be accelerated in heat transfer through the first and second radiation portions 311 and 312 in the first turn portion. The similar advantages can be also obtained in not-shown second and third turn portions of a flow channel. Therefore, the heat exchanger of the second embodiment can obtain the advantage in accelerating the heat transfer between the cooling water and a power module through the fin portions in the straight line portions of the flow channel and the heat radiation portions in the turn portions of the flow channel, in addition to the advantages of the heat exchanger previously described herein

[0052] Incidentally, in the previously described embodiments, the fin portions 3 may be formed by using a method of partially cutting off the surface of the main body 4a of the upper case 4 to rise therefrom as shown in FIG. 18, or by a method of crimping the surface of the main body 4a to form fin portions as shown in FIG. 19, or a method of ruffling the surface of the main body 4a and fixing fins 36 with brazing material or solder material as shown in FIG. 20. Further, the fin portions 3 may be formed to have a wave shape shown in FIG. 21 or a round corner, along the turn portion, shown in FIG. 22. In these modifications, a part of the fin portions are cut off to be received into the recess 5a of the lower case 5.

[0053] Next, a heat exchanger of a third embodiment according to the present invention will be described.

[0054] As shown in FIG. 23 to FIG. 25, the heat exchanger 2 of the third embodiment has an upper case 4 and a lower case 5 joined with the upper case 4. The upper case 4 is formed with a plurality of fin portions 3 on its lower surface as one unit, and the lower case 5 is formed with a recess 5a, which forms a part of a flow channel 21 for running cooling water and receives the fin portions 3 of the upper case 4 when the upper and lower cases 4 and 5 are joined with each other.

[0055] Specifically, at first the fin portions 3 are formed on a main body 4a of the upper case 4 as one unit similarly to those shown in FIG. 6, an then the fin portions 3 corresponding to a center portion and first to third turn portions 522a to 522c of the flow channel 21 are cut off similarly to the previously described embodiment as shown in FIG. 26 and FIG. 27 before the upper and lower case 4 and 5 are joined, while the rest thereof are inserted into first to fourth straight line portions 521a to 521d of the flow channel 21. The first to fourth straight line portions 521 a to 521d and the first to third turn portions 522a to 522c are constructed similarly to those of the previously described embodiment.

[0056] As shown in FIG. 24, FIG. 25, FIG. 28 and FIG. 29, the lower case 5 is provided with a first projecting portion 5c at one end portion with an inlet port 53 and an outlet port 54, a second projecting portion 5d and a third projecting portion 5e at the other end of the lower case 5. The first to third projecting portions 5c to 5e are projected downward from a lower surface of the lower case 5, and they are formed therein with recesses forming first to third downward turn portions 523a to 523c as parts of the flow channel 21, respectively.

[0057] The first downward turn portion 523a of the first projecting portion 5c is fluidically communicated with the first turn portion 522a, the second downward turn portion 523b of the second projecting portion 5d is fluidically communicated with the second turn portion 522b, and the third downward turn portion 523c of the third projecting portion 5e is fluidically communicated with the third turn portion 522c. The first to third downward turn portions 523a to 523c are fluidically connected with the straight line portions 521a, 521 b, 521c and 521d by a perpendicular step.

[0058] As shown in FIG. 30, depth "B" at the downward turn portion 523a, 523b, 523c is set to be larger than that at the straight line portion 521a, 521b, 521c, 521d. An outer end side wall portion, defining the first to third downward turn portions 523a to 523c, of the projecting portions 5c, 5d, 5e is on the same plane as that, defining the flow channel 21, of the turn portion 522a, 522b, 522c. An inner end side wall portion, defining the downward turn portion 523a, 523b, 523c, of the projecting portion 5c, 5d, 5e is overlapped by several millimeters "d" with an outer end portion of the fin portion 3. Depth of the downward turn portion 523a, 523b, 523c (= the depth "B" at the downward turn portion 5c, 5d, 5e - a depth "A" at the turn portion 522a, 522b, 522c) is set to be larger than a width "C" of the downward turn portion 523. In this embodiment, (B - A) / C is set to be approximately three. Each of the downward turn portion 523a, 523b and 523c is provided with a first slanted portion 524a at its inlet side, and a second slanted portion 524b at its outlet side as shown in FIG. 31. The first and second slanted portions 524a and 524b extend and are slanted along a lateral direction of the lower case 5.

[0059] Therefore, as shown in FIG. 31, after the cooling water runs strait in the straight line portion 521a of the flow channel 21 as indicated by an arrow 101, it turns its flow direction downward into the first downward turn portion 523a, as indicated by an arrow 102, at the turn portion 522a. Then it runs obliquely downward along the first slanted portion 524a as indicated by an arrow 103, changing its direction horizontally at a bottom of the first downward turn portion 523a as indicated by an arrow 104. The cooling water goes obliquely upward along the second slanted portion 524b as indicated by an arrow 105, then moving up as indicated by an arrow 106. Then the cooling water changes its direction to flow along the second straight line portion 521b. The cooling water flows in the second to fourth straight line portions 521b to 521d and the second to thirds turn portions 522b and 522c similarly to in the first straight line portion 521 a and the first turn portion 522a, respectively.

[0060] In the first to third downward turn portions 523a to 523c of the first to third turn portions 522a to 523, some of the cooling water flows through clearances formed between the outer end portions of the fin portions 3 and the inner wall portion of the turn portions 5c to 5e, and the rest thereof flows through the fist to third downward turn portions 523a to 523c.

[0061] Therefore, the heat exchanger 2 of the third embodiment has the following advantages in addition to those of the previously described embodiment.

[0062] A sufficient amount of the cooling water can flow through the flow channel 21 without increasing a longitudinal length of the turn portions 522a to 522c. Therefore, it is advantageous for the heat exchanger 2 to be installed on a motor vehicle when a power module to be cooled has a large cooling area, because the heat exchanger does not need its long portion projecting from the power module.

[0063] The cooling area of the power module becomes large because of many chips and others of the power module in a case where it supplies electric power to three-phase motor. For example, the power module needs two IGBT chips (including twelve Insulated Gate Bipolar Transistors and twelve Fast Recovery Diodes) or three IGBT chips (including 18 Insulated Gate Bipolar Transistors and 18 Fast Recovery Diodes) in order to increase output power thereof, which causes the cooling area of the power module to become larger.

[0064] In addition, the first and second slanted portions 524a and 524b of the turn portion 522a, 522b, 522c can smoothly flow the cooling water in the turn portions 522a, 522b and 522c, suppressing flow loss generated therein.

[0065] Further, the fin portions 3 extend at positions partially overlapping with the first to third downward turn portions 523a to 523c, which enables the cooling water to start to flow downward in the first to third downward turn portions 523a to 523c before it runs over the end portions of the fin portions 3. Therefore, the cooling water can also smoothly flow in the turn portions 522a, 522b and 52c, with the flow loss being suppressed.

[0066] Next a heat exchanger of a fourth embodiment according to the present invention will be described.

[0067] As shown in FIG. 32 to FIG. 34, the heat exchanger 2 of the fourth embodiment has an upper case 4, formed with fin portions 3, and a lower case 5, coupled with the upper case 4 and formed with a recess 5a for receiving the fin portions 3. The fin portions 3 are formed on a main body 4a of the upper case 4 as one unit, and then a part thereof is cut off so as to be insertable into the recess 5a, similarly to the earlier embodiment.

[0068] The recess 5a forms a part of a flow channel 21 which includes first to fourth straight line portions 521 a to 521d and first to third turn portions 522a to 522c. The first to third turn portions 522a to 522c are provided continuously with first to third downward turn portions 525a to 525c formed in first to third downward projecting portions 5c to 5e that project downward from the lower surfaces thereof. The first to third downward turn portions 525a to 525c correspond to the enlarged turn portion of the present invention.

[0069] As shown in FIG. 34 and FIG. 35, Each of the first to third downward turn portions 525a to 525c is provided on its inner surface forming a part of the flow channel 21 with a third slanted portion 526 that extends and is gradually slanted downward along a longitudinal direction of the lower case 5. The depth of the downward turn portion 525a, 525b, 525c is set to be smaller than that of the fourth embodiment, and a partially overlapped portions of the fin portions 3 and the flow channel 21 of the downward turn portion 525a, 525b, 525c is set to be longer than that of the earlier embodiment, for example the overlapped portions is from more than ten millimeters and to several tens of millimeters.

[0070] In the fourth embodiment, the cooling water, flowing through the first straight line portion 521a as indicated by an arrow 201 in FIG. 35, flows downward along the third slanted portion 526 toward the bottom of the downward turn portion 525a, 525b, 525c in the longitudinal direction of the lower case 5 as indicated by an arrow 202. It turns its flow direction and runs in the lateral direction of the lower case 5 as indicated by an arrow 203, and then it turns its direction again to go up along the third slanted portion 526 toward the second straight line portion 521b as indicated by an arrow 204. The cooling water flows in a direction opposite to a flow direction in the first straight line portion 521a as indicated by an arrow 205. It flows at the other straight line portions 521c and 521d and the other turn portions 522b and 522c similarly to at the firs and second straight portions 521a and 521b and the first turn portion 522a.

[0071] Therefore, the heat exchanger 2 of the fourth embodiment has the following advantages in addition to those of the earlier embodiment.

[0072] A sufficient amount of the cooling water can flow through the flow channel 21 without increasing a longitudinal length of the turn portions 522a to 522c. Therefore, it is advantageous for the heat exchanger 2 to be installed on a motor vehicle when a power module to be cooled has a large cooling area, because the heat exchanger does not need its long portion projecting from the power module.

[0073] In addition, the third slanted portion 526 of the turn portion 522a, 522b, 522c can smoothly flow the cooling water in the turn portions 522a, 522b and 522c, suppressing flow loss generated therein.

[0074] Further, the fin portions 3 extend at positions partially overlapping with the first to third downward turn portions 525a to 525c, which enables the cooling water to start to flow downward in the downward turn portions 523 before it runs over the end portions of the fin portions 3. Therefore, the cooling water can also smoothly flow in the turn portions 522a, 522b and 522c, with the flow loss being suppressed.

[0075] Next, a heat exchanger of a fifth embodiment according to the present invention will be described.

[0076] In this fifth embodiment, a flow channel is simplified to have only two straight line portions where flow medium runs at faster speed relative to speeds in the previous embodiments.

[0077] As shown in FIGS. 36 to 40, a lower case 5 has the flow channel 21, mainly consisting of the first straight line portion 521 a, the second straight line portion 521b and a turn portion 522a. At one end portion of the lower case 5 is provided with an inlet portion 53, communicating with one end portion of the first straight line portion 521a, and an outlet portion 54, communicating with one end portion of the second straight portion 521b. The turn portion 522a is provided at the other end portion of the lower case 5 to communicate with the other end portions of the first and second straight line portions 521a and 521 b.

[0078] The lower case 5 is formed with a fourth downward projecting portion 5f and a sixth projecting portion 5h, which are projected downward from a bottom surface of the lower case 5 at portions corresponding to the one end portions of the first and second straight line portions 521a and 521b, respectively. A fifth downward projecting portion 5g is formed to project downward from the bottom surface of the lower case 5 at a portion corresponding to the other end portions of the first and second straight line portions 521a and 521b.

[0079] The fourth to sixth downward projecting portions 5 f to h are provided therein with recesses to form forth to sixth downward turn portions 523d that constitute a part of the flow channel 21, respectively. As shown in FIGS. 36, 39 and 40, the forth to sixth downward turn portions 523d are deeper than bottom surfaces of the first and second straight line portions 521a and 521b. The inlet port 53 and the outlet port 54 face lower side portions of the forth and sixth downward turn portions 523d and 523f, respectively. The fifth downward turn portions 523e is formed at a lower part of the turn portion 522a, and an intermediate portion thereof is narrowed in a longitudinal direction of the lower case 5 due to formation of an inward projecting portion 510 formed on the end portion of the lower case 5 as shown in FIG. 36 and FIG. 40. The inward projecting portion 510 extends from an upper portion to a bottom portion of the downward turn portion 522a. The inward projecting portion 510 corresponds to a speed-distribution changing means of the present invention.

[0080] On the other hand, as shown in FIG. 42, an upper case 4 is provided with a plurality of radiation fin portions 3, arranged in two rows corresponding to the first and second straight line portions of the lower case 4. The radiation fin portions 3 are formed by using an extrusion process method so that they extend in a longitudinal direction of the upper case 4 from one end portion to the other end portion of a main body 4a of the upper case 4 as shown in FIG. 43, and then both end portions of the fin portions 3 are cut off as shown in FIG. 42. The end portion of the fin portions 3 are extended at intermediate portions of the fourth to sixth downward turn portions 523d to 523f as indicated by dot lines (of the fin portions 3) in FIG. 36.

[0081] The other portions and parts are constructed similarly to those of the earlier embodiment.

[0082] In the heat exchanger of the fifth embodiment, the flow medium is supplied at high speed to the first straight line portion 521a through the inlet port 53. The fin portions 3 in the first straight line portion 521 draw heat from a power module through the upper case 4 to give the heat to the flow medium. The flow medium, reaching the turn portion 522a through the end portion of the first straight line portion 521 a, is turned its flow direction toward downward to be moved into the downward the fifth turn portion 523a due to the existence of extended portions of the fin portions 3, and then it moves toward the second straight line portion 521b. In this movement, flow speed of the flow medium becomes higher at portions near a central wall portion 511 than at portions distant therefrom. This may cause peak speed of a speed distribution of the flow medium in the turn portion 522a to be slanted toward the central wall portion 511 at the first straight line portion 521 a side and at the second straight line portion 521 b. Consequently, the flow speed of the flow medium that runs in the second straight line portion 521 b becomes lower at its outer side portions thereof relative to that at its inner side thereof, deteriorating its heat exchange efficiency.

[0083] However, the inner projecting portion 510 disturbs flow movement of the flow medium, entering the turn portion 522a, at the inner side so as to suppress the flow speed thereof, thereby changing speed distribution of the flow medium so that it can come to be flat as possible after the flow medium runs through the inner projecting portion 510.

[0084] Then, the flow medium goes upward toward the second straight line portion 521b after passing through the inner projecting portion 510, flowing in the second straight line portion 521b with the flatter speed distribution thereof. This efficiently cools the power module. Then, the flow medium is discharged through the outlet port 54.

[0085] The heat exchanger of the fifth embodiment has the following advantage in addition to those of the first and second embodiments.

[0086] In the heat exchanger of the fifth embodiment, the lower case 5 is provided with the inner projecting portion 510 at the turn portion 522a, which suppresses the peak speed of the flow medium at the inner side to change the speed distribution thereof to be close to a flat one as possible after it passes through the inner projecting portion 510. This can improve the heat exchange efficiency and decrease the size of the heat exchanger.

[0087] While there have been particularly shown and described with reference to preferred embodiments thereof, it will be understood that various modifications may be made therein.

[0088] In the embodiments, the fin portions 3 are formed on the main body 4a of the upper case 4 from the one end portion to the other end portion of the main body 4a before they are partially cut off, while the fin portions 3 may be formed without their outer peripheral portions from the beginning as shown in FIG. 36. In this case, the fin portions can be formed easily and at low manufacturing costs by using the extrusion process method.

[0089] The speed-distribution changing means may be a flat plate or others as long as it can suppress the peak speed of the flow medium at the turn portion so that the speed distribution of the flow medium can come to be close to a flat one after the flow medium passes through the speed-distribution changing means.

[0090] In the embodiments described above, although the heat exchangers use the cooling water to cool an object such as the inverter, the cooling water may be replaced with other cooling medium different from water. In addition, the heat exchanger may use a hot water and the like as the flowing medium so as to warm an object.

Claims

1. A heat exchanger (2) comprising:

(a) a first member (4) including a main body (4a) and a heat transfer accelerating portion (3) formed on the main body (4a) as one unit, the main body (4a) having a lower surface and an upper surface configured to receive an object (1) to be heat-exchanged; and

(b) a second member (5) having an upper surface as a reference surface (51) and a lower surface including a recess (5a) indented in the downward direction from the reference surface (51) and functioning as a flow channel (21), wherein the flow channel (21) has a plurality of straight line portions (521a to 521d) parallel to each other and turn portions (522a to 522c)which fluidically communicates end portions of the straight line portions (521a to 521d), and wherein

(c) the first member (4) and the second member (5) are joined with each other at the reference surface (51) in a state where the heat transfer accelerating portion (3) of the first member (4) is inserted into the recess (5a)of the second member (5), wherein the recess (5a) is divided by wall portions (511, 512, 513) of the lower case (5) to form said plurality ofstraight line portions (521 a to 521 d),

characterized in that

(d) the second member (5) is provided on the lower surface with a projecting portion (5d, 5e, 5c, 5g, 5h) that projects in a downward direction from an end portion of the lower surface, wherein

(e) the turn portions are (522a - 522c) formed in the projecting portion (5d, 5e, 5c, 5g, 5h), the straight line portions (521a - 521 d) having a bottom, the turn portions (522a to 522c) having a bottom and fluidically communicating end portions of the adjacent straight line portions (521a - 521d) to turn a flow direction between the adjacent straight line portions (521a - 521d), and wherein

(f) a depth (B, H) between the reference surface (51) and the bottom of the turn portions (522a - 522c) is set to be larger than depths (A) between the reference surface (51) and the bottoms of the straight line portions (521a-521d), in an area of the turn portions (522a - 522c) fluidically extending from an outermost end portion of one of the adjacent straight line portions (521a-521d) to an outermost end portion of the other adjacent straight line portions (521 a-521 d) in such a way that cooling medium lows in the downward direction from the one of the adjacent straight line portions (521 a-52 I d), then in a horizontal direction perpendicular to the downward direction, and then in an upward direction to other of the adjacent straight line portions (521a-521d) in the turn portions (522a-522c) wherein the wall portion (512) at the center of the heat exchanger is offset in a lateral direction of the lower case (5) at its intermediate portion which is gradually slanted along the longitudinal direction so that cooling water can smoothly change its flow volumes and flow speed

2. The heat exchanger (2) according to claim 1, wherein a portion, corresponding to the turn portion (522a to 522c), of the heat transfer accelerating portion (3) is removed.

3. The heat exchanger (2) according to claim 1 or claim 2, wherein at least the second member (5) is an aluminum casting.

4. The heat exchanger (2) according to any one of claims 1 to 3, wherein a surface, opposite to the heat transfer accelerating portion (3), of the first member (4) is one of a cooling surface and a warming surface.

5. The heat exchanger (2) according to any one of claims 1 to 4, wherein
the heat transfer accelerating portion (3) has a plurality of projecting pieces (311, 312; 321, 322), in the turn portion (522 a to 522c), the projecting pieces rising from the main body (4a) and allowing a flowing medium to flow straight and turn directions thereof.

6. The heat exchanger (2) according to claim 1, wherein
the turn portion (522a to 522c) has an enlarged turn portion (523a to 523c; 525a to 525c) forming a part of the flow channel (21).

7. The heat exchanger (2) according to claim 6, wherein the straight line portion (521a to 521d) and the enlarged turn portion (523a to 523c; 525a to 525c) are fluidically connected by a perpendicular step.

8. The heat exchanger (2) according to claim 6 or claim 7, wherein the enlarged turn portion (523a to 523c; 525a to 525c) has a slanted portion (524a, 524b; 526) fluidically connected with the straight line portion (521a to 521d).

9. The heat exchanger (2) according to claim 8, wherein the slanted portion (524a, 524b) is slanted along a direction perpendicular to the straight line portion (521a to 521d).

10. The heat exchanger (2) according to claim 8, wherein the slanted portion (526) is slanted along a direction of the straight line portion (521a to 521d).

11. The heat exchanger (2) according to any one of claims 6 to 10, wherein a corner, perpendicular to the straight line portion (521a to 521d), of the turn portion (522a to 522c) is chamfered.

12. The heat exchanger (2) according to any one of claims 6 to 11, wherein a part of the enlarged turn portion (523a to 523c;, 525a to 525c) is partially overlapped with the heat transfer accelerating portion (3).

13. The heat exchanger (2) according to any one of claims 1, 2 and 4 to 12, wherein the heat transfer accelerating portion is a plurality of fin portions (3).

14. The heat exchanger (2) according to any one of claims 1, 2 and 4 to 13, wherein the heat transfer accelerating portion is fin portions (3) that extends straight and parallel to each other.

15. The heat exchanger (2) according to any one of claims 1, 2 and 4 to 14, wherein the heat transfer accelerating portion (3) is formed by using an extrusion process method.

16. The heat exchanger according to any one of claims 1, 2 and 4 to 15, wherein
the turn portion (522a, 522b) is provided at an intermediate portion of the turn portion (552a, 552b) with a speed-distribution changing means (510) that narrows a flowing area of the intermediate portion to suppress a peak speed of flow medium running through the flow channel (21) to change speed distribution thereof so as to close to be a flat speed distribution after the flow medium passes through the speed-distribution changing means (510).

17. A heat exchanger (2) manufacturing method for manufacturing a heat exchanger according to any one of the preceding claims, comprising the steps of:

preparing blocks to be a first member (4) and a second member (5);

forming a heat transfer accelerating portion(3) on a main body (4a) of the first member (4) as one unit so that the heat transfer accelerating portion (3) projects from the main body (4a);

forming a recess (5a) in the second member (5) so that the recess (5a) is indented from a reference surface (51) of the second member (5) and forms a part of a flow channel (21) wherein the flow channel (21) has a plurality of straight line portions (521a to 521d) parallel to each other and turn portions (522a to 522c) which fluidically communicates end portions of the straight line portions (521a to 521d); cutting off a portion, deviating from the flow channel (21) when the first and second members (4, 5) are joined, of the heat transfer accelerating portion (3); and

joining the first member (4) and the second member (5) with each other at the reference surface (51) of the second member (5),

wherein
the second member (5) is provided in the lower surface with a projecting portion (5d, 5e, 5c, 5g, 5h) that projects in a downward direction from an end portion of the lower surface, wherein the turn portions are (522a-522c) formed in the projecting portion (5d, 5e, 5c, 5g, 5h), the straight line portions (521a-521d) having a bottom, the turn portions (522a to 522c) having a bottom and
fluidically communicating end portions of adjacent straight line portions (521a-521d) of the straight line portions (521a-521d) to turn a flow direction between the adjacent straight line portions (521a-521d), and wherein a depth (B) between the reference surface (51) and the bottom of the turn portions (522a to 522c) is set to be larger than depths (A) between the reference surface (51) and the bottoms of the straight line portions (521 a-521d), in an area of the turn portions (522a to 522c) fluidically extending from an outermost end portion of one of the adjacent straight line portions (521a-521d) to an outermost end portion of the other adjacent straight line portions (521a-521d) in such a way that cooling medium flows in the downward direction from the one of the adjacent straight line portions (521a-521d), then in a horizontal direction perpendicular to the downward direction, and then in an upward direction to the other of the adjacent straight line portions (521a-521d) in the turn portion (522a to 522c) wherein the wall portion (512) at the center of the heat exchanger is offset in a lateral direction of the lower case (5) at its intermediate portion which is gradually slanted along the longitudinal direction so that cooling water can smoothly change its flow volumes and flow speed.

18. The heat exchanger (2) manufacturing method according to claim 17, wherein the heat transfer accelerating portion (3) is formed on the main body (4a) by using an extrusion process method.

19. The heat exchanger (2) manufacturing method according to claim 17 or claim 18, wherein the heat transfer accelerating portion is constituted by fin portions (3) that extend straight over the straight line portion (521a to 521d) and parallel to each other.

Ansprüche

1. Wärmetauscher (2), der Folgendes umfasst:

(a) ein erstes Element (4), das einen Hauptkörper (4a) und einen Wärmeübertragungsbeschleunigungsabschnitt (3), der an dem Hauptkörper (4a) als eine Einheit geformt ist, einschließt, wobei der Hauptkörper (4a) eine untere Fläche und eine obere Fläche, dafür konfiguriert, einen Gegenstand (1) zum Wärmeaustauschen aufzunehmen, aufweist, und

(b) ein zweites Element (5), das eine obere Fläche als eine Bezugsfläche (51) und eine untere Fläche, die eine Aussparung (5a) einschließt, die in der Richtung nach unten von der Bezugsfläche (51) vertieft ist und als ein Strömungskanal (21) fungiert, aufweist, wobei der Strömungskanal (21) mehrere geradlinige Abschnitte (521a bis 521d) parallel zueinander und Wendeabschnitte (522a bis 522c), die Endabschnitte der geradlinigen Abschnitte (521a bis 521d) fluidmäßig verbinden, aufweist, und wobei

(c) das erste Element (4) und das zweite Element (5) in einem Zustand, wobei der Wärmeübertragungsbeschleunigungsabschnitt (3) des ersten Elements (4) in die Aussparung (5a) des zweiten Elements (5) eingesetzt ist, an der Bezugsfläche (51) miteinander verbunden sind, wobei die Aussparung (5a) durch Wandabschnitte (511, 512, 513) der unteren Hülle (5) geteilt wird, um die mehreren geradlinigen Abschnitte (521a bis 521d) zu bilden,

dadurch gekennzeichnet, dass

(d) das zweite Element (5) an der unteren Fläche mit einem vorspringenden Abschnitt (5d, 5e, 5c, 5g, 5h) versehen ist, der in einer Richtung nach unten von einem Endabschnitt der unteren Fläche vorspringt, wobei

(e) die Wendeabschnitte (522a bis 522c) in dem vorspringenden Abschnitt (5d, 5e, 5c, 5g, 5h) geformt sind, die geradlinigen Abschnitte (521a bis 521d) einen Boden aufweisen, die Wendeabschnitte (522a bis 522c) einen Boden aufweisen und fluidmäßig Endabschnitte der benachbarten geradlinigen Abschnitte (521a bis 521d) verbinden, um eine Strömungsrichtung zwischen den benachbarten geradlinigen Abschnitten (521a bis 521d) zu wenden, und wobei

(f) eine Tiefe (B, H) zwischen der Bezugsfläche (51) und dem Boden der Wendeabschnitte (522a bis 522c) so festgesetzt ist, dass sie größer ist als Tiefen (A) zwischen der Bezugsfläche (51) und den Böden der geradlinigen Abschnitte (521a bis 521d), in einem Bereich der Wendeabschnitte (522a bis 522c), der sich fluidmäßig von einem äußersten Endabschnitt des einen der benachbarten geradlinigen Abschnitte (521a bis 521d) zu einem äußersten Endabschnitt der anderen benachbarten geradlinigen Abschnitte (521a bis 521d) erstreckt, auf eine solche Weise, dass ein Kühlmittel in der Richtung nach unten aus dem einen der benachbarten geradlinigen Abschnitte (521a bis 521d), dann in einer horizontalen Richtung, senkrecht zu der Richtung nach unten, und dann in einer Richtung nach oben zu einem anderen der benachbarten geradlinigen Abschnitte (521a bis 521d) in den Wendeabschnitten (522a bis 522c) strömt, wobei der Wandabschnitt (512) an der Mitte des Wärmetauschers in einer seitlichen Richtung der unteren Hülle (5) an seinem Zwischenabschnitt versetzt ist, der allmählich entlang der Längsrichtung abgeschrägt ist, so dass Kühlwasser sanft seine Strömungsvolumina und Strömungsgeschwindigkeit ändern kann.

2. Wärmetauscher (2) nach Anspruch 1, wobei ein Abschnitt des Wärmeübertragungsbeschleunigungsabschnitts (3), der dem Wendeabschnitt (522a bis 522c) entspricht, entfernt wurde.

3. Wärmetauscher (2) nach Anspruch 1 oder Anspruch 2, wobei wenigstens das zweite Element (5) ein Aluminium-Gussteil ist.

4. Wärmetauscher (2) nach einem der Ansprüche 1 bis 3, wobei eine Fläche des ersten Elements (4), entgegengesetzt zu dem Wärmeübertragungsbeschleunigungsabschnitt (3), entweder eine Kühlfläche oder eine Wärmfläche ist.

5. Wärmetauscher (2) nach einem der Ansprüche 1 bis 4, wobei
der Wärmeübertragungsbeschleunigungsabschnitt (3) eine Vielzahl von vorspringenden Stücken (311, 312; 321, 322) in dem Wendeabschnitt (522a bis 522c) hat, wobei die vorspringenden Stücke von dem Hauptkörper (4a) aufsteigen und ermöglichen, dass ein strömendes Medium gerade strömt und die Richtungen desselben wendet.

6. Wärmetauscher (2) nach Anspruch 1, wobei
der Wendeabschnitt (522a bis 522c) einen vergrößerten Wendeabschnitt (523a bis 523c; 525a bis 525c) aufweist, der einen Teil des Strömungskanals (21) bildet.

7. Wärmetauscher (2) nach Anspruch 6, wobei der geradlinige Abschnitt (521a bis 521d) und der vergrößerte Wendeabschnitt (523a bis 523c; 525a bis 525c) durch eine senkrechte Stufe fluidmäßig verbunden sind.

8. Wärmetauscher (2) nach Anspruch 6 oder Anspruch 7, wobei der vergrößerte Wendeabschnitt (523a bis 523c; 525a bis 525c) einen abgeschrägten Abschnitt (524a, 524b; 526) aufweist, der fluidmäßig mit dem geradlinigen Abschnitt (521a bis 521d) verbunden ist.

9. Wärmetauscher (2) nach Anspruch 8, wobei der abgeschrägte Abschnitt (524a, 524b) entlang einer Richtung, senkrecht zu dem geradlinigen Abschnitt (521a bis 521d), abgeschrägt ist.

10. Wärmetauscher (2) nach Anspruch 8, wobei der abgeschrägte Abschnitt (526) entlang einer Richtung des geradlinigen Abschnitts (521a bis 521d) abgeschrägt ist.

11. Wärmetauscher (2) nach einem der Ansprüche 6 bis 10, wobei eine Ecke des Wendeabschnitts (522a bis 522c), senkrecht zu dem geradlinigen Abschnitt (521a bis 521d) abgekantet ist.

12. Wärmetauscher (2) nach einem der Ansprüche 6 bis 11, wobei ein Teil des vergrößerten Wendeabschnitts (523a bis 523c; 525a bis 525c) teilweise mit dem Wärmeübertragungsbeschleunigungsabschnitt (3) überlappt ist.

13. Wärmetauscher (2) nach einem der Ansprüche 1, 2 und 4 bis 12, wobei der Wärmeübertragungsbeschleunigungsabschnitt eine Vielzahl von Rippenabschnitten (3) ist.

14. Wärmetauscher (2) nach einem der Ansprüche 1, 2 und 4 bis 13, wobei der Wärmeübertragungsbeschleunigungsabschnitt aus Rippenabschnitten (3) besteht, die sich gerade und parallel zueinander erstrecken.

15. Wärmetauscher (2) nach einem der Ansprüche 1, 2 und 4 bis 14, wobei der Wärmeübertragungsbeschleunigungsabschnitt (3) durch die Verwendung eines Strangpressbearbeitungsverfahrens geformt ist.

16. Wärmetauscher (2) nach einem der Ansprüche 1, 2 und 4 bis 15, wobei
der Wendeabschnitt (522a, 522b) an einem Zwischenabschnitt des Wendeabschnitts (522a, 522b) mit einem Geschwindigkeitsverteilungsänderungsmittel (510) versehen ist, das eine Durchflussfläche des Zwischenabschnitts verengt, um eine Spitzengeschwindigkeit des Strömungsmediums, das durch den Strömungskanal (21) läuft, zu unterdrücken, um die Geschwindigkeitsverteilung desselben zu ändern, so dass sie nahe einer flachen Geschwindigkeitsverteilung ist, nachdem das Strömungsmedium durch das Geschwindigkeitsverteilungsänderungsmittel (510) hindurchgeht.

17. Wärmetauscher (2) - Fertigungsverfahren zum Fertigen eines Wärmetauschers nach einem der vorhergehenden Ansprüche, das die folgenden Schritte umfasst:

das Vorbereiten von Blocks, die ein erstes Element (4) und ein zweites Element (5) sein sollen,

das Formen eines Wärmeübertragungsbeschleunigungsabschnitts (3) an einem Hauptkörper (4a) des ersten Elements (4) als eine Einheit, so dass der Wärmeübertragungsbeschleunigungsabschnitt (3) von dem Hauptkörper (4a) vorspringt,

das Formen einer Aussparung (5a) in dem zweiten Element (5), so dass die Aussparung (5a) von einer Bezugsfläche (51) des zweiten Elements (5) vertieft ist und einen Teils eines Strömungskanals (21) bildet, wobei der Strömungskanal (21) mehrere geradlinige Abschnitte (521a bis 521d) parallel zueinander und Wendeabschnitte (522a bis 522c), die Endabschnitte der geradlinigen Abschnitte (521a bis 521d) fluidmäßig verbinden, aufweist,

das Abschneiden eines Abschnitts des Wärmeübertragungsbeschleunigungsabschnitts (3), der von dem Strömungskanal (21) abweicht, wenn das erste und das zweite Element (4, 5) verbunden werden, und

das Verbinden des ersten Elements (4) und des zweiten Elements (5) miteinander an der Bezugsfläche (51) des zweiten Elements (5),

wobei

das zweite Element (5) in der unteren Fläche mit einem vorspringenden Abschnitt (5d, 5e, 5c, 5g, 5h) versehen ist, der in einer Richtung nach unten von einem Endabschnitt der unteren Fläche vorspringt, wobei

die Wendeabschnitte (522a bis 522c) in dem vorspringenden Abschnitt (5d, 5e, 5c, 5g, 5h) geformt sind, die geradlinigen Abschnitte (521a bis 521d) einen Boden aufweisen, die Wendeabschnitte (522a bis 522c) einen Boden aufweisen und

das fluidmäßige Verbinden von Endabschnitten von benachbarten geradlinigen Abschnitten (521a bis 521d) der geradlinigen Abschnitte (521a bis 521d), um eine Strömungsrichtung zwischen den benachbarten geradlinigen Abschnitten (521a bis 521d) zu wenden, und wobei

eine Tiefe (B) zwischen der Bezugsfläche (51) und dem Boden der Wendeabschnitte (522a bis 522c) so festgesetzt ist, dass sie größer ist als Tiefen (A) zwischen der Bezugsfläche (51) und den Böden der geradlinigen Abschnitte (521a bis 521d), in einem Bereich der Wendeabschnitte (522a bis 522c), der sich fluidmäßig von einem äußersten Endabschnitt des einen der benachbarten geradlinigen Abschnitte (521a bis 521d) zu einem äußersten Endabschnitt des anderen benachbarten geradlinigen Abschnitts (521a bis 521d) erstreckt, auf eine solche Weise, dass ein Kühlmittel in der Richtung nach unten aus dem einen der benachbarten geradlinigen Abschnitte (521a bis 521d), dann in einer horizontalen Richtung, senkrecht zu der Richtung nach unten, und dann in einer Richtung nach oben zu dem anderen der benachbarten geradlinigen Abschnitte (521a bis 521d) in dem Wendeabschnitt (522a bis 522c) strömt, wobei der Wandabschnitt (512) an der Mitte des Wärmetauschers in einer seitlichen Richtung der unteren Hülle (5) an seinem Zwischenabschnitt versetzt ist, der allmählich entlang der Längsrichtung abgeschrägt ist, so dass Kühlwasser sanft seine Strömungsvolumina und Strömungsgeschwindigkeit ändern kann.

18. Wärmetauscher (2) - Fertigungsverfahren nach Anspruch 17, wobei der Wärmeübertragungsbeschleunigungsabschnitt (3) an dem Hauptkörper (4a) durch die Verwendung eines Strangpressbearbeitungsverfahrens geformt ist.

19. Wärmetauscher (2) - Fertigungsverfahren nach Anspruch 17 oder Anspruch 18, wobei der Wärmeübertragungsbeschleunigungsabschnitt aus Rippenabschnitten (3) besteht, die sich gerade über den geradlinigen Abschnitt (521a bis 521d) und parallel zueinander erstrecken.

Revendications

1. Échangeur de chaleur (2), comprenant :

(a) un premier élément (4) comprenant un corps principal (4a) et une partie accélération de transfert de chaleur (3) formée d'un seul tenant avec le corps principal (4a), ledit corps principal (4a) présentant une surface inférieure et une surface supérieure configurée pour recevoir un objet (1) devant subir un échange de chaleur ; et

(b) un deuxième élément (5) présentant une surface supérieure faisant office de surface de référence (51) et une surface inférieure comprenant un renfoncement (5a) creusé en direction du bas à partir de la surface de référence (51) et fonctionnant comme un canal de circulation (21), ledit canal de circulation (21) présentant une pluralité de parties en ligne droite (521a à 521d) parallèles les unes aux autres et des parties en courbe (522a à 522c) qui relient de manière fluidique des parties extrémité des parties en ligne droite (521a à 521d), et dans lequel

(c) le premier élément (4) et le deuxième élément (5) sont réunis l'un à l'autre au niveau de la surface de référence (51) dans un état dans lequel la partie accélération de transfert de chaleur (3) du premier élément (4) est insérée dans le renfoncement (5a) du deuxième élément (5), ledit renfoncement (5a) étant divisé par des parties paroi (511, 512, 513) du boîtier inférieur (5) afin de former ladite pluralité de parties en ligne droite (521a, 521d),

caractérisé en ce que

(d) le deuxième élément (5) est fourni sur la surface inférieure avec une partie saillante (5d, 5e, 5c, 5g, 5h) qui fait saillie en direction du bas à partir d'une partie extrémité de la surface inférieure, dans lequel

(e) les parties en courbe (522a à 522c) sont formées dans la partie saillante (5d, 5e, 5c, 5g, 5h), les parties en ligne droite (521a à 521d) présentent un fond, les parties en courbe (522a à 522c) présentent un fond et relient de manière fluidique des parties extrémité des parties en ligne droite (521a à 521d) adjacentes pour suivre une direction de circulation entre les parties en ligne droite (521a à 521d) adjacentes, et dans lequel

(f) une profondeur (B, H) entre la surface de référence (51) et le fond des parties en courbe (522a à 522c) est définie comme étant supérieure à des profondeurs (A) entre la surface de référence (51) et les fonds des parties en ligne droite (521a 521d), dans une zone des parties en courbe (522a à 522c) s'étendant de manière fluidique à partir d'une partie extrémité la plus extérieure de l'une des parties en ligne droite (521a à 521d) adjacentes vers une partie extrémité la plus extérieure des autres parties en ligne droite (521a à 521d) adjacentes, de sorte qu'un agent réfrigérant circule en direction du bas à partir de l'une des parties en ligne droite (521a à 521d) adjacentes, puis dans une direction horizontale perpendiculaire à la direction du bas, et ensuite en direction du haut vers l'autre des parties en ligne droite (521a à 521d) adjacentes dans les parties en courbe (522a à 522c), la partie paroi (512) au niveau du centre de l'échangeur de chaleur étant décalée dans une direction latérale du boîtier inférieur (5) au niveau de sa partie intermédiaire qui est progressivement inclinée en direction longitudinale de sorte qu'il est possible de modifier progressivement les volumes de circulation et la vitesse de circulation de l'eau de refroidissement.

2. Échangeur de chaleur (2) selon la revendication 1, dans lequel une partie, correspondant à la partie en courbe (522a à 522c), de la partie accélération de transfert de chaleur (3) est retirée.

3. Échangeur de chaleur (2) selon la revendication 1 ou 2, dans lequel au moins le deuxième élément (5) est une pièce coulée en aluminium.

4. Échangeur de chaleur (2) selon l'une quelconque des revendications 1 à 3, dans lequel une surface, opposée à la partie accélération de transfert de chaleur (3), du premier élément (4) est une surface parmi une surface de refroidissement et une surface de réchauffement.

5. Échangeur de chaleur (2) selon l'une quelconque des revendications 1 à 4, dans lequel la partie accélération de transfert de chaleur (3) présente une pluralité de pièces saillantes (311, 312 ; 321, 322), dans la partie en courbe (522a à 522c), les pièces saillantes s'élevant à partir du corps principal (4a) et permettant à un milieu en circulation de circuler dans des directions en ligne droite et en courbe de celles-ci.

6. Échangeur de chaleur (2) selon la revendication 1, dans lequel la partie en courbe (522a à 522c) présente une partie en courbe (523a à 523c ; 525a à 525c) agrandie formant une partie du canal de circulation (21).

7. Échangeur de chaleur (2) selon la revendication 6, dans lequel la partie en ligne droite (521a à 521d) et la partie en courbe (523a à 523c ; 525a à 525c) agrandie sont raccordées de manière fluidique grâce à un degré perpendiculaire.

8. Échangeur de chaleur (2) selon la revendication 6 ou 7, dans lequel la partie en courbe (523a à 523c ; 525a à 525c) agrandie présente une partie inclinée (524a, 524b ; 526) raccordée de manière fluidique à la partie en ligne droite (521a à 521d).

9. Échangeur de chaleur (2) selon la revendication 8, dans lequel la partie inclinée (524a, 524b) est inclinée dans une direction perpendiculaire à la partie en ligne droite (521a à 521d).

10. Échangeur de chaleur (2) selon la revendication 8, dans lequel la partie inclinée (526) est inclinée dans une direction de la partie en ligne droite (521a à 521d).

11. Échangeur de chaleur (2) selon l'une quelconque des revendications 6 à 10, dans lequel un coude, perpendiculaire à la partie en ligne droite (521a à 521d), de la partie en courbe (522a à 522c) est biseauté.

12. Échangeur de chaleur (2) selon l'une quelconque des revendications 6 à 11, dans lequel une partie de la partie en courbe (523a à 523c ; 525a à 525c) agrandie est partiellement superposée à la partie accélération de transfert de chaleur (3).

13. Échangeur de chaleur (2) selon l'une quelconque des revendications 1, 2 et 4 à 12, dans lequel la partie accélération de transfert de chaleur consiste en une pluralité de parties ailette (3).

14. Échangeur de chaleur (2) selon l'une quelconque des revendications 1, 2 et 4 à 13, dans lequel la partie accélération de transfert de chaleur consiste en des parties ailette (3) qui s'étendent de manière linéaire et parallèle les unes aux autres.

15. Échangeur de chaleur (2) selon l'une quelconque des revendications 1, 2 et 4 à 14, dans lequel la partie accélération de transfert de chaleur (3) est formée en utilisant un procédé d'extrusion.

16. Échangeur de chaleur selon l'une quelconque des revendications 1, 2 et 4 à 15, dans lequel la partie en courbe (522a, 522b) est fournie au niveau d'une partie intermédiaire de la partie en courbe (552a, 552b) avec un moyen de modification de répartition de vitesse (510) qui restreint une surface de circulation de la partie intermédiaire afin de supprimer une vitesse de pointe du milieu en circulation traversant le canal de circulation (21) afin de modifier une répartition de vitesse de celui-ci de manière à être proche d'une répartition de vitesse plate après que le milieu en circulation a traversé le moyen de modification de répartition de vitesse (510).

17. Procédé de fabrication d'un échangeur de chaleur (2) permettant de fabriquer un échangeur de chaleur selon l'une quelconque des revendications précédentes, comprenant les étapes consistant à :

préparer des blocs destinés à constituer un premier élément (4) et un deuxième élément (5) ;

former une partie accélération de transfert de chaleur (3) d'un seul tenant avec un corps principal (4a) du premier élément (4) de sorte que la partie accélération de transfert de chaleur (3) fait saillie à partir du corps principal (4a) ;

former un renfoncement (5a) dans le deuxième élément (5) de sorte que le renfoncement (5a) est creusé à partir d'une surface de référence (51) du deuxième élément (5) et forme une partie d'un canal de circulation (21), ledit canal de circulation (21) présentant une pluralité de parties en ligne droite (521a à 521d) parallèles les unes aux autres et des parties en courbe (522a à 522c) qui relient de manière fluidique des parties extrémité des parties en ligne droite (521a à 521d) ;

couper une partie, s'écartant du canal de circulation (21) lorsque les premier et deuxième éléments (4, 5) sont réunis, de la partie accélération de transfert de chaleur (3) ; et

réunir le premier élément (4) et le deuxième élément (5) l'un avec l'autre au niveau de la surface de référence (51) du deuxième élément (5),

dans lequel le deuxième élément (5) est fourni dans la surface inférieure avec une partie saillante (5d, 5e, 5c, 5g, 5h) qui fait saillie en direction du bas à partir d'une partie extrémité de la surface inférieure, dans lequel

les parties en courbe (522a à 522c) sont formées dans la partie saillante (5d, 5e, 5c, 5g, 5h), les parties en ligne droite (521a à 521d) présentent un fond, les parties en courbe (522a à 522c) présentent un fond et relient de manière fluidique des parties extrémité de parties en ligne droite (521a à 521d) adjacentes parmi les parties en ligne droite (521a à 521d) pour suivre une direction de circulation entre les parties en ligne droite (521a à 521d) adjacentes, et dans lequel

une profondeur (B) entre la surface de référence (51) et le fond des parties en courbe (522a à 522c) est définie comme étant supérieure à des profondeurs (A) entre la surface de référence (51) et les fonds des parties en ligne droite (521a à 521d), dans une zone des parties en courbe (522a à 522c) s'étendant de manière fluidique à partir d'une partie extrémité la plus extérieure de l'une des parties en ligne droite (521a à 521d) adjacentes vers une partie extrémité la plus extérieure des autres parties en ligne droite (521a à 521d) adjacentes de sorte qu'un agent réfrigérant circule en direction du bas à partir de l'une des parties en ligne droite (521a à 521d) adjacentes, puis dans une direction horizontale perpendiculaire à la direction du bas, et ensuite en direction du haut vers l'autre des parties en ligne droite (521a à 521d) adjacentes dans la partie en courbe (522a à 522c), la partie paroi (512) au niveau du centre de l'échangeur de chaleur étant décalée dans une direction latérale du boîtier inférieur (5) au niveau de sa partie intermédiaire qui est progressivement inclinée en direction longitudinale de sorte qu'il est possible de modifier progressivement les volumes de circulation et la vitesse de circulation de l'eau de refroidissement.

18. Procédé de fabrication d'un échangeur de chaleur (2) selon la revendication 17, dans lequel la partie accélération de transfert de chaleur (3) est formée sur le corps principal (4a) en utilisant un procédé d'extrusion.

19. Procédé de fabrication d'un échangeur de chaleur (2) selon la revendication 17 ou 18, dans lequel la partie accélération de transfert de chaleur consiste en des parties ailette (3) qui s'étendent de manière rectiligne sur la partie en ligne droite (521a à 521d) et de manière parallèle les unes aux autres.

Drawing