HEAT TRANSFER ELEMENT AND METHOD FOR MANUFACTURING HEAT TRANSFER ELEMENT

Abstract

 A heat exchange element (1) includes an opposing flow-path portion (13); a first flow-path separator portion (14); and a second flow-path separator portion (15), each of which is formed by alternately stacking a plurality of partition plates (2) and a plurality of spacing plates (3) having a corrugated shape in cross section. In the opposing flow-path portion (13), the spacing plates (3) are disposed in such a manner that peaks of the corrugated shape extend parallel to each other when viewed in a direction in which the partition plates (2) and the spacing plates (3) are stacked, and a first flow path and a second flow path are formed alternately with the partition plate (2) interposed between the first and second flow paths. The first flow-path separator portion (14) and the second flow-path separator portion (15) separate air that flows through the first flow path and air that flows through the second flow path from each other in different directions. Each partition plate (2) of the opposing flow-path portion (13) and each partition plate (2) of the first flow-path separator portion (14) are joined with a tape (7). Each partition plate (2) of the opposing flow-path portion (13) and each partition plate (2) of the second flow-path separator portion (15) are joined with the tape (7).

Description

Field

[0001] The present invention relates to a heat exchange element that performs heat exchange between a supplied-air flow and an exhaust-air flow, and relates to a manufacturing method of a heat exchange element.

Background

[0002] In conventionally used heat exchange elements, a plurality of partition plates are stacked with spacing therebetween, and the spaces between the partition plates function as flow paths along which an air flow can pass. In the heat exchange element, heat exchange is performed through the partition plate between air flows that pass along adjacent flow paths with the partition plate interposed therebetween. The heat exchange element as described above for example can perform heat exchange and ventilation by causing a supplied-air flow to pass along a flow path formed on one side of the partition plate and an exhaust-air flow to pass along a flow path formed on the other side, thereby exchanging heat between the supplied-air flow and the exhaust-air flow.

[0003] Further, there is an opposing-flow type heat exchange element, in which the adjacent flow paths with the partition plate interposed therebetween are formed to extend parallel to each other, and the air-flow directions of these adjacent flow paths differ by 180 degrees. Patent Literature 1 discloses an opposing-flow type heat exchange element, which combines an opposing flow-path portion having a cuboid shape with a flow-path separator portion having a triangular prism shape. In the opposing flow-path portion, the air-flow directions on one side and the other side of the partition plate differ by 180 degrees. The flow-path separator portion separates the air flows from each other after they have passed through the opposing flow-path portion. The flow-path separator portion causes a supplied-air flow that flows along an air-supply passage outside the heat exchange element and an exhaust-air flow that flows along a discharge passage outside the heat exchange element to approach and meet in the opposing flow-path portion or separates the supplied-air flow and the exhaust-air flow from each other after they have passed through the opposing flow-path portion.

Citation List

Patent Literature

[0004] Patent Literature 1: Japanese Patent Application Laid-open No. H11-325780

Summary

Technical Problem

[0005] Various sizes of heat exchange element are used, and it is necessary to form an opposing flow-path portion and a flow-path separator portion in accordance with the size of the heat exchange element. In Patent Literature 1 listed above, an opposing flow-path portion is formed by using an element frame with an outer periphery that consists of a sealing rib and a supporting frame; therefore, a die is needed in order to mold the element frame in accordance with the size of the opposing flow-path portion. Consequently, the manufacturing costs tend to increase.

[0006] The present invention has been achieved to solve the above problems, and an object of the present invention is to provide a heat exchange element that enables manufacturing costs to be reduced and that can also accommodate a wide range of sizes.

Solution to Problem

[0007] In order to solve the above problems and achieve the object, an aspect of the present invention is a heat exchange element including: an opposing flow-path portion; a first flow-path separator portion; and a second flow-path separator portion, each of which is formed by alternately stacking a plurality of partition plates and a plurality of spacing plates that have a corrugated shape in cross section. The opposing flow-path portion has a box shape, in which the spacing plates are disposed in such a manner that peaks of a corrugated shape extend parallel to each other when viewed in a direction in which the partition plates and the spacing plates are stacked and in which one side in a direction in which the peaks of the corrugated shape extend is defined as a first surface and another side is defined as a second surface; and a first flow path, through which air passes from the first surface toward the second surface and a second flow path, through which air passes from the second surface toward the first surface, are formed alternately with the partition plate interposed between the first flow path and the second flow path. The first flow-path separator portion includes a third surface that is opposed to the first surface, a fourth surface that faces in a direction different from the third surface, and a fifth surface that faces in a direction different from the third surface and the fourth surface; on a layer that is opposed to the first flow path, peaks of a corrugated shape of the spacing plate extend from the third surface toward the fourth surface; and on a layer that is opposed to the second flow path, the peaks of the corrugated shape of the spacing plate extend from the third surface toward the fifth surface. The second flow-path separator portion includes a sixth surface that is opposed to the second surface, a seventh surface that faces in a direction different from the sixth surface, and an eighth surface that faces in a direction different from the sixth surface and the seventh surface; on a layer that is opposed to the first flow path, peaks of a corrugated shape of the spacing plate extend from the sixth surface toward the seventh surface; and on a layer that is opposed to the second flow path, the peaks of the corrugated shape of the spacing plate extend from the sixth surface toward the eighth surface. Each of the partition plates of the opposing flow-path portion and each of the partition plates of the first flow-path separator portion are joined with a tape, and each of the partition plates of the opposing flow-path portion and each of the partition plates of the second flow-path separator portion are joined with a tape.

Advantageous Effects of Invention

[0008] The heat exchange element according to the present invention has an effect where the manufacturing costs can be reduced and a wider range of sizes can be accommodated.

Brief Description of Drawings

[0009] 

FIG. 1 is a perspective view of a heat exchange element according to a first embodiment of the present invention.

FIG. 2 is a perspective view of an opposing flow-path portion of the heat exchange element according to the first embodiment.

FIG. 3 is a plan view of the opposing flow-path portion of the heat exchange element according to the first embodiment.

FIG. 4 is a perspective view of a first flow-path separator portion of the heat exchange element according to the first embodiment.

FIG. 5 is a plan view of the first flow-path separator portion of the heat exchange element according to the first embodiment.

FIG. 6 is a perspective view of a layer including a first flow path, which is cut away from the heat exchange element according to the first embodiment.

FIG. 7 is a perspective view of a layer including a second flow path, which is cut away from the heat exchange element according to the first embodiment.

FIG. 8 is an explanatory diagram of a manufacturing method of the heat exchange element according to the first embodiment and illustrates how a quadrangular member is cut out from a corrugated roll.

FIG. 9 is an explanatory diagram of the manufacturing method of the heat exchange element according to the first embodiment and illustrates how a first parallelogram member is cut out from the quadrangular member.

FIG. 10 is an explanatory diagram of the manufacturing method of the heat exchange element according to the first embodiment and illustrates how a second parallelogram member is cut out from the quadrangular member.

FIG. 11 is a plan view illustrating a state in which first parallelogram members are joined to a rectangular unit member, in the manufacturing method of the heat exchange element according to the first embodiment.

FIG. 12 is a plan view illustrating a state in which second parallelogram members are joined to the rectangular unit member, in the manufacturing method of the heat exchange element according to the first embodiment.

FIG. 13 is a plan view illustrating a state in which first joint members and second joint members are stacked, in the manufacturing method of the heat exchange element according to the first embodiment.

FIG. 14 is a diagram illustrating cutting of a stacked-layer member in the manufacturing method of the heat exchange element according to the first embodiment.

FIG. 15 is a perspective view of a heat exchange element according to a second embodiment of the present invention.

FIG. 16 is a perspective view of a first flow path portion, which is cut away from the heat exchange element according to the second embodiment.

FIG. 17 is a perspective view of a second flow path portion, which is cut away from the heat exchange element according to the second embodiment.

FIG. 18 is a diagram illustrating an example of cutting a stacked-layer member in a manufacturing method of the heat exchange element according to the second embodiment.

Description of Embodiments

[0010] A heat exchange element and a manufacturing method of a heat exchange element according to embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The present invention is not limited to the embodiments.

First embodiment.

[0011] FIG. 1 is a perspective view of a heat exchange element according to a first embodiment of the present invention. A heat exchange element 1 is used in a heat exchange and ventilation device that exchanges heat between a supplied-air flow that supplies outdoor air to a room and an exhaust-air flow that discharges room air to the outdoors. The heat exchange element 1 includes an opposing flow-path portion 13 having a cuboid shape; a first flow-path separator portion 14 having a triangular prism shape; and a second flow-path separator portion 15 having a triangular prism shape.

[0012] FIG. 2 is a perspective view of the opposing flow-path portion 13 of the heat exchange element 1 according to the first embodiment. FIG. 3 is a plan view of the opposing flow-path portion 13 of the heat exchange element 1 according to the first embodiment. FIG. 4 is a perspective view of the first flow-path separator portion 14 and the second flow-path separator portion 15 of the heat exchange element 1 according to the first embodiment. FIG. 5 is a plan view of the first flow-path separator portion 14 and the second flow-path separator portion 15 of the heat exchange element 1 according to the first embodiment.

[0013] Each of the opposing flow-path portion 13, the first flow-path separator portion 14, and the second flow-path separator portion 15 is constituted by partition plates 2 and spacing plates 3 that are stacked alternately. The partition plate 2 is made from a material having heat-transfer properties and moisture permeability or from a material having only heat-transfer properties. Further, the partition plate 2 is made from a non-breathable material. The spacing plate 3 has a corrugated shape in cross section. The spacing plate 3 is joined at the peaks of its corrugated shape to the partition plate 2. The spacing plate 3 having a corrugated shape is provided between the partition plates 2 so as to hold the partition plates 2 apart with a given spacing. The space formed between the partition plates 2 functions as a flow path through which air can pass. In the flow path, air can pass along the direction in which the peaks of the corrugated shape of the spacing plate 3 extend. In the following descriptions, the space between two partition plates 2 is sometimes described as a single layer. The direction in which the peaks of the corrugated shape of the spacing plate 3 extend is also referred to as a "flow-path direction". The direction in which the partition plates 2 and the spacing plates 3 are stacked is also simply referred to as a "layer-stacking direction".

[0014] As illustrated in FIGS. 2 and 3, when the opposing flow-path portion 13 is viewed in the layer-stacking direction, different layers of the spacing plates 3 are disposed in such a manner that the peaks of the corrugated shape extend in parallel to each other. In FIGS. 2 and 3, the dotted lines illustrate the positions of the peaks of the corrugated shape.

[0015] The opposing flow-path portion 13 has a first surface 13a on one side and a second surface 13b on the other side in the flow-path direction. A plurality of flow paths formed between the partition plates 2 are categorized as a first flow path 21, through which air passes from the first surface 13a to the second surface 13b, and as a second flow path 22, through which air passes from the second surface 13b to the first surface 13a. The first flow path 21 and the second flow path 22 are provided alternately in the layer-stacking direction in such a manner that one side with respect to the partition plate 2 functions as the first flow path 13a and the other side with respect to the partition plate 2 functions as the second flow path 13b. The direction in which an air flow passes through the first flow path 13a is opposite to the direction in which an air flow passes through the second flow path 13b. That is, these directions are different from each other by 180 degrees. In the following descriptions, an example is given in which a supplied-air flow passes through the first flow path 21 and an exhaust-air flow passes through the second flow path 22.

[0016] As illustrated in FIGS. 4 and 5, the first flow-path separator portion 14 includes a third surface 14a that is opposed to the first surface 13a of the opposing flow-path portion 13; a fourth surface 14b that faces in a direction different from the third surface 14a; and a fifth surface 14c that faces in a direction different from the third surface 14a and the fourth surface 14b.

[0017] Among the layers in the first flow-path separator portion 14, on the layer that is opposed to the first flow path 21 of the opposing flow-path portion 13, the spacing plate 3 is provided in such a manner that a flow path extends in the direction from the third surface 14a toward the fourth surface 14b. Among the layers in the first flow-path separator portion 14, on the layer that is opposed to the second flow path 22 of the opposing flow-path portion 13, the spacing plate 3 is provided in such a manner that the flow path extends in the direction from the third surface 14a toward the fifth surface 14c. Therefore, in the first flow-path separator portion 14, air flows through the flow paths on opposite sides of the partition plate 2 in directions that cross each other. From the fourth surface 14b, air cannot enter the layer connecting to the second flow path 22. From the fifth surface 14c, air cannot enter the layer connecting to the first flow path 21.

[0018] As illustrated in FIGS. 4 and 5, the second flow-path separator portion 15 includes a sixth surface 15a that is opposed to the second surface 13b of the opposing flow-path portion 13; a seventh surface 15b that faces in a direction different from the sixth surface 15a; and an eighth surface 15c that faces in a direction different from the sixth surface 15a and the seventh surface 15b.

[0019] Among the layers in the second flow-path separator portion 15, on the layer that is opposed to the first flow path 21 of the opposing flow-path portion 13, the spacing plate 3 is provided in such a manner that the flow path extends in the direction from the sixth surface 15a toward the seventh surface 15b. Among the layers in the second flow-path separator portion 15, on the layer that is opposed to the second flow path 22 of the opposing flow-path portion 13, the spacing plate 3 is provided in such a manner that the flow path extends in the direction from the sixth surface 15a toward the eighth surface 15c. Therefore, in the second flow-path separator portion 15, air flows through the flow paths on opposite sides of the partition plate 2 in directions that cross each other. From the seventh surface 15b, air cannot enter the layer connecting to the second flow path 22. From the eighth surface 15c, air cannot enter the layer connecting to the first flow path 21. In the manner as described above, each of the first flow-path separator portion 14 and the second flow-path separator portion 15 separates a supplied-air flow in the first flow path 21 and an exhaust-air flow in the second flow path, which flow parallel to each other in the opposing flow-path portion, into the air flows that flow in directions different from each other.

[0020] FIG. 6 is a perspective view of the layer including the first flow path 21, which is cut away from the heat exchange element 1 according to the first embodiment. FIG. 7 is a perspective view of the layer including the second flow path 22, which is cut away from the heat exchange element 1 according to the first embodiment.

[0021] As illustrated in FIG. 6, the layer including the first flow path 21 is constituted by a rectangular unit member (quadrangular unit member) 31 and first triangular unit members 32 that are joined with tape 7. The rectangular unit member 31 is formed by stacking the rectangle-shaped partition plate 2 and the rectangle-shaped spacing plate 3 on top of each other. The first triangular unit member 32 is formed by stacking the triangle-shaped partition plate 2 and the triangle-shaped spacing plate 3 on top of each other. The partition plate 2 in the rectangular unit member 31 and the partition plates 2 in the first triangular unit members 32 are joined with the tape 7. The tape 7 has the same function as the partition plate 2 and is therefore made from a non-breathable material.

[0022] As illustrated in FIG. 7, the layer including the second flow path 22 is constituted by the rectangular unit member 31 and second triangular unit members 33 that are joined with the tape 7. The rectangular unit member 31 is formed by stacking the rectangle-shaped partition plate 2 and the rectangle-shaped spacing plate 3 on top of each other. The second triangular unit member 33 is formed by stacking the triangle-shaped partition plate 2 and the triangle-shaped spacing plate 3 on top of each other. The partition plate 2 in the rectangular unit member 31 and the partition plates 2 in the second triangular unit members 33 are joined with the tape 7.

[0023] The layer including the first flow path 21 illustrated in FIG. 6 and the layer including the second flow path 22 illustrated in FIG. 7 are stacked so as to form the heat exchange element 1 in FIG. 1. In the heat exchange element 1, a supplied-air flow that has entered from the fourth surface 14b of the first flow-path separator portion 14 toward the layer including the first flow path 21 passes through the third surface 14a, the first surface 13a of the opposing flow-path portion 13, the second surface 13b of the opposing flow-path portion 13, and the sixth surface 15a of the second flow-path separator portion 15 in the order described, and then flows out from the seventh surface 15b (the flow illustrated by the arrow X in FIG. 6).

[0024] In the heat exchange element 1, an exhaust-air flow that has entered from the eighth surface 15c of the second flow-path separator portion 15 toward the layer including the second flow path 22 passes through the sixth surface 15a, the second surface 13b of the opposing flow-path portion 13, the first surface 13a of the opposing flow-path portion 13, and the third surface 14a of the first flow-path separator portion 14 in the order described, and then flows out from the fifth surface 14c (the flow illustrated by the arrow Y in FIG. 7). During the process of passing through the interior of the heat exchange element 1, a supplied-air flow and an exhaust-air flow exchange heat with each other through the partition plates 2. The heat exchange element 1 is what is called an opposing-flow type heat exchange element in which, in the opposing flow-path portion 13, a supplied-air flow and an exhaust-air flow flow in directions different from each other by 180 degrees.

[0025] Next, the manufacturing method of the heat exchange element 1 is described. FIG. 8 is an explanatory diagram of the manufacturing method of the heat exchange element 1 according to the first embodiment. FIG. 8 illustrates how a quadrangular member is cut out from a corrugated roll. First, as illustrated in FIG. 8, a quadrangular member 42 having a quadrangular shape is cut out from a corrugated roll 41 in which the long partition plate 2 and the long spacing plate 3 are joined and which are in the form of a roll. The corrugated roll 41 is a corrugated-board-like member that is formed such that it has a larger area than the finished dimensions. In the corrugated roll 41, the direction in which the peaks of the corrugated shape of the spacing plate 3 extend (the flow-path direction) is defined as a width direction, and the direction perpendicular to the peak extending direction (the flow-path direction) is defined as a longitudinal direction. The corrugated roll 41, for example, is formed with a length of several tens of meters in the longitudinal direction. The quadrangular member 42 is cut out from the corrugated roll 41 in a direction parallel to the flow-path direction, i.e., in the direction parallel to the width direction. Next, the quadrangular member 42 is cut along the line A extending in the direction perpendicular to the flow-path direction so as to obtain the rectangular unit member 31 illustrated in FIGS. 6 and 7.

[0026] FIG. 9 is an explanatory diagram of the manufacturing method of the heat exchange element 1 according to the first embodiment. FIG. 9 illustrates how a first parallelogram member 34 is cut out from the quadrangular member 42. FIG. 10 is an explanatory diagram of the manufacturing method of the heat exchange element 1 according to the first embodiment. FIG. 10 illustrates how a second parallelogram member 35 is cut out from the quadrangular member 42.

[0027] Apart from the step of obtaining the rectangular unit member 31, the quadrangular member 42 is cut along the direction oblique to the flow-path direction of the spacing plate 3 to obtain the first parallelogram member 34 and the second parallelogram member 35. As illustrated in FIG. 9, the first parallelogram member 34 is obtained by cutting the rectangular member 42 along the line B1 and the line B2, which are angled at α° in the counterclockwise direction relative to the flow-path direction. The angle α is an acute angle. As illustrated in FIG. 10, the second parallelogram member 35 is obtained by cutting the rectangular member 42 along the line C1 and the line C2, which are angled at β° in the clockwise direction relative to the flow-path direction. The angle β is an obtuse angle.

[0028] Next, the rectangular unit member 31 and the first parallelogram members 34 are joined to form a first joint member 36. FIG. 11 is a plan view illustrating the state in which the first parallelogram members 34 are joined to the rectangular unit member 31, in the manufacturing method of the heat exchange element 1 according to the first embodiment. As illustrated in FIG. 11, the edges of the rectangular unit member 31, which are perpendicular to the flow-path direction, are caused to oppose the edges of the first parallelogram members 34, which are oblique to the flow-path direction, and then the partition plates 2 are joined to each other with the tape 7. At this point in time, a gap is provided between the rectangular unit member 31 and the first parallelogram member 34.

[0029] Next, the rectangular unit member 31 and the second parallelogram members 35 are joined to form a second joint member 37. FIG. 12 is a plan view illustrating a state in which the second parallelogram members 35 are joined to the rectangular unit member 31, in the manufacturing method of the heat exchange element 1 according to the first embodiment. As illustrated in FIG. 12, the edges of the rectangular unit member 31, which are perpendicular to the flow-path direction, are caused to oppose the edges of the second parallelogram members 35, which are oblique to the flow-path direction, and then the partition plates 2 are joined to each other with the tape 7. At this point in time, a gap is provided between the rectangular unit member 31 and the second parallelogram member 35.

[0030] Next, a plurality of first joint members 36 and a plurality of second joint members 37 are stacked alternately. FIG. 13 is a plan view illustrating a state in which the first joint members 36 and the second joint members 37 are stacked, in the manufacturing method of the heat exchange element 1 according to the first embodiment. As illustrated in FIG. 13, the first joint members 36 and the second joint members 37 are stacked in such a manner that the rectangular unit members 31 are overlaid when viewed in the layer-stacking direction. Therefore, the respective flow-path directions of the rectangular unit members 31 correspond with each other and the flow-path direction of the first parallelogram member 34 is different from that of the second parallelogram member 35. The first joint member 36 and the second joint member 37 are joined with an adhesive applied to the peaks of the corrugated portion of the spacing plate 3. This stacked-layer member is cut along the line D that extends parallel to the flow-path direction of the rectangular unit member 31. The number of lines D may be two or more.

[0031] In this manner, the stacked-layer member illustrated in FIG. 14 is obtained. Next, this stacked-layer member is cut along the line E1 and the line E2 that extend parallel to the flow-path direction of the first parallelogram member 34 and along the line F1 and the line F2 that extend parallel to the flow-path direction of the second parallelogram member 35, thereby obtaining the heat exchange element 1 illustrated in FIG. 1. That is, the first parallelogram member 34 and the second parallelogram member 35 are cut along the line D, the line E1, the line E2, the line F1, and the line F2; therefore, they become the first triangular unit member 32 and the second triangular unit member 33. Further, by cutting the stacked-layer member along the line D, the line E1, the line E2, the line F1, and the line F2, the first flow-path separator portion 14 and the second flow-path separator portion 15 are formed, in each of which the first triangular unit members 32 and the second triangular unit members 33 are stacked. On the side surface of the heat exchange element, the joint section of the opposing flow-path portion 13 and the second flow-path separator portion 15 is sealed with an airtight processed portion 16 so as to prevent air leakage from the side surface.

[0032] As described above, according to the present embodiment, the heat exchange element 1 that includes the opposing flow-path portion 13, and the flow-path separator portions 14 and 15 can be manufactured by cutting the corrugated roll 41, which is a corrugated-board-like large-sized sheet and by joining the cut members with the tape 7. Therefore, it is not necessary for the formation of an opposing flow-path portion to prepare an element frame whose outer periphery consists of a sealing rib and a supporting frame. This makes it unnecessary to manufacture a die for forming the element frame; therefore, the manufacturing costs can be reduced and a wider range of sizes of the heat exchange element 1 can be accommodated.

[0033] In the flow-path separator portions 14 and 15, the fourth surface 14b, the fifth surface 14c, the seventh surface 15b, and the eighth surface 15c are formed parallel to the flow-path direction; therefore, the wall of the air passage can be formed by the corrugated shape of the spacing plate 3. Consequently, a sealing rib and a supporting frame for sealing the air passage are not needed. The time and effort required to manufacture these parts can be saved. This makes it unnecessary to manufacture a die for forming the sealing rib and the supporting frame; therefore, the manufacturing costs can be reduced.

[0034] A gap is formed between the opposing flow-path portion 13 and the flow-path separator portions 14 and 15. Consequently, even if the corrugated shapes of the spacing plates 3 do not perfectly align with each other in the joint sections of the opposing flow-path portion 13 and the flow-path separator portions 14 and 15, the gap functions as a chamber so as to smooth the air flow.

[0035] A plurality of finished heat exchange element 1 can be manufactured by cutting the single stacked-layer member illustrated in FIG. 13; therefore, an improvement in production efficiency can be achieved. Cutting the stacked-layer member can make the edge surface of the heat exchange element 1 less rough. However, if in order to eliminate the cutting step, the stacked-layer member is manufactured such that it can have the same size as a finished heat exchange element, the heat exchange element is more likely to have roughness on its edge surface due to misalignment at the layer stacking step. Therefore, in the first embodiment, an improvement in the external appearance of the heat exchange element 1 can be achieved.

[0036] FIG. 11 illustrates an example in which the first parallelogram member 34 is joined to the left side and the right side of the rectangular unit member 31. However, it is also possible that a first joint member is formed by joining the first parallelogram member 34 to the right side of the rectangular unit member 31 with the tape and by joining the second parallelogram member 35 to the left side of the rectangular unit member 31 with the tape 7. In this case, in FIG. 11, air that passes through the portion of the rectangular unit member 31 is separated obliquely upward relative to the plane of the figure on both the left and right sides of the rectangular unit member 31.

[0037] FIG. 12 illustrates an example in which the second parallelogram member 35 is joined to the left side and the right side of the rectangular unit member 31. However, it is also possible that a second joint member is formed by joining the second parallelogram member 35 to the right side of the rectangular unit member 31 with the tape and by joining the first parallelogram member 34 to the left side of the rectangular unit member 31 with the tape. In this case, in FIG. 12, air that passes through the portion of the rectangular unit member 31 is separated obliquely downward relative to the plane of the figure on both the left and right sides of the rectangular unit member 31.

[0038] It is also possible that a stacked-layer member in which the joint members formed in the manner as described above are stacked alternately is cut to obtain a heat exchange element. Even with the heat exchange element formed in the manner as described above, air can still flow through the flow paths on opposite sides of the partition plate 2 in directions that cross each other in the first flow-path separator portion and the second flow-path separator portion. That is, in the first flow-path separator portion and the second flow-path separator portion, when air can flow through the flow paths on opposite sides of the partition plate 2 in directions that cross each other, then when forming the joint member illustrated as an example in FIGS. 11 and 12, it is not necessary to join identical parallelogram members on both sides of the rectangular unit member 31. The same applies to a second embodiment of the present invention described below.

Second embodiment.

[0039] FIG. 15 is a perspective view of a heat exchange element according to the second embodiment of the present invention. FIG. 16 is a perspective view of the layer including the first flow path, which is cut away from the heat exchange element according to the second embodiment. FIG. 17 is a perspective view of the layer including the second flow path, which is cut away from the heat exchange element according to the second embodiment. Constituent elements identical to those described in the above embodiment are denoted by like reference signs and detailed descriptions thereof will be omitted. In the second embodiment, a first flow-path separator portion 54 and a second flow-path separator portion 55 have a cuboid shape.

[0040] In the first flow-path separator portion 54, the surface that faces the opposite side to the surface that is opposed to the first surface of the opposing flow-path portion 13 is sealed with a gasket 12 in order to prevent leakage of a supplied-air flow and an exhaust-air flow (see the arrow P in FIG. 16 and the arrow Q in FIG. 17). In the first flow-path separator portion 54, the surface that faces the opposite side to the surface that is opposed to the second surface of the opposing flow-path portion 13 is sealed with the gasket 12 in order to prevent leakage of a supplied-air flow and an exhaust-air flow. FIG. 15 illustrates a heat exchange element 51 in a state in which the gaskets 12 have been removed.

[0041] FIG. 18 is a diagram illustrating an example of cutting a stacked-layer member in a manufacturing method of the heat exchange element 51 according to the second embodiment. As illustrated in FIG. 12, the stacked-layer member is cut along a plurality of lines G in the section where the first parallelogram member 34 and the second parallelogram member 35 are overlaid. The heat exchange element 51 with the gasket 12 removed can thereby be obtained. Therefore, the heat exchange element 51 can be manufactured with a reduced number of cutting steps as compared to the first embodiment.

[0042] It is preferable for the first flow-path separator portion 54 and the second flow-path separator portion 55 that the flow-path direction is parallel to the diagonal line of the quadrangular shape when viewed in the layer-stacking direction (in plan view). In the case where the flow-path direction is not parallel to the diagonal line of the quadrangular shape when viewed in the layer-stacking direction, for example in the first flow-path separator portion 54, a fourth surface 54b is more likely to communicate with a fifth surface 54c. If the fourth surface 54b communicates with the fifth surface 54c, a supplied-air flow and an exhaust-air flow are mixed. Further, in the second flow-path separator portion 55, a seventh surface 55b is more likely to communicate with an eighth surface 55c. If the seventh surface 55b communicates with the eighth surface 55c, a supplied-air flow and an exhaust-air flow are mixed. Furthermore, the flow path is more likely to become narrower at its exit section. Therefore, it is preferable that the flow-path direction is parallel to the diagonal line of the quadrangular shape when viewed in the layer-stacking direction.

[0043] The configurations described in the above embodiments are only examples of the content of the present invention. The configurations can be combined with other well-known techniques, and a part of each of the configurations can be omitted or modified without departing from the scope of the present invention.

Reference Signs List

[0044] 1 heat exchange element, 2 partition plate, 3 spacing plate, 7 tape, 12 gasket, 13 opposing flow-path portion, 13a first surface, 13b second surface, 14 first flow-path separator portion, 14a third surface, 14b fourth surface, 14c fifth surface, 15 second flow-path separator portion, 15a sixth surface, 15b seventh surface, 15c eighth surface, 16 airtight processed portion, 21 first flow path, 22 second flow path, 31 rectangular unit member (quadrangular unit member), 32 first triangular unit member, 33 second triangular unit member, 34 first parallelogram member, 35 second parallelogram member, 36 first joint member, 37 second joint member, 41 corrugated roll, 42 quadrangular member, 51 heat exchange element, 54 first flow-path separator portion, 54b fourth surface, 54c fifth surface, 55 second flow-path separator portion.

Claims

1. A heat exchange element comprising: an opposing flow-path portion; a first flow-path separator portion; and a second flow-path separator portion, each of which is formed by alternately stacking a plurality of partition plates and a plurality of spacing plates that have a corrugated shape in cross section, wherein
the opposing flow-path portion has a box shape, in which the spacing plates are disposed in such a manner that peaks of a corrugated shape extend parallel to each other when viewed in a direction in which the partition plates and the spacing plates are stacked and in which one side in a direction in which the peaks of the corrugated shape extend is defined as a first surface and another side is defined as a second surface; and a first flow path, through which air passes from the first surface toward the second surface and a second flow path, through which air passes from the second surface toward the first surface, are formed alternately with the partition plate interposed between the first flow path and the second flow path,
the first flow-path separator portion includes a third surface that is opposed to the first surface, a fourth surface that faces in a direction different from the third surface, and a fifth surface that faces in a direction different from the third surface and the fourth surface; on a layer that is opposed to the first flow path, peaks of a corrugated shape of the spacing plate extend from the third surface toward the fourth surface; and on a layer that is opposed to the second flow path, the peaks of the corrugated shape of the spacing plate extend from the third surface toward the fifth surface,
the second flow-path separator portion includes a sixth surface that is opposed to the second surface, a seventh surface that faces in a direction different from the sixth surface, and an eighth surface that faces in a direction different from the sixth surface and the seventh surface; on a layer that is opposed to the first flow path, peaks of a corrugated shape of the spacing plate extend from the sixth surface toward the seventh surface; and on a layer that is opposed to the second flow path, the peaks of the corrugated shape of the spacing plate extend from the sixth surface toward the eighth surface, and
each of the partition plates of the opposing flow-path portion and each of the partition plates of the first flow-path separator portion are joined with a tape, and each of the partition plates of the opposing flow-path portion and each of the partition plates of the second flow-path separator portion are joined with a tape.

2. The heat exchange element according to claim 1, wherein
a gap is provided between the opposing flow-path portion and the first flow-path separator portion, and
a gap is provided between the opposing flow-path portion and the second flow-path separator portion.

3. A manufacturing method of a heat exchange element, comprising:

a step of cutting out a plurality of quadrangular unit members, each of which has a quadrangular shape in plan view, and a first parallelogram member and a second parallelogram member, each of which has a parallelogram shape in plan view, from a corrugated roll in which a partition plate and a spacing plate having a corrugated shape are layered on top of each other and joined;

a step of forming a first joint member by joining a partition plate of the quadrangular unit member and a partition plate of the first parallelogram member with a tape;

a step of forming a second joint member by joining a partition plate of a quadrangular unit member that is different from the quadrangular unit member joined to the first parallelogram member, and a partition plate of the second parallelogram member with a tape;

a step of forming a stacked-layer member by stacking the first joint member and the second joint member in such a manner that the quadrangular unit members are overlaid; and

a step of cutting the stacked-layer member, wherein

the quadrangular unit member includes two sides that are parallel to a direction in which a corrugated shape of the spacing plate extends and two sides that are perpendicular to the direction in which the corrugated shape of the spacing plate extends,

the first parallelogram member includes two sides that are parallel to a direction in which a corrugated shape of the spacing plate extends and two sides that are angled at an acute angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends,

the second parallelogram member includes two sides that are parallel to a direction in which a corrugated shape of the spacing plate extends and two sides that are angled at an obtuse angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends,

at the step of forming the first joint member, a side of the quadrangular unit member perpendicular to a direction in which peaks of the corrugated shape of the spacing plate extend among sides of the quadrangular unit member and a side of the first parallelogram member angled at an acute angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends among sides of the first parallelogram member are opposed to each other and joined,

at the step of forming the second joint member, a side of the quadrangular unit member perpendicular to the direction in which peaks of the corrugated shape of the spacing plate extend among the sides of the quadrangular unit member and a side of the second parallelogram member angled at an obtuse angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends among sides of the second parallelogram member are opposed to each other and joined, and

at the step of cutting the stacked-layer member, the stacked-layer member is cut along a direction parallel to the direction in which the corrugated shape of the spacing plate in the quadrangular unit member extends.

4. The manufacturing method of a heat exchange element according to claim 3, wherein
at the step of forming the first joint member, a gap is provided between the side of the quadrangular unit member perpendicular to the direction in which the peaks of the corrugated shape of the spacing plate extend among the sides of the quadrangular unit member and the side of the first parallelogram member angled at an acute angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends among the sides of the first parallelogram member, and
at the step of forming the second joint member, a gap is provided between the side of the quadrangular unit member perpendicular to the direction in which the peaks of the corrugated shape of the spacing plate extend among the sides of the quadrangular unit member and the side of the second parallelogram member angled at an obtuse angle in a clockwise direction relative to the direction in which the corrugated shape of the spacing plate extends among the sides of the second parallelogram member.

5. The manufacturing method of a heat exchange element according to claim 3, wherein at the step of cutting the stacked-layer member, a section where the first parallelogram member is stacked and a section where the second parallelogram member is stacked are formed into a triangular prism shape, and a surface of the triangular prism shape, which is not opposed to the quadrangular unit member, is parallel to the direction in which the peaks of the spacing plate in the triangular prism-shaped section extend.

6. The manufacturing method of a heat exchange element according to claim 3, wherein at the step of cutting the staked-layer member, a section where the first parallelogram member is stacked and a section where the second parallelogram member is stacked are formed into a cuboid shape, and the peaks of the spacing plate in the cuboid-shaped section extend in a direction parallel to a diagonal line of the cuboid-shaped section in plan view.

7. The manufacturing method of a heat exchange element according to claim 6, further comprising a step of sealing, with a gasket, a surface of the cuboid-shaped section, which faces in a direction opposite to a surface that is opposed to the quadrangular unit member.

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