This nonprovisional application is based on Japanese Patent Application No. 2025-028838 filed on February 26, 2025 with the Japan Patent Office, the entire contents of which are hereby incorporated by reference.

The present disclosure relates to a heat exchanger, an outdoor unit, and an air conditioner.

Japanese Patent Laying-Open No. 2020-060353 discloses an air heat exchanger unit composed of an upper heat exchanger and a lower heat exchanger stacked in the vertical direction. The upper heat exchanger and the lower heat exchanger are coupled together by a bracket.

Japanese Patent Laying-Open No. 2020-060353 describes that the bracket and the lower or upper heat exchanger are engaged with each other so as to restrict relative movement in a direction intersecting the vertical direction, that is, a direction in which a tube extends and a direction in which a bent portion has its thickness. The bracket has first and second hanging portions with their inner surfaces in contact with a surface of a panel of the lower heat exchanger, and the bracket has first and second erect portions with their inner surfaces in contact with a surface of a panel of the upper heat exchanger.

When the air heat exchanger unit disclosed in Japanese Patent Laying-Open No. 2020-060353 has a dimensional difference between the lower heat exchanger and the upper heat exchanger, it is difficult to appropriately couple the upper heat exchanger and the lower heat exchanger together by the bracket.

A main object of the present disclosure is to provide a heat exchanger allowing a lower heat exchanger and an upper heat exchanger to be appropriately coupled together even when there is a dimensional difference between the lower heat exchanger and the upper heat exchanger.

The presently disclosed heat exchanger comprises a lower heat exchanger and an upper heat exchanger aligned in a vertical direction, and a positioning member to position the upper heat exchanger with respect to the lower heat exchanger. The lower heat exchanger and the upper heat exchanger each include a heat transfer tube extending in a direction intersecting the vertical direction. The positioning member includes a first member and a second member. The first member includes a fixed portion fixed to one end of the lower heat exchanger in the direction in which the heat transfer tube extends and an engagement portion engaged with one end of the upper heat exchanger in the direction in which the heat transfer tube extends. The second member has a fixed portion fixed to the other end of the lower heat exchanger in the direction in which the heat transfer tube extends and a connection portion connected to a corner of the other end of the upper heat exchanger in the direction in which the heat transfer tube extends.

The foregoing and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.

• Fig. 1 is a perspective view of an example of a heat exchanger and an outdoor unit according to an embodiment.
• Fig. 2 is a partially enlarged perspective view for illustrating a first member of a positioning member shown in Fig. 1.
• Fig. 3 is a partially enlarged perspective view for illustrating a second member of the positioning member shown in Fig. 1.
• Fig. 4 is a partially enlarged perspective view for illustrating a lower heat exchanger and the positioning member shown in Fig. 1.
• Fig. 5 is an exploded enlarged perspective view for illustrating the first member, the second member, and a third member of the positioning member shown in Fig. 1.
• Fig. 6 is a plan view for illustrating the first, second and third members of the positioning member shown in Fig. 1.
• Fig. 7 is a partially enlarged plan view of the second and third members of the Fig. 6 positioning member when the third member is in a first position with respect to the first and second members.
• Fig. 8 is a partially enlarged plan view of the second and third members of the Fig. 6 positioning member when the third member is in a second position with respect to the first and second members.
• Fig. 9 is a partially enlarged cross section illustrating a relationship between the lower heat exchanger, the upper heat exchanger and the third member, that can be implemented when the third member is in the first position with respect to the first and second members.
• Fig. 10 is a partially enlarged cross section illustrating a relationship between the lower heat exchanger, the upper heat exchanger and the third member, that can be implemented when the third member is in the second position with respect to the first and second members.
• Fig. 11 is a partially enlarged perspective view of a first variation of a heat exchanger according to an embodiment.
• Fig. 12 is a partially enlarged perspective view of a second variation of a heat exchanger according to an embodiment.
• Fig. 13 is a partially enlarged perspective view of a third variation of a heat exchanger according to an embodiment.

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following description, identical or equivalent components are identically denoted and will not be described repeatedly.

A heat exchanger according to an embodiment of the present disclosure acts as at least one of a condenser and an evaporator in a refrigerant circuit that an air conditioner according to an embodiment of the present disclosure comprises. The air conditioner according to the present embodiment comprises an outdoor unit including an outdoor heat exchanger and an indoor unit including an indoor heat exchanger. The heat exchanger according to the present embodiment is, for example, an outdoor heat exchanger accommodated in an outdoor unit of an air conditioner. The heat exchanger according to the present embodiment is accommodated in a housing of an outdoor unit.

With reference to Figs. 1 to 5, a heat exchanger 101 and an outdoor unit 200 will be described as an example of a heat exchanger and an outdoor unit according to an embodiment of the present disclosure. Fig. 1 is a perspective view of heat exchanger 101 and outdoor unit 200. Fig. 2 is a partially enlarged perspective view of a region II in Fig. 1 for illustrating a first member of a positioning member shown in Fig. 1. Fig. 3 is a partially enlarged perspective view for illustrating a second member of the positioning member shown in Fig. 1. Fig. 4 is a partially enlarged perspective view for illustrating a lower heat exchanger and the positioning member shown in Fig. 1. Fig. 4 does not show an upper heat exchanger 2. Fig. 5 is an exploded enlarged perspective view for illustrating a first member, a second member, and a third member of the positioning member shown in Fig. 1. Fig. 5 does not show any member other than a positioning member 3. For the sake of illustration, each figure indicates a vertical direction VDR, a first direction DR1 intersecting vertical direction VDR, and a second direction DR2 intersecting both vertical direction VDR and first direction DR1. First direction DR1 and second direction DR2 are, for example, horizontal directions.

As shown in Fig. 1, heat exchanger 101 comprises lower heat exchanger 1, upper heat exchanger 2, and positioning member 3. Heat exchanger 101 is, for example, an outdoor heat exchanger accommodated in outdoor unit 200. Outdoor unit 200 comprises heat exchanger 101 and a housing 120 that accommodates heat exchanger 101. Outdoor unit 200 has lower heat exchanger 1 fixed to housing 120. Upper heat exchanger 2 is positioned with respect to lower heat exchanger 1 by positioning member 3. Positioning member 3 is a member for positioning upper heat exchanger 2 with respect to lower heat exchanger 1. For heat exchanger 101, an allowable range is predetermined for a dimensional difference between lower heat exchanger 1 and upper heat exchanger 2. Positioning member 3 can position upper heat exchanger 2 with respect to lower heat exchanger 1 when lower heat exchanger 1 and upper heat exchanger 2 have a dimensional difference within the allowable range.

As shown in Fig. 1, lower heat exchanger 1 and upper heat exchanger 2 are aligned in vertical direction VDR. Lower heat exchanger 1 and upper heat exchanger 2 each have at least one heat transfer tube. Lower heat exchanger 1 has a first heat exchange unit 10, a first end 11, and a second end 12. Upper heat exchanger 2 has a second heat exchange unit 20, a third end 21, and a fourth end 22.

First heat exchange unit 10 and second heat exchange unit 20 are each provided so that refrigerant flowing through the heat transfer tube and a heat medium such as air flowing around the heat transfer tube exchange heat. First heat exchange unit 10 and second heat exchange unit 20 each include at least a portion of the heat transfer tube and a fin connected to at least the portion of the heat transfer tube, for example. The heat transfer tube may be a round tube or a flat tube. First heat exchange unit 10 and second heat exchange unit 20 are each provided with a ventilation air passage extending in a direction intersecting a direction in which the heat transfer tube extends. First heat exchange unit 10 and second heat exchange unit 20 may each include the heat transfer tube and the fin in any number set as desired. First heat exchange unit 10 and second heat exchange unit 20 may each include the heat transfer tube in any number of columns set as desired and any number of stages set as desired.

Lower heat exchanger 1 and upper heat exchanger 2 may each have heat transfer tubes connected in series or in parallel.

First heat exchange unit 10 and second heat exchange unit 20 each include a U-shaped portion having a U-shape as seen in vertical direction VDR, for example. First heat exchange unit 10 and second heat exchange unit 20 each have the heat transfer tube bent in the form of the letter U, for example. The U-shaped portion of first heat exchange unit 10 includes a first portion 10A and a second portion 10B facing each other in first direction DR1 intersecting vertical direction VDR, and a third portion 10C bridging first portion 10A and second portion 10B. The U-shaped portion of first heat exchange unit 10 further includes a plurality of bent portions. The plurality of bent portions include a bent portion connecting first portion 10A and third portion 10C together and a bent portion connecting second portion 10B and third portion 10C together. The U-shaped portion of second heat exchange unit 20 includes a first portion 20A and a second portion 20B facing each other in first direction DR1 intersecting vertical direction VDR, and a third portion 20C bridging first portion 20A and second portion 20B. The U-shaped portion of second heat exchange unit 20 further includes a plurality of bent portions. The plurality of bent portions include a bent portion connecting first portion 20A and third portion 20C together and a bent portion connecting second portion 20B and third portion 20C together.

First and second portions 10A and 10B of first heat exchange unit 10 and first and second portions 20A and 20B of second heat exchange unit 20 extend in second direction DR2. First and second portions 10A and 10B of first heat exchange unit 10 and first and second portions 20A and 20B of second heat exchange unit 20 each have the heat transfer tube extending in second direction DR2. First and second portions 10A and 10B of first heat exchange unit 10 and first and second portions 20A and 20B of second heat exchange unit 20 are each provided with a ventilation air passage extending in first direction DR1.

Third portion 10C of first heat exchange unit 10 and third portion 20C of second heat exchange unit 20 extend in first direction DR1. Third portion 10C of first heat exchange unit 10 and third portion 20C of second heat exchange unit 20 each have the heat transfer tube extending in first direction DR1. Third portion 10C of first heat exchange unit 10 and third portion 20C of second heat exchange unit 20 are each provided with a ventilation air passage extending in second direction DR2.

When first heat exchange unit 10 is seen in vertical direction VDR, first and second portions 10A and 10B each form a right angle with third portion 10C, for example. When first heat exchange unit 10 is seen in vertical direction VDR, first and second portions 10A and 10B may each form any angle with third portion 10C, and may form an obtuse angle.

Second heat exchange unit 20 has first portion 20A, second portion 20B, and third portion 20C on first portion 10A, second portion 10B, and third portion 10C, respectively, of first heat exchange unit 10. First portion 20A, second portion 20B, and third portion 20C of second heat exchange unit 20 at least partially overlap first portion 10A, second portion 10B, and third portion 10C, respectively, of first heat exchange unit 10 in vertical direction VDR. First portion 20A, second portion 20B, and third portion 20C of second heat exchange unit 20 may not have a portion overlapping first portion 10A, second portion 10B, and third portion 10C, respectively, of first heat exchange unit 10 in vertical direction VDR. From a different viewpoint, a dimensional difference in a direction intersecting vertical direction VDR is allowed between lower heat exchanger 1 and upper heat exchanger 2 within a predetermined range.

As shown in Fig. 1, first end 11 and second end 12 are connected to opposite ends of heat exchange unit 10 in the direction in which the heat transfer tube extends. First end 11 is connected to first portion 10A of first heat exchange unit 10. Second end 12 is connected to second portion 10B of first heat exchange unit 10. Third end 21 and fourth end 22 are connected to opposite ends of heat exchange unit 20 in the direction in which the heat transfer tube extends. Third end 21 is connected to first portion 20A of second heat exchange unit 20. Fourth end 22 is connected to second portion 20B of second heat exchange unit 20. First end 11, second end 12, third end 21, and fourth end 22 may each further include an end of the heat transfer tube or a folded portion of the heat transfer tube. First end 11, second end 12, third end 21, and fourth end 22 may each have a header.

Lower heat exchanger 1 and upper heat exchanger 2 may each have a plurality of columns of heat exchange units aligned in a direction orthogonal to the direction in which the heat transfer tube extends. Lower heat exchanger 1 may have a plurality of first ends 11 each connected to one end of one of the plurality of columns of first heat exchange units 10. Upper heat exchanger 2 may have a plurality of third ends 21 each connected to one end of one of the plurality of columns of second heat exchange units 20.

As shown in Fig. 1, positioning member 3 of heat exchanger 101 comprises a first member 4, a second member 5, and a third member 6. First member 4 connects first portion 10A of lower heat exchanger 1 and first portion 20A of upper heat exchanger 2 together. First member 4 has a portion located between first portion 10A of lower heat exchanger 1 and first portion 20A of upper heat exchanger 2. Second member 5 connects second portion 10B of lower heat exchanger 1 and second portion 20B of upper heat exchanger 2 together. Second member 5 has a portion located between second portion 10B of lower heat exchanger 1 and second portion 20B of upper heat exchanger 2. Third member 6 connects third portion 10C of lower heat exchanger 1 and third portion 20C of upper heat exchanger 2 together. Third member 6 has a portion located between third portion 10C of lower heat exchanger 1 and third portion 20C of upper heat exchanger 2.

As shown in Fig. 2, first member 4 includes a first fixed portion 41 and an engagement portion 42. First fixed portion 41 is fixed to one end of lower heat exchanger 1 in the direction in which the heat transfer tube extends. First fixed portion 41 is fixed for example to first end 11 of lower heat exchanger 1. First fixed portion 41 for example has a plate-shaped portion extending in both vertical direction VDR and second direction DR2. First fixed portion 41 may be fixed to lower heat exchanger 1 by any fixing means. First fixed portion 41 is fixed to first end 11 for example with a first fixing member 45. First fixing member 45 is, for example, a screw. First fixing member 45 is, for example, a male screw. First fixing member 45 may be a female screw.

Engagement portion 42 is provided to engage with one end of upper heat exchanger 2 in the direction in which the heat transfer tube extends. Engagement portion 42 is provided to engage with third end 21 of upper heat exchanger 2, for example. Engagement portion 42 and first fixed portion 41 are provided in one piece, for example. Engagement portion 42 is provided for example as a through hole penetrating first member 4 in vertical direction VDR.

As shown in Fig. 2, first end 11 and third end 21 each for example have a plate portion extending in vertical direction VDR and second direction DR2. The plate portion is larger in rigidity than the fin of the heat exchange unit. The plate portion is formed of material including metal for example. The plate portion of each of first end 11 and third end 21 is dimensionally (or in thickness) smaller in first direction DR1 than in vertical direction VDR and second direction DR2.

The plate portion of first end 11 projects from first heat exchange unit 10 in second direction DR2. The plate portion of third end 21 projects from second heat exchange unit 20 in second direction DR2. The plate portion of third end 21 has a projection 23 projecting downwardly of second heat exchange unit 20. Engagement portion 42 of first member 4 is provided so as to engage with projection 23. Projection 23 may be included in second heat exchange unit 20 of upper heat exchanger 2.

Engagement portion 42 of first member 4 and third end 21 of upper heat exchanger 2 may have any structure insofar as they can engage with each other. One of engagement portion 42 of first member 4 and third end 21 of upper heat exchanger 2 may be provided with a recess that opens in vertical direction VDR, and the other of engagement portion 42 of first member 4 and third end 21 of upper heat exchanger 2 may be provided with a projection that is fitted in the recess. Engagement portion 42 may be provided as a recess that only opens at an upper surface of first member 4. Furthermore, engagement portion 42 may be provided as a projection projecting upward from the upper surface of first member 4. In that case, third end 21 of upper heat exchanger 2 may be provided with a recess into which the projection is fitted.

As shown in Fig. 2, first member 4 further includes an intermediate portion 43 located between first heat exchange unit 10 of lower heat exchanger 1 and second heat exchange unit 20 of upper heat exchanger 2 in vertical direction VDR. First fixed portion 41 extends downward from one end of intermediate portion 43 as seen in second direction DR2, for example. First fixed portion 41 has an upper end connected for example to one end of intermediate portion 43 in second direction DR2. Engagement portion 42 is provided for example at one end of intermediate portion 43 in second direction DR2.

Preferably, first member 4 is provided with a plurality of through holes penetrating intermediate portion 43 in vertical direction VDR. The plurality of through holes can act as a path to pass liquid such as condensation. While the plurality of through holes may each have an opening in any shape, it is circular for example. The plurality of through holes for example include a plurality of first through holes 43H1 and a plurality of second through holes 43H2. The plurality of first through holes 43H1 each have an opening larger in area than the plurality of second through holes 43H2 each do. The plurality of first through holes 43H1 are spaced from one another in second direction DR2. The plurality of first through holes 43H1 each have a center for example on a center line of intermediate portion 43 extending in first direction DR1. The plurality of second through holes 43H2 are spaced from one another around the plurality of first through holes 43H1. The plurality of second through holes 43H2 are spaced from one another in first direction DR1 and second direction DR2, for example.

Preferably, first member 4 further includes a pair of downward projecting portions 44A and 44B. The pair of downward projecting portions 44A and 44B project downward from opposite ends of intermediate portion 43 in first direction DR1 (or a widthwise direction) intersecting both vertical direction VDR and the direction in which the heat transfer tube extends. Downward projecting portion 44A is for example contiguous to an upper end of first fixed portion 41. First fixed portion 41 and downward projecting portion 44A for example have an L-shape. The pair of downward projecting portions 44A and 44B is provided so as to sandwich an upper end portion of first portion 10A of first heat exchange unit 10.

Preferably, first member 4 is provided with a plurality of through holes 44H penetrating each of the paired downward projecting portions 44A and 44B in the widthwise direction. The plurality of through holes 44H can act as a path to pass a heat medium such as air. Preferably, the plurality of through holes 44H of downward projecting portion 44A are provided so as to at least partially overlap the plurality of through holes 44H of downward projecting portion 44B in the widthwise direction. More preferably, the plurality of through holes 44H of downward projecting portion 44A are provided so as to entirely overlap the plurality of through holes 44H of downward projecting portion 44B in the widthwise direction. While the plurality of through holes 44H may each have an opening in any shape, it is circular for example. The plurality of through holes 44H are spaced from one another in second direction DR2.

As shown in Fig. 2, when lower heat exchanger 1 has a plurality of columns of first heat exchange units 10 and a plurality of first ends 11, and upper heat exchanger 2 has a plurality of columns of second heat exchange units 20 and a plurality of third ends 21, first fixed portion 41 of first member 4 is fixed to one of the plurality of first ends 11 of first heat exchange unit 10 that is located outermost in the widthwise direction. In that case, engagement portion 42 of first member 4 is provided so as to engage for example with projection 23 included in one of the plurality of third ends 21 of upper heat exchanger 2 that is located outermost in the widthwise direction.

As shown in Fig. 3, second member 5 includes a second fixed portion 51 and a connection portion 52. Second fixed portion 51 is fixed to the other end of lower heat exchanger 1 in the direction in which the heat transfer tube extends (on a side opposite to one end of lower heat exchanger 1 to which first fixed portion 41 is fixed.). Second fixed portion 51 is fixed for example to second end 12 of lower heat exchanger 1.

Second fixed portion 51 for example has a plate-shaped portion extending in both vertical direction VDR and second direction DR2. Second fixed portion 51 may be fixed to lower heat exchanger 1 by any fixing means. Second fixed portion 51 is fixed to second end 12 for example by a second fixing member 55. Second fixing member 55 is, for example, a screw.

Connection portion 52 can be connected to a corner of the other end of upper heat exchanger 2 in the direction in which the heat transfer tube extends (on a side opposite to one end of upper heat exchanger 2 with which engagement portion 42 is engaged). Connection portion 52 can be connected for example to a corner of fourth end 22 of upper heat exchanger 2. Connection portion 52 and second fixed portion 51 are provided in one piece, for example. Second fixed portion 51 and connection portion 52 are provided for example as a T-shaped member together with a downward projecting portion 54A described hereinafter.

As shown in Fig. 3, second end 12 and fourth end 22 each have a corner for example. The corner is larger in rigidity than the fin of the heat exchange unit. The corner is formed of material including metal for example.

Second end 12 has a third surface 12A and a fourth surface 12B. Third surface 12A faces away from second portion 10B in the direction in which the heat transfer tube extends in second portion 10B of first heat exchange unit 10. Third surface 12A extends for example in vertical direction VDR and first direction DR1. Fourth surface 12B extends in the direction in which the heat transfer tube extends in second portion 10B of first heat exchange unit 10. Fourth surface 12B extends for example in vertical direction VDR and second direction DR2. Fourth surface 12B is connected to third surface 12A.

Fourth end 22 has a first surface 22A and a second surface 22B. First surface 22A faces away from second portion 20B in the direction in which the heat transfer tube extends in second portion 20B of second heat exchange unit 20. First surface 22A extends for example in vertical direction VDR and first direction DR1. Second surface 22B extends in the direction in which the heat transfer tube extends in second portion 20B of second heat exchange unit 20. Second surface 22B extends for example in vertical direction VDR and second direction DR2. Second surface 22B is connected to first surface 22A.

Preferably, connection portion 52 of second member 5 includes a first connection portion 52A that can come into contact with first surface 22A of fourth end 22, and a second connection portion 52B connectable to second surface 22B of fourth end 22. First connection portion 52A extends for example in first direction DR1 from one end of second connection portion 52B in second direction DR2.

Preferably, second fixed portion 51 of second member 5 includes a third connection portion 51A that can come into contact with third surface 12A of second end 12, and a fourth connection portion 51B connectable to fourth surface 12B of second end 12. Third connection portion 51A extends for example in first direction DR1 from one end of fourth connection portion 51B in second direction DR2.

As shown in Fig. 3, second member 5 further includes an intermediate portion 53 located between first heat exchange unit 10 of lower heat exchanger 1 and second heat exchange unit 20 of upper heat exchanger 2 in vertical direction VDR. Second fixed portion 51 extends downward from one end of intermediate portion 53 in second direction DR2, for example. Second fixed portion 51 has an upper end connected for example to one end of intermediate portion 53 in second direction DR2. Connection portion 52 is provided for example at one end of intermediate portion 53 in second direction DR2.

Preferably, second member 5 is provided with a plurality of through holes 53H1 and 53H2 penetrating intermediate portion 53 in vertical direction VDR. The plurality of through holes 53H1 and 53H2 provided through intermediate portion 53 may be similar in configuration to the plurality of through holes 43H1 and 43H2 provided through intermediate portion 43.

Preferably, second member 5 further includes a pair of downward projecting portions 54A and 54B. The paired downward projecting portions 54A and 54B project downward from opposite ends of intermediate portion 53 in first direction DR1 (or the widthwise direction) intersecting both vertical direction VDR and the direction in which the heat transfer tube extends. Downward projecting portion 54A is for example contiguous to an upper end of second fixed portion 51 and a lower end of connection portion 52. For example, downward projecting portion 54A is contiguous to second fixed portion 51 and connection portion 52 so as to form a T-shape. The pair of downward projecting portions 54A and 54B is provided so as to sandwich an upper end portion of second portion 10B of first heat exchange unit 10.

Preferably, second member 5 is provided with a plurality of through holes 54H penetrating each of the paired downward projecting portions 54A and 54B in the widthwise direction. The plurality of through holes 54H may be similar in configuration to the plurality of through holes 44H.

As shown in Fig. 4, second fixed portion 51 of second member 5 is located opposite to first fixed portion 41 of first member 4 in the direction in which the heat transfer tube extends. Connection portion 52 of second member 5 is located opposite to engagement portion 42 of first member 4 in the direction in which the heat transfer tube extends. Second fixed portion 51 is located for example opposite to first fixed portion 41 in first direction DR1. Connection portion 52 is located for example opposite to engagement portion 42 of first member 4 in first direction DR1. First fixed portion 41 and second fixed portion 51 for example face each other in first direction DR1 with first portion 10A and second portion 10B interposed therebetween. Engagement portion 42 and connection portion 52 for example face each other in first direction DR1 with first portion 10A and second portion 10B interposed therebetween.

As shown in Fig. 4, third member 6 includes an intermediate portion 63, a downward projecting portion 64, and an upward projecting portion 65. Intermediate portion 63 is located between lower heat exchanger 1 and upper heat exchanger 2 in vertical direction VDR. Intermediate portion 63 is located between third portion 10C of lower heat exchanger 1 and third portion 20C of upper heat exchanger 2 (see Fig. 1) in vertical direction VDR. Downward projecting portion 64 projects downward from one end of intermediate portion 63 in the widthwise direction intersecting both vertical direction VDR and the direction in which the heat transfer tube extends. Downward projecting portion 64 projects downward from one end of intermediate portion 63 in second direction DR2, for example. Upward projecting portion 65 projects upward from the other end of intermediate portion 63 in the widthwise direction. Upward projecting portion 65 projects upward from the other end of intermediate portion 63 in second direction DR2, for example. Downward projecting portion 64 is located for example inwardly of the U-shaped portion of lower heat exchanger 1. Upward projecting portion 65 is located for example outwardly of the U-shaped portion of lower heat exchanger 1.

Preferably, third member 6 is provided with a plurality of through holes 63H1 and 63H2 penetrating intermediate portion 63 in vertical direction VDR. The plurality of through holes 63H1 and 63H2 provided through intermediate portion 63 may be similar in configuration to the plurality of through holes 43H1 and 43H2 provided through intermediate portion 43.

Preferably, third member 6 is provided with a plurality of through holes 64H penetrating downward projecting portion 64 in the widthwise direction. Preferably, third member 6 is provided with a plurality of through holes 65H penetrating upward projecting portion 65 in the widthwise direction. The plurality of through holes 64H and 65H may be similar in configuration to the plurality of through holes 44H.

As shown in Fig. 5, first member 4, second member 5, and third member 6 are distinct members for example. First member 4 is connected to third member 6. Second member 5 is connected to first member 4 via third member 6.

As shown in Fig. 5, third member 6 further includes a plurality of fixing members 7 and 8. Fixing member 7 is for fixing third member 6 to first member 4. Fixing member 8 is for fixing third member 6 to second member 5. Preferably, the plurality of fixing members 7 and 8 are switchable between a fixing state in which third member 6 is fixed to first member 4 and second member 5, and a non-fixing state in which third member 6 is movable relative to first member 4 and second member 5. The plurality of fixing members 7 and 8 are, for example, screws. The plurality of fixing members 7 and 8 may be other fixing means such as a clamp.

Third member 6 is fixed to first member 4 and second member 5 at a position, which is changeable in the widthwise direction of third member 6. Third member 6 is fixed to first member 4 and second member 5 at a position, which is changeable for example in the widthwise direction of third member 6, or second direction DR2. Preferably, third member 6 is movable relative to first member 4 and second member 5 in second direction DR2. For example, third member 6 is movable between a first position and a second position relative to first member 4 and second member 5. Third member 6 in the first position is maximally moved to one side in the widthwise direction with respect to first member 4 and second member 5. Third member 6 in the second position is maximally moved to the other side in the widthwise direction with respect to first member 4 and second member 5.

Fig. 6 is a plan view of positioning member 3 when third member 6 is in an intermediate position between the first position and the second position with respect to first member 4 and second member 5. Fig. 7 is a partially enlarged plan view of second member 5 and third member 6 when third member 6 is in the first position with respect to first member 4 and second member 5. Fig. 8 is a partially enlarged plan view of second member 5 and third member 6 when third member 6 is in the second position with respect to first member 4 and second member 5.

As shown in Fig. 6, first member 4 is provided with a first recess 47 through which fixing member 7 is passed. First recess 47 for example has an internally threaded portion to engage with an externally threaded portion of fixing member 7. First recess 47 is provided for example as a through hole. First recess 47 may be provided as a bottomed trench having an internally threaded portion. First recess 47 may be provided as a through hole without any internally threaded portion. For the latter, fixing member 7 with an externally threaded portion and an internally threaded portion suffices. Third member 6 is provided with a third through hole 67A through which fixing member 7 is passed. Third through hole 67A has an opening with a width in the widthwise direction of third member 6 larger than that of an opening of first recess 47 in the widthwise direction of third member 6. Third through hole 67A has the opening with a width in second direction DR2 larger than that of the opening of first recess 47 in second direction DR2. First member 4 is further provided with a second recess 48. Third member 6 includes a first tab 68A movable inside second recess 48 of first member 4 in the widthwise direction of third member 6. Second recess 48 has an opening with a width in the widthwise direction of third member 6 larger than a length of first tab 68A in the widthwise direction. Second recess 48 has the opening with a width in second direction DR2 larger than a length of first tab 68A in second direction DR2. Second recess 48 has the opening with a width in first direction DR1 larger than a width of first tab 68A in first direction DR1.

As shown in Fig. 6, a portion of third member 6 connected to first member 4 is axisymmetrical to a portion of third member 6 connected to second member 5, for example.

As shown in Figs. 7 and 8, second member 5 is provided with a first recess 57 through which fixing member 8 is passed. First recess 57 may be similar in configuration to first recess 47. First recess 57 for example has an internally threaded portion to engage with an externally threaded portion of fixing member 8. First recess 57 is provided as a through hole, for example. First recess 57 may be provided as a bottomed trench having an internally threaded portion. First recess 57 may be provided as a through hole without any internally threaded portion. For the latter, fixing member 8 with an externally threaded portion and an internally threaded portion suffices. Third member 6 is provided with a fourth through hole 67B through which fixing member 8 is passed. Fourth through hole 67B has an opening with a width W4 in the widthwise direction of third member 6 (see Fig. 8) larger than a width W3 of an opening of first recess 57 in the widthwise direction of third member 6 (see Fig. 8). Fourth through hole 67B has the opening with a width in second direction DR2 larger than that of the opening of first recess 57 in second direction DR2. Second member 5 is further provided with a second recess 58. Third member 6 includes a second tab 68B movable inside second recess 58 of first member 4 in the widthwise direction of third member 6. Second recess 58 has an opening with a width W2 in the widthwise direction of third member 6 (see Fig. 7) larger than a length W1 of second tab 68B in the widthwise direction (see Fig. 7). Second recess 58 has the opening with a width in second direction DR2 larger than a length of second tab 68B in second direction DR2. Second recess 58 has the opening with a width in first direction DR1 larger than that of second tab 68B in first direction DR1.

Third member 6 has first tab 68A located outwardly of third through hole 67A. Third member 6 has second tab 68B located outwardly of fourth through hole 67B. First tab 68A and second tab 68B face each other with third through hole 67A and fourth through hole 67B interposed therebetween. First tab 68A and third through hole 67A are for example axisymmetrical to fourth through hole 67B and second tab 68B.

A difference between the width W2 of the opening of second recess 58 in the widthwise direction of third member 6 and the length W1 of second tab 68B in the widthwise direction, i.e., W2 - W1, and a difference between the width W4 of the opening of fourth through hole 67B in the widthwise direction of third member 6 and the width W3 of the opening of first recess 57 in the widthwise direction of third member 6, i.e., W4 - W3, are set based on an allowable range for a dimensional difference between lower heat exchanger 1 and upper heat exchanger 2. The difference W2 - W1 may be equal to a maximum allowable value for the dimensional difference between lower heat exchanger 1 and upper heat exchanger 2. In that case, a difference W4 - W3 equal to or larger than the maximum allowable value for the dimensional difference between lower heat exchanger 1 and upper heat exchanger 2, suffices. The difference W4 - W3 may be equal to the maximum allowable value, and the difference W2 - W1 may be equal to or larger than the maximum allowable value.

In the first position shown in Fig. 7, second tab 68B for example comes into contact with one end of second recess 58 located on a side opposite to second fixed portion 51 in second direction DR2. In the first position, fixing member 8 passed through fourth through hole 67B and first recess 57 for example comes into contact with the other end of fourth through hole 67B located on a side opposite to upward projecting portion 65 in second direction DR2.

Similarly, when third member 6 is in the first position, first tab 68A for example comes into contact with one end of second recess 48 located on a side opposite to the first fixed portion 41 in second direction DR2. When third member 6 is in the first position, fixing member 7 passed through third through hole 67A and first recess 47 for example comes into contact with the other end of third through hole 67A located on a side opposite to upward projecting portion 65 in second direction DR2.

In the second position shown in Fig. 8, second tab 68B for example comes into contact with the other end of second recess 58 located closer to second fixed portion 51 in second direction DR2. In the second position, fixing member 8 passed through fourth through hole 67B and first recess 57 for example comes into contact with one end of fourth through hole 67B located closer to upward projecting portion 65 in second direction DR2.

Similarly, when third member 6 is in the second position, first tab 68A for example comes into contact with the other end of second recess 48 located closer to the first fixed portion 41 in second direction DR2. When third member 6 is in the second position, fixing member 7 passed through third through hole 67A and first recess 47 for example comes into contact with one end of third through hole 67A located closer to upward projecting portion 65 in second direction DR2.

Hereinafter, a method for manufacturing heat exchanger 101 will be described. Firstly, lower heat exchanger 1 is fixed to housing 120 (see Fig. 1). Secondly, first member 4 or second member 5 is fixed to lower heat exchanger 1. For example, second fixed portion 51 of second member 5 is initially fixed to second end 12 of lower heat exchanger 1, and thereafter, first fixed portion 41 of first member 4 is fixed to first end 11 of lower heat exchanger 1. Note that first fixed portion 41 of first member 4 may initially be fixed to first end 11 of lower heat exchanger 1, and thereafter, second fixed portion 51 of second member 5 may be fixed to second end 12 of lower heat exchanger 1.

Thirdly, third member 6 is provisionally fastened to first and second members 4 and 5 fixed to lower heat exchanger 1. Preferably, as shown in Fig. 7, third member 6 is provisionally fastened to first member 4 and second member 5 in the first position. Preferably, third member 6 is provisionally fastened while third member 6 has downward projecting portion 64 in contact with first heat exchange unit 10 of lower heat exchanger 1 (see Fig. 9).

Fourthly, upper heat exchanger 2 is disposed on positioning member 3. A corner of fourth end 22 of upper heat exchanger 2 is connected to connection portion 52 of second member 5, and projection 23 of third end 21 of upper heat exchanger 2 is engaged with engagement portion 42 of first member 4. Thus, upper heat exchanger 2 is positioned with respect to lower heat exchanger 1 in first direction DR1. As shown in Fig. 9, there can be implemented a state in which third portion 20C of second heat exchange unit 20 of upper heat exchanger 2 is spaced from upward projecting portion 65 of third member 6 in second direction DR2.

Fifthly, third member 6 is moved relative to first member 4 and second member 5 to implement a state in which third member 6 has upward projecting portion 65 in contact with second heat exchange unit 20 of upper heat exchanger 2, as shown in Fig. 10. In this state, third member 6 is fixed to first member 4 and second member 5. Upper heat exchanger 2 is positioned with respect to lower heat exchanger 1 in second direction DR2 while being sandwiched between upward projecting portion 65 of third member 6, and engagement portion 42 of first member 4 and connection portion 52 of second member 5. Downward projecting portion 64 of third member 6 is spaced from second heat exchange unit 20 of upper heat exchanger 2 in second direction DR2.

In this way, heat exchanger 101 has upper heat exchanger 2 appropriately positioned with respect to lower heat exchanger 1. Preferably, upper heat exchanger 2 is further fixed to the housing by a fixing member (not shown).

Hereinafter, an effect of heat exchanger 101 will be described. Heat exchanger 101 comprises lower heat exchanger 1 and upper heat exchanger 2 each including a heat exchange unit having a U-shaped portion. Positioning member 3 can position upper heat exchanger 2 with respect to lower heat exchanger 1 in first direction DR1 and second direction DR2 even when there is a dimensional difference between lower heat exchanger 1 and upper heat exchanger 2.

Specifically, heat exchanger 101 has upper heat exchanger 2 positioned with respect to lower heat exchanger 1 via positioning member 3 as upper heat exchanger 2 has third end 21 engaged with engagement portion 42 of first member 4 of positioning member 3 fixed to lower heat exchanger 1. Furthermore, the heat exchanger has upper heat exchanger 2 positioned with respect to lower heat exchanger 1 via positioning member 3 as the upper heat exchanger has fourth end 22 connected to connection portion 52 of second member 5 of positioning member 3 fixed to lower heat exchanger 1. In this way, upper heat exchanger 2 can be positioned with respect to lower heat exchanger 1 in first direction DR1.

The engagement and the connection can also be easily achieved even when there is a dimensional difference between lower heat exchanger 1 and upper heat exchanger 2 in at least one of first direction DR1 and second direction DR2. For example, upper heat exchanger 2 dimensionally larger than lower heat exchanger 1 in second direction DR2 (see Fig. 9) or smaller than the lower heat exchanger in the second direction can also be positioned with respect to lower heat exchanger 1 in first direction DR1. Furthermore, if upper heat exchanger 2 should dimensionally be larger than lower heat exchanger 1 in first direction DR1, upper heat exchanger 2 can be compressed and deformed in first direction DR1 and thus positioned with respect to lower heat exchanger 1 in first direction DR1. When this is done, positioning member 3 allows a middle portion of third portion 20C of upper heat exchanger 2 in first direction DR1 to be deformed to project outward in second direction DR2, and the positioning member thus does not prevent the deformation of upper heat exchanger 2 (see Fig. 9).

Furthermore, heat exchanger 101 is switchable from the state shown in Fig. 9 to the state shown in Fig. 10 by changing a position in which third member 6 is fixed to first and second members 4 and 5 fixed to lower heat exchanger 1. Thus, upper heat exchanger 2 can also be positioned with respect to lower heat exchanger 1 in second direction DR2.

The states can also be easily switched even when there is a dimensional difference between lower heat exchanger 1 and upper heat exchanger 2 in at least one of first direction DR1 and second direction DR2. As shown in Fig. 9, if the middle portion of third portion 20C of upper heat exchanger 2 in first direction DR1 should project outward in second direction DR2 by a distance D1, the middle portion of third portion 20C of upper heat exchanger 2 can be disposed inwardly of upward projecting portion 65 of third member 6 in second direction DR2 insofar as the distance D1 falls within the allowable range for the dimensional difference. In the example shown in Fig. 9, the sum of the distance D1 and a spacing D2 in second direction DR2 between upward projecting portion 65 of third member 6 and the middle portion of third portion 20C of upper heat exchanger 2 corresponds to the maximum allowable value for the dimensional difference between lower heat exchanger 1 and upper heat exchanger 2 in second direction DR2.

In heat exchanger 101, positioning member 3 can also suppress positional displacement of upper heat exchanger 2 with respect to lower heat exchanger 1 even when upper heat exchanger 2 receives a force in a direction intersecting vertical direction VDR. For example, the positioning member can suppress positional displacement of upper heat exchanger 2 with respect to lower heat exchanger 1 even when heat exchanger 101 vibrates as it is transported or the like.

In heat exchanger 101, engagement portion 42 of first member 4 is provided as a recess that opens in vertical direction VDR, and third end 21 of upper heat exchanger 2 is provided with projection 23 that is fitted into the recess. Therefore, when upper heat exchanger 2 is disposed on positioning member 3 fixed to lower heat exchanger 1, third end 21 of upper heat exchanger 2 can be easily engaged with engagement portion 42 of first member 4.

Engagement portion 42 of first member 4 may be provided as a projection projecting upward, and fourth end 22 of upper heat exchanger 2 may be provided with a recess to which the projection is fitted.

In heat exchanger 101, a corner of fourth end 22 of upper heat exchanger 2 has first surface 22A and second surface 22B, and connection portion 52 of second member 5 has first connection portion 52A that can come into contact with first surface 22A and second connection portion 52B that can come into contact with second surface 22B. This can suppress movement of upper heat exchanger 2 in a direction intersecting vertical direction VDR while third end 21 is engaged with engagement portion 42 and fourth end 22 is connected to connection portion 52.

In heat exchanger 101, first member 4, second member 5, and third member 6 have intermediate portions 43, 53, and 63, respectively, provided with a plurality of through holes 43H1 and 43H2, 53H1 and 53H2, and 63H1 and 63H2, respectively, and positioning member 3 does not impair upper heat exchanger 2 in performance for drainage. Heat exchanger 101 can for example suppress ventilation resistance otherwise increased and performance otherwise deteriorated etc., as condensation builds up in upper heat exchanger 2.

In heat exchanger 101, first member 4, second member 5, and third member 6 have a pair of downward projecting portions 44A and 44B, a pair of downward projecting portions 54A and 54B, and downward projecting portion 64 and upward projecting portion 65, respectively, provided with a plurality of through holes 44H, 54H, and 64H and 65H, respectively, and this can suppress ventilation resistance otherwise increased and performance otherwise deteriorated due to positioning member 3.

In heat exchanger 101, third member 6 has third and fourth through holes 67A and 67B each having an opening with a width larger in second direction DR2 than that of the opening of each of first recesses 47 and 57 of first and second members 4 and 5, respectively, and third member 6 has a plurality of tabs 68A and 68B to be movable inside second recesses 48 and 58 of first member 4 and second member 5, respectively, in second direction DR2. Such positioning member 3 facilitates adjusting a position in which third member 6 is fixed with respect to first member 4 and second member 5.

For heat exchanger 101, positioning member 3 at least including first member 4 and second member 5 suffices. Positioning member 3 may not include third member 6. As has been described above, first member 4 and second member 5 can appropriately couple the lower heat exchanger and the upper heat exchanger together at least in first direction DR1 even when there is a dimensional difference between the lower heat exchanger and the upper heat exchanger. Furthermore, first member 4 and second member 5 with first connection portion 52A and second connection portion 52B can suppress positional displacement between the lower heat exchanger and the upper heat exchanger in second direction DR2 even when there is a dimensional difference between the lower heat exchanger and the upper heat exchanger.

Figs. 11 to 13 show variations of heat exchanger 101. Figs. 11 to 13 do not show the upper heat exchanger.

As shown in Fig. 11, lower heat exchanger 1 and the upper heat exchanger may each include a heat exchange unit having an L-shaped portion instead of the U-shaped portion. For this case as well, positioning member 3 at least including first member 4 and second member 5 fixed to lower heat exchanger 1 at first end 11 and second end 12, respectively, and connectable to upper heat exchanger 2 at the third end and the fourth end, respectively, suffices. Preferably, second member 5 includes first connection portion 52A and second connection portion 52B. Preferably, positioning member 3 further includes third member 6. Positioning member 3 may have second member 5 and third member 6 provided in one piece as a single member.

As shown in Fig. 12, lower heat exchanger 1 and the upper heat exchanger may each include a heat exchange unit having an I-shaped (or linear) portion instead of the U-shaped portion. Positioning member 3 at least including first member 4 and second member 5 suffices. Positioning member 3 is fixed to lower heat exchanger 1 at first end 11 and second end 12, engageable with upper heat exchanger 2 at the third end, and connectable thereto at the fourth end. Preferably, second member 5 includes first connection portion 52A and second connection portion 52B. Second member 5 may further include a connection portion 59 connectable to upper heat exchanger 2 at fourth end 22 at a corner different from that at which connection portion 52 is connected. Positioning member 3 may further include third member 6. Positioning member 3 may have first and second members 4 and 5 and third member 6 provided in one piece as a single member.

As shown in Fig. 13, positioning member 3 may include first member 4 without engagement portion 42, and instead having a connection portion 49 connectable to upper heat exchanger 2 at third end 21. Connection portion 49 may be located on the same side as connection portion 52 of second member 5 in the widthwise direction intersecting the direction in which the heat transfer tube extends. In that case, preferably, second member 5 further includes connection portion 59 connectable to upper heat exchanger 2 at fourth end 22 at a corner different from that at which connection portion 52 is connected. Note that first member 4 may further include a connection portion facing connection portion 49 in second direction DR2. Lower heat exchanger 1 and upper heat exchanger 2 having an I-shaped portion can also be positioned with respect to each other by such a positioning member 3.

Although the embodiments of the present invention have been described, it should be understood that the embodiments disclosed herein are illustrative and non-restrictive in any respect. The scope of the present invention is defined by the terms of the claims and encompasses any modification equivalent in meaning and scope to the claimed scope.