HEAT EXCHANGER AND AIR CONDITIONER EMPLOYING THE SAME

Abstract

An air conditioner includes a heat exchanger. The heat exchanger includes a tube having a flat tube form, and fins respectively provided on an upper surface and a lower surface of the tube. The fins include a plurality of ridges and a plurality of valleys alternately arranged along a longitudinal direction of the tube. A first fin provided on the upper surface of the tube includes a downwardly protruding portion that protrudes from a corresponding one of the plurality of valleys toward the lower surface of the tube and contacts one end of the tube in the flow direction of the fluid. A second fin provided on the lower surface of the tube includes an upwardly protruding portion that protrudes from a corresponding one of the plurality of ridges toward the upper surface of the tube and contacts the one end of the tube.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Application No. PCT/KR2026/002014, filed Feb. 4, 2026, and claims foreign priority to Japanese Application No. 2025-026638, filed Feb. 21, 2025, and which are incorporated herein by reference in their entireties.

TECHNICAL FIELD

The disclosure relates to a heat exchanger and an air conditioner employing the same.

BACKGROUND ART

An air conditioner includes an indoor heat exchanger that performs heat exchange between a refrigerant and indoor air. The indoor heat exchanger includes heat transfer tubes through which the refrigerant flows, and heat dissipation fins that are in contact with the heat transfer tubes to secure a heat exchange area between the refrigerant and the air. During a heat exchange process, moisture in the air may condense, resulting in the formation of condensate water. When the condensate water is not drained from the heat exchanger and remains on surfaces of the heat transfer tubes or the heat dissipation fins, heat exchange efficiency may deteriorate. In consideration of this, a drainage structure for discharging the condensate water is provided in the heat exchanger.

Technologies for forming drainage paths for condensate water by using heat dissipation fins are described in publications such as Chinese Utility Model Publication No. CN221259600U, Japanese Patent Application Publication No. 2013-124808, International Publication No. WO 2009/153985, and Japanese Patent Application Publication No. H09-101092.

DISCLOSURE

Technical Solution

According to an aspect of the disclosure, a heat exchanger includes a first header, a second header, and a tube having a flat tube form. A refrigerant introduced from the first header flows along the tube and is discharged to the second header. Fins are provided on an upper surface of the tube, which is parallel to a flow direction of a fluid, and a lower surface opposite to the upper surface. Each of the fins includes ridges and valleys alternately arranged in a longitudinal direction of the tube. The fins may include a first fin provided on the upper surface of the tube and a second fin provided on the lower surface of the tube. The first fin may include a downwardly protruding portion that protrudes from a corresponding one of the valleys toward the lower surface of the tube and contacts one end of the tube in the flow direction of the fluid. The second fin may include an upwardly protruding portion that protrudes from a corresponding one of the ridges toward the upper surface of the tube and contacts the one end of the tube.

According to an aspect of the disclosure, an air conditioner includes an outdoor heat exchanger and an indoor heat exchanger. At least one of the outdoor heat exchanger or the indoor heat exchanger may include the heat exchanger described above.

DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic diagram illustrating a configuration of an air conditioner according to an embodiment of the disclosure.

FIG. 2 is a cross-sectional view of an example of an indoor unit of an air conditioner, according to an embodiment of the disclosure.

FIG. 3 is a schematic perspective view of a heat exchanger according to an embodiment of the disclosure.

FIG. 4 is a diagram illustrating an example of a method of manufacturing a fin, according to an embodiment of the disclosure.

FIG. 5 is a perspective view illustrating an example in which the fin manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger.

FIG. 6 is a front view illustrating an example in which the fin manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger.

FIG. 7 is a side view illustrating an example in which the fin manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger.

FIG. 8 is a diagram illustrating an example of a method of manufacturing a fin, according to an embodiment of the disclosure.

FIG. 9 is a perspective view illustrating an example in which the fin manufactured by the method illustrated in FIG. 8 is applied to a heat exchanger.

FIG. 10 is a side view illustrating an example in which the fin manufactured by the method illustrated in FIG. 8 is applied to a heat exchanger.

FIG. 11 is a side view illustrating an example of a drainage path of a heat exchanger.

FIG. 12 is a cross-sectional view illustrating an example of an indoor unit of an air conditioner, according to an embodiment of the disclosure.

FIG. 13 is a side view illustrating an example of a drainage path of a heat exchanger shown in FIG. 12.

MODE FOR INVENTION

It should be understood that various embodiments of the disclosure in this document and terms used therein are not intended to limit the technical features described herein to particular embodiments of the disclosure and that the disclosure includes various modifications, equivalents, or substitutions of the embodiments of the disclosure.

With regard to the description of the drawings, like reference numerals may be used to represent like or related elements.

A singular form of a noun corresponding to an item may include one or a plurality of the items unless the context clearly indicates otherwise.

As used herein, each of the phrases such as “A or B,” “at least one of A and B, “at least one of A or B,” “A, B, or C,” “at least one of A, B, and C,” and “at least one of A, B, or C” may include any one of the items listed together in a corresponding one of the phrases, or all possible combinations thereof.

For example, the phrase “at least one of A, B, and C” may include one of only A, only B, only C, both A and B, both A and C, both B and C, and all of A, B, and C. As another example, “at least one of A or B” may include one of only A, only B, both A and B.

The term “and/or” includes any combination of a plurality of associated elements listed, or any one of the plurality of associated listed elements.

Terms such as “first,” “second,” etc. may be used simply to distinguish an element from other elements and do not limit the elements in any other respect (e.g., importance or order).

It will be understood that when an element (e.g., a first element) is referred to, with or without the term “functionally” or “communicatively”, as being “coupled” or “connected” to another element (e.g., a second element), the element may be coupled to the other element directly (e.g., in a wired manner), wirelessly, or via a third element.

The terms such as “comprise,” “include,” or “have” are intended to specify the presence of stated features, numbers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof.

It will also be understood that when an element is referred to as being “connected,” “coupled,” “supported,” or “in contact” with another element, this includes not only when the elements are directly connected, coupled, supported, or in contact, but also when they are indirectly connected, coupled, supported, or in contact via a third element.

It will also be understood that when an element is referred to as being “on” another element, the element may be directly on the other element, or intervening elements may also be present therebetween.

An air conditioner according to various embodiments of the disclosure is an apparatus that performs functions such as air purification, ventilation, humidity control, cooling, or heating in an air-conditioned space (hereinafter referred to as an “indoor space”) and is equipped with at least one of these functions.

According to an embodiment of the disclosure, the air conditioner may include a heat pump system to perform a cooling function or a heating function. The heat pump system may include a refrigeration cycle in which a refrigerant is circulated through a compressor, a first heat exchanger, an expansion device, and a second heat exchanger. All components of a heat pump system may be built into a single housing that forms an external appearance of an air conditioner, and window-type air conditioners or portable air conditioners are examples of such an air conditioner. On the other hand, components of the heat pump system may be split into several parts and built into a plurality of housings that form a single air conditioner, and examples of such an air conditioner include wall-mounted air conditioners, stand-type air conditioners, and system air conditioners.

An air conditioner including a plurality of housings may include at least one outdoor unit installed outdoors and at least one indoor unit installed indoors. For example, an air conditioner may be equipped with one outdoor unit and one indoor unit connected via a refrigerant pipe. For example, an air conditioner may include one outdoor unit and two or more indoor units connected via a refrigerant pipe. For example, an air conditioner may include two or more outdoor units and two or more indoor units connected via a plurality of refrigerant pipes.

An outdoor unit may be electrically connected to an indoor unit. For example, information (or commands) for controlling an air conditioner may be input via an input interface provided on the outdoor or indoor unit, and the outdoor unit and the indoor unit may operate simultaneously or sequentially in response to a user input.

The air conditioner may include an outdoor heat exchanger provided in the outdoor unit, an indoor heat exchanger provided in the indoor unit, and a refrigerant pipe connecting the outdoor heat exchanger to the indoor heat exchanger.

An outdoor heat exchanger may exchange heat between a refrigerant and outdoor air by using a phase change (e.g., evaporation or condensation) of the refrigerant. For example, the refrigerant may release heat into the outdoor air during condensation of the refrigerant in the outdoor heat exchanger, and the refrigerant may absorb heat from the outdoor air during evaporation of the refrigerant flowing in the outdoor heat exchanger.

An indoor unit is installed indoors. For example, indoor units may be classified into ceiling-mounted indoor units, stand-type indoor units, wall-mounted indoor units, etc., depending on how they are arranged. For example, ceiling-mounted indoor units may be subdivided into 4-way cassette indoor units, 1-way cassette indoor units, duct-type indoor units, etc. depending on an air discharge method.

Similarly, an indoor heat exchanger may exchange heat between a refrigerant and indoor air by using a phase change (e.g., evaporation or condensation) of the refrigerant. For example, while the refrigerant evaporates in the indoor heat exchanger, the refrigerant may absorb heat from the indoor air, and the indoor air is cooled as it passes through the cold indoor heat exchanger and then blown out to cool the indoor space. Furthermore, while a refrigerant condenses in the indoor heat exchanger, the refrigerant may release heat into the indoor air, and the indoor air is heated as it passes through the high-temperature indoor heat exchanger and then blown out to heat the indoor space.

That is, the air conditioner performs a cooling or heating function through a phase change process undergone by the refrigerant circulating between the outdoor heat exchanger and the indoor heat exchanger, and for this circulation of the refrigerant, the air conditioner may include a compressor that compresses the refrigerant. The compressor may suck in refrigerant gas through a suction port and compress the refrigerant gas. The compressor may discharge high-temperature, high-pressure refrigerant gas via a discharge port. The compressor may be located inside the outdoor unit.

The refrigerant may circulate, via a refrigerant pipe, through the compressor, the outdoor heat exchanger, the expansion device, and the indoor heat exchanger in the stated order, or through the compressor, the indoor heat exchanger, the expansion device, and the outdoor heat exchanger in the stated order.

For example, when the air conditioner has one outdoor unit and one indoor unit directly connected via a refrigerant pipe, the refrigerant may circulate between the one outdoor unit and the one indoor unit through the refrigerant pipe.

For example, when the air conditioner has one outdoor unit connected to two or more indoor units via a refrigerant pipe, refrigerants may flow into the plurality of indoor units via refrigerant pipes branching from the outdoor unit. The refrigerants discharged from the plurality of indoor units may be combined together and circulated in the outdoor unit. For example, the plurality of indoor units may each be directly connected to the one outdoor unit in parallel via separate refrigerant pipes.

Each of the plurality of indoor units may operate independently according to an operating mode set by a user. That is, some of the plurality of indoor units may operate in a cooling mode, and others may operate in a heating mode simultaneously. In this case, the refrigerant may be selectively introduced into each indoor unit in either a high or low pressure state along a designated circulation path via a flow path diverter valve as described below, and then discharged from the indoor unit and circulated to the outdoor unit.

For example, when the air conditioner has two or more outdoor units and two or more indoor units connected via a plurality of refrigerant pipes, refrigerants discharged from the plurality of outdoor units are combined and flow through a single refrigerant pipe, and then diverge again at a certain point to enter the plurality of indoor units.

The plurality of outdoor units may all be driven, or at least some of the outdoor units may not be driven, depending on an operating load corresponding to the amount of operation of the plurality of indoor units. In this case, the refrigerant may flow into and circulate in an outdoor unit that is selectively driven via a flow path diverter valve. The air conditioner may include an expansion device to lower the pressure of the refrigerant entering a heat exchanger. For example, the expansion device may be located inside an indoor unit, inside an outdoor unit, or both.

For example, the expansion device may lower the temperature and pressure of the refrigerant by using a throttling effect. The expansion device may include an orifice capable of reducing a cross-sectional area of a flow path. The refrigerant passing through the orifice may undergo a decrease in temperature and pressure.

For example, the expansion device may be implemented as an electronic expansion valve capable of adjusting an opening ratio (a ratio of a cross-sectional area of a flow path in a valve in a partially open state to a cross-sectional area of a flow path in the valve in a fully open state). The amount of refrigerant passing through the expansion device may be controlled depending on the opening ratio of the electronic expansion valve.

The air conditioner may further include a flow path diverter valve provided on a refrigerant circulation flow path. The flow path diverter valve may include, for example, a 4-way valve. The flow path diverter valve may determine a path of circulation of the refrigerant depending on an operating mode of an indoor unit (e.g., cooling operation or heating operation). The flow path diverter valve may be connected to the discharge port of the compressor.

The air conditioner may include an accumulator. The accumulator may be connected to the suction port of the compressor. Low-temperature, low-pressure refrigerant evaporated from an indoor heat exchanger or an outdoor heat exchanger may flow into the accumulator.

When a refrigerant in which refrigerant liquid and refrigerant gas are mixed flows into the accumulator, the accumulator may separate the refrigerant liquid from the refrigerant gas and provide the refrigerant gas from which the refrigerant liquid has been separated to the compressor.

An outdoor fan may be provided in the vicinity of the outdoor heat exchanger. The outdoor fan may blow outdoor air into the outdoor heat exchanger to facilitate heat exchange between the refrigerant and the outdoor air.

An outdoor unit of the air conditioner may include at least one sensor. For example, an outdoor unit sensor may be provided as an environment sensor. An outdoor unit sensor may be located at any position inside or outside the outdoor unit. For example, outdoor unit sensors may include, for example, a temperature sensor for detecting air temperature around the outdoor unit, a humidity sensor for detecting humidity in the air around the outdoor unit, a refrigerant temperature sensor for detecting a refrigerant temperature inside a refrigerant pipe passing through the outdoor unit, or a refrigerant pressure sensor for detecting a refrigerant pressure inside the refrigerant pipe passing through the outdoor unit.

The outdoor unit of the air conditioner may include an outdoor unit communication interface. The outdoor unit communication interface may be provided to receive a control signal from an indoor unit controller of the air conditioner, as described later. The outdoor unit may control, based on a control signal received via the outdoor unit communication interface, an operation of a compressor, an outdoor heat exchanger, an expansion device, a flow path diverter valve, an accumulator, or an outdoor fan. The outdoor unit may transmit, via the outdoor unit communication interface, a sensing value detected by an outdoor unit sensor to the indoor unit controller.

The indoor unit of the air conditioner may include a housing, a blower that circulates air inside or outside the housing, and an indoor heat exchanger that exchanges heat with air flowing into the housing.

The housing may include an air inlet. Indoor air may be drawn into the housing via the air inlet.

The indoor unit of the air conditioner may include a filter provided to filter out foreign substances from the air drawn into the housing via the air inlet.

The housing may include an air outlet. Air flowing inside the housing may be discharged from the housing via the air outlet.

The housing of the indoor unit may include an airflow guide that guides a direction of air discharged through the air outlet. For example, the airflow guide may include a blade located on the air outlet. For example, the airflow guide may include an auxiliary fan for regulating an exhaust airflow. However, the disclosure is not limited thereto, and the airflow guide may be omitted.

Inside the housing of the indoor unit, the indoor heat exchanger and the blower may be provided on a flow path connecting the air inlet and the air outlet.

The blower may include an indoor fan and a fan motor. For example, indoor fans may include an axial fan, a diagonal fan, a crossflow fan, and a centrifugal fan.

The indoor heat exchanger may be located between the blower and the air outlet, or between the air inlet and the blower. The indoor heat exchanger may absorb heat from air drawn in through the air inlet or transfer heat to air drawn in through the air inlet. The indoor heat exchanger may include a heat exchange tube in which a refrigerant flows, and heat exchange fins that are in contact with the heat exchange tube to increase the heat transfer area.

The indoor unit of the air conditioner may include a drain tray located below the indoor heat exchanger to collect condensate water generated in the indoor heat exchanger. The condensate water collected in the drain tray may be drained to the outside via a drain hose. The drain tray may be provided to support the indoor heat exchanger.

The indoor unit of the air conditioner may include an input interface. The input interface may include any type of user input devices, including buttons, switches, touch screens, and/or touch pads. The user may directly input setting data (e.g., desired indoor temperature, operating mode settings for cooling/heating/dehumidification/air purification, outlet selection settings, and/or air volume settings) via the input interface.

The input interface may be connected to an external input device. For example, the input interface may be electrically connected to a wired remote controller. The wired remote controller may be installed at a specific location in an indoor space (e.g., a portion of a wall). The user may operate the wired remote controller to input setting data regarding an operation of the air conditioner. An electrical signal corresponding to setting data obtained via the wired remote controller may be transmitted to the input interface. In addition, the input interface may include an infrared sensor. The user may remotely input setting data regarding the operation of the air conditioner by using a wireless remote controller. The setting data input via the wireless remote controller may be transmitted to the input interface as an infrared signal.

Also, the input interface may include a microphone. A user's voice command may be obtained via the microphone. The microphone may convert the user's voice command into an electrical signal and transmit the electrical signal to the indoor unit controller. The indoor unit controller may control components of the air conditioner to perform a function corresponding to the user's voice command. Setting data (e.g., desired indoor temperature, operating mode settings for cooling/heating/dehumidification/air purification, outlet selection settings, and/or air volume settings) obtained via the input interface may be transmitted to the indoor unit controller as described later. For example, the setting data obtained via the input interface may be transmitted to the outside, i.e., an outdoor unit or a server, via an indoor unit communication interface as described below.

The indoor unit of the air conditioner may include a power module. The power module may be connected to an external power source to supply power to components of the indoor unit.

The indoor unit of the air conditioner may include an indoor unit sensor. The indoor unit sensor may be an environment sensor located inside or outside the housing. For example, the indoor unit sensor may include one or more temperature sensors and/or one or more humidity sensors arranged in a predetermined space inside or outside the housing of the indoor unit. For example, the indoor unit sensor may include a refrigerant temperature sensor for detecting a refrigerant temperature inside a refrigerant pipe passing through the indoor unit. For example, the indoor unit sensor may include refrigerant temperature sensors that respectively detect temperatures at an inlet, a middle, and/or an outlet of the refrigerant pipe passing through the indoor heat exchanger.

For example, pieces of environment information respectively detected by the indoor unit sensors may be transmitted to the indoor unit controller as described below, or may be transmitted to the outside via the indoor unit communication interface as described below.

The indoor unit of the air conditioner may include the indoor unit communication interface. The indoor unit communication interface may include at least one of a short-range communication module or a long-range communication module. The indoor unit communication interface may include at least one antenna for wirelessly communicating with other devices. The outdoor unit may include the outdoor unit communication interface. The outdoor unit communication interface may also include at least one of a short-range communication module or a long-range communication module.

The short-range communication module may include, but is not limited to, a Bluetooth communication module, a Bluetooth Low Energy (BLE) communication module, a near field communication (NFC) communication module, a wireless local area network (WLAN) (or Wi-Fi) communication module, a ZigBee communication module, an Infrared Data Association (IrDA) communication module, a Wi-Fi Direct (WFD) communication module, an ultra-wideband (UWB) communication module, an Ant+ communication module, a microwave (uWave) communication module, and the like.

The long-range communication module may include a communication module that performs various types of long-range communications, and include a mobile communication interface. The mobile communication interface transmits or receives a wireless signal to or from at least one of a base station, an external terminal, or a server on a mobile communication network.

The indoor unit communication interface may communicate with an external device such as a server, a mobile device, or another home appliance via a nearby access point (AP). The AP may connect a LAN to which the air conditioner or a user device is connected to a wide area network (WAN) to which a server is connected. The air conditioner or user device may be connected to the server via the WAN. The indoor unit of the air conditioner may include the indoor unit controller that controls the components of the indoor unit, including the blower. The outdoor unit of the air conditioner may include an outdoor unit controller that controls components of the outdoor unit, including a compressor. The indoor unit controller may communicate with the outdoor unit controller via the indoor unit communication interface and the outdoor unit communication interface. The outdoor unit communication interface may transmit, to the indoor unit communication interface, a control signal generated by the outdoor unit controller, or may transmit, to the outdoor unit controller, a control signal transmitted from the indoor unit communication interface. In other words, the outdoor unit and the indoor unit may perform bi-directional communication. The outdoor unit and the indoor unit may transmit and receive various signals generated during an operation of the air conditioner.

The outdoor unit controller may be electrically connected to the components of the outdoor unit and control an operation of each component. For example, the outdoor unit controller may adjust a frequency of the compressor and control a flow path diverter valve to change a circulation direction of a refrigerant. The outdoor unit controller may adjust a rotation speed of the outdoor fan. In addition, the outdoor unit controller may generate a control signal for adjusting the degree of opening of an expansion valve. Under the control of the outdoor unit controller, the refrigerant may circulate along a refrigerant circulation circuit including the compressor, the flow path diverter valve, the outdoor heat exchanger, the expansion valve, and the indoor heat exchanger.

Various temperature sensors included in the outdoor unit and the indoor unit may each transmit an electrical signal corresponding to a temperature detected by each of the temperature sensors (to the outdoor unit controller and/or the indoor unit controller. For example, each of humidity sensors included in the outdoor unit and the indoor unit may transmit an electrical signal corresponding to its detected humidity to the outdoor unit controller and/or the indoor unit controller.

The indoor unit controller may obtain a user input from a user device including a mobile device or the like via the indoor unit communication interface, and obtain a user input directly via the input interface or through a remote controller. The indoor unit controller may control the components of the indoor unit, including the blower, etc., in response to the received user input. The indoor unit controller may transmit information about the received user input to the outdoor unit controller of the outdoor unit.

The outdoor unit controller may control the components of the outdoor unit, including the compressor, etc., based on information about a user input received from the indoor unit. For example, when a control signal corresponding to a user input for selecting an operating mode such as cooling operation, heating operation, blowing operation, defrosting operation, or dehumidifying operation is received from the indoor unit, the outdoor unit controller may control the components of the outdoor unit to perform an operation of the air conditioner, corresponding to the selected operating mode.

The outdoor unit controller and the indoor unit controller may each include a processor and memory. The indoor unit controller may include at least one first processor and at least one first memory, and the outdoor unit controller may include at least one second processor and at least one second memory.

The memory may record/store various pieces of information necessary for operations of the air conditioner. The memory may store instructions, applications, data, and/or programs necessary for operations of the air conditioner. For example, the memory may store various programs for cooling operation, heating operation, dehumidifying operation, and/or defrosting operation of the air conditioner. The memory may include volatile memories, such as static random access memory (SRAM) and dynamic RAM (DRAM), for temporarily storing data. Furthermore, the memory may include non-volatile memories for long-term storage of data, such as read-only memory (ROM), erasable programmable ROM (EPROM), and electrically erasable PROM (EEPROM).

The processor may generate control signals for controlling operations of the air conditioner, based on instructions, applications, data, and/or programs stored in the memory. The processor is a hardware component and may include logic circuits and arithmetic circuits. The processor may process data according to programs and/or instructions provided from the memory and generate control signals based on processing results. The memory and processor may each be implemented as a single control circuit or as a plurality of circuits.

The indoor unit of the air conditioner may include an output interface. The output interface is electrically connected to the indoor unit controller and may output information related to an operation of the air conditioner under the control of the indoor unit controller. For example, the output interface may output information such as operating mode, wind direction, air volume, and temperature selected by a user input. In addition, the output interface may output sensing information and warning/error messages obtained from the indoor unit sensor or the outdoor unit sensor.

The output interface may include a display and a speaker. The speaker is an audio device that may output a variety of sounds. The display may display information input by the user or information provided to the user by using various graphical elements. For example, operation information about the air conditioner may be displayed as at least one of an image or text. The display may also include indicators that provide specific information. The display may include a liquid crystal display (LCD) panel, a light emitting diode panel (LED) panel, an organic light emitting diode (OLED) panel, a micro LED panel, and/or a plurality of LEDs.

In the heat exchanger, a heat transfer tube in the form of a flat tube including a plurality of microchannels may be used as a heat transfer tube, and a corrugated fin may be used as a heat dissipation fin. Condensate water tends to remain on an upper surface of the flat tube and on ridges and valleys of the corrugated fin, and in this case, the heat exchange performance of the heat exchanger may deteriorate. Because dimensions of heat transfer tubes, heat dissipation fins, etc., or an installation type of the heat exchanger vary depending on a product to which the heat exchanger is applied, it is not easy to enable the drainage of condensate water for all installation types.

The disclosure is to provide a heat exchanger capable of securing drainage of condensate water, and an air conditioner employing the heat exchanger. The disclosure is to provide a heat exchanger capable of securing drainage in various applications. However, technical problems to be solved from the disclosure are not limited to those described above, and other technical problems not described herein will be clearly understood by those of ordinary skill in the art from the following description.

Hereinafter, embodiments of a heat exchanger and an air conditioner employing the same according to the disclosure are described with reference to the accompanying drawings.

FIG. 1 is a schematic diagram illustrating a configuration of an air conditioner according to an embodiment of the disclosure. Referring to FIG. 1, an air conditioner 1 according to an embodiment of the disclosure may include an outdoor unit 10, an indoor unit 20, and a pipe 30.

The outdoor unit 10 is installed, for example, outdoors of a building. The outdoor unit 10 may include a heat exchanger (an outdoor heat exchanger) 11, a fan 12, an expansion valve 13, a 4-way diverter valve 14, an accumulator 15, and a compressor 16. The 4-way diverter valve 14 is connected to the heat exchanger 11, the accumulator 15, and the compressor 16 via the pipe 30. The heat exchanger 11 and the expansion valve 13 are connected via the pipe 30, and the accumulator 15 and the compressor 16 are also connected via the pipe 30. In addition, the outdoor unit 10 includes a control device 17.

The heat exchanger 11 is a device that transfers heat from a higher-temperature object to a lower-temperature object. The fan 12 creates an air flow passing through the heat exchanger 11 to thereby promote heat exchange between a refrigerant and air. The expansion valve 13 expands a condensed refrigerant liquid to a low pressure and a low temperature. The 4-way diverter valve 14 switches a flow path of the refrigerant according to an operating mode of the air conditioner 1. FIG. 1 illustrates a switched connection state of the 4-way diverter valve 14 for a case where a cooling operation is performed. In this case, the refrigerant flows along a path indicated by a solid line in the 4-way diverter valve 14. The accumulator 15 filters out liquid refrigerant from a vapor-liquid mixture refrigerant introduced into the outdoor unit 10 and supplies vapor refrigerant to the compressor 16. The compressor 16 compresses the refrigerant. The control device 17 controls operations of the fan 12, the expansion valve 13, the compressor 16, etc., switching of a flow path by the 4-way diverter valve 14, and the like. The control device 17 may be realized, for example, by a microcomputer. The above description of the outdoor unit and the outdoor unit controller may be applied to the outdoor unit 10 and the control device 17.

The indoor unit 20 is installed, for example, in each room within a building. In FIG. 1, two indoor units 20 are connected to one outdoor unit 10, but one or three or more indoor units 20 may be connected to the one outdoor unit 10. The indoor unit 20 may include a heat exchanger (an indoor heat exchanger) 21, a fan 22, and an expansion valve 23.

The heat exchanger 21 is a device that transfers heat from a higher-temperature object to a lower-temperature object. The fan 22 creates an air flow passing through the heat exchanger 21 to thereby promote heat exchange between a refrigerant and air. The expansion valve 23 expands a condensed refrigerant liquid provided from the outdoor unit 10 to a low pressure and a low temperature.

The pipe 30 is connected between the outdoor unit 10 and the indoor unit 20 to form a circulation path for the refrigerant between the outdoor unit 10 and the indoor unit 20. The pipe 30 may include a liquid refrigerant pipe 31 and a gas refrigerant pipe 32. Liquefied refrigerant flows through the liquid refrigerant pipe 31. The liquid refrigerant pipe 31 forms a flow path for the refrigerant between the expansion valve 23 of the indoor unit 20 and the expansion valve 13 of the outdoor unit 10. Gaseous refrigerant flows through the gas refrigerant pipe 32. The gas refrigerant pipe 32 forms a flow path for the refrigerant between the 4-way diverter valve 14 of the outdoor unit 10 and a gas side of the heat exchanger 21 of the indoor unit 20. The above description of the indoor unit may be applied to the indoor unit 20.

FIG. 2 is a cross-sectional view of an example of the indoor unit 20 of the air conditioner 1, according to an embodiment of the disclosure. An indoor unit as an embodiment of the indoor unit 20 is denoted by reference numeral 20a. The indoor unit 20a according to the embodiment of the disclosure is a 4-way ceiling cassette type indoor unit. Referring to FIG. 2, according to an embodiment of the disclosure, the indoor unit 20a includes a heat exchanger 21a and a fan 22a. An air flow is generated in a direction indicated by an arrow F1 by rotation of the fan 22a, and the air flow passes through the heat exchanger 21a. Heat exchange between air and a refrigerant is performed in the heat exchanger 21a. The indoor unit 20a may include other general components of the indoor unit 20, such as the expansion valve 23 shown in FIG. 1.

FIG. 3 is a schematic perspective view of the heat exchanger 21a according to an embodiment of the disclosure. Referring to FIG. 3, the heat exchanger 21a is arranged such that a downstream side of the air flow is at the front with respect to the direction F1. FIG. 3 illustrates a case where the heat exchanger 21a is used as an evaporator. However, the disclosure is not limited thereto, and the heat exchanger 21a may be a heat exchanger having another form of usage in which the generation of condensate water may be problematic. The heat exchanger 21a may include a heat exchange part 200, a liquid-side header (a first header) 500, and a gas-side header (a second header) 600.

The heat exchange part 200 includes a plurality of tubes 300 and a plurality of fins 400 that are alternately stacked. Each of the tubes 300 is a refrigerant pipe in which a plurality of flow paths through which a refrigerant flows are formed. The refrigerant introduced from the liquid-side header 500 into each of the tubes 300 passes through the corresponding tube 300 and is discharged to the gas-side header 600. The tube 300 may be, for example, a flat tube with both ends in the air flow direction F1 having a rounded shape, such as an arc shape.

The fins 400 may be provided on an upper surface (a first surface) of the corresponding tube 300, which is parallel to the air flow direction F1, and on a lower surface (a second surface) opposite to the upper surface. The fin 400 provided on the upper surface of the tube 300 is an example of a first fin, and the fin 400 provided on the lower surface of the tube 300 is an example of a second fin. For example, the fin 400 may be a corrugated fin in which ridges and valleys are alternately arranged.

With this configuration, in the heat exchange part 200, heat exchange is performed between the refrigerant passing through the flow paths of the tubes 300 and air passing between the fins 400. In addition, a medium performing heat exchange with the refrigerant may be a fluid other than air. Hereinafter, because the description relates to a heat exchanger applied to the air conditioner 1, air is described as an example of the medium for heat exchange with the refrigerant.

The liquid-side header 500 is connected to one end of each of the plurality of tubes 300 constituting the heat exchange part 200. A space communicating with the flow paths of the plurality of tubes 300 is formed inside the liquid-side header 500. A refrigerant that performs heat exchange with a fluid, e.g., air, is introduced through the liquid-side header 500.

The gas-side header 600 is connected to the other end of each of the plurality of tubes 300 constituting the heat exchange part 200. A space communicating with the flow paths of the plurality of tubes 300 is formed inside the gas-side header 600. The refrigerant that has passed through the plurality of tubes 300 is discharged to the gas-side header 600.

Various forms of the fin 400 are described below. One embodiment of the fin 400 is referred to as a fin 410, and another embodiment is referred to as a fin 420. In the following description, it is assumed that ridges and valleys of the fins 410 and 420 are horizontal flat surfaces, but the disclosure is not limited thereto. The ridges and valleys of the fins 410 and 420 may be horizontal curved surfaces.

FIG. 4 is a diagram illustrating an example of a method of manufacturing the fin 410, according to an embodiment of the disclosure. Referring to FIG. 4, according to an embodiment of the disclosure, the fin 410 is manufactured from a plate-shaped member, for example, a metal plate 710.

Reference numerals L11 to L14 denote virtual bending lines. The fin 410 may be manufactured by bending the metal plate 710 along the virtual bending lines L11 to L14.

In detail, the metal plate 710 is bent with a ridge fold along the bending lines (first and second bending lines) L11 and L12. Then, a region 711 between the first and second bending lines L11 and L12 forms a horizontal portion of a ridge of the fin 410. In addition, the metal plate 710 is bent with a valley fold along the bending lines(third and fourth bending lines) L13 and L14. Then, a region 712 between the third and fourth bending lines L13 and L14 forms a horizontal portion of a valley of the fin 410. Accordingly, the fin 410 has a shape in which ridges and valleys are repeated along a longitudinal direction of the tube 300.

The metal plate 710 is also provided with slit lines L15 to L18. Protruding portions are formed on the fin 410 by the action of the slit lines L15 to L18.

In detail, the slit line (first slit line) L15 is a line extending from a point(first point) P11 on the first bending line L11, passing through the second bending line L12, to a point (second point) P12 parallel to the longitudinal direction of the metal plate 710. The first point P11 may not be a point on the first bending line L11. In this case, the first point P11 may be a point on an opposite side of the second bending line L12 with respect to the first bending line L11. The second point P12 may be a point on the second bending line L12. The slit line (second slit line) L16 is a line extending from the second point P12 to a point (third point) P13, which is the foot of a perpendicular line dropped from the second point P12 to one side edge of the metal plate 710. When the metal plate 710 is bent with a ridge fold along the first and second bending lines L11 and L12, a region 713 surrounded by the first and second slit lines L15 and L16, the first bending line L11, and the side edge of the metal plate 710 forms an upwardly protruding portion projecting upward from the ridge of the fin 410.

In addition, the slit line (third slit line) L17 is a line extending from a point (fourth point) P14 on the third bending line L13, passing through the fourth bending line L14, to a point (fifth point) P15, parallel to the longitudinal direction of the metal plate 710. The fourth point P14 may not be a point on the third bending line L13. In this case, the fourth point P14 may be a point on an opposite side of the fourth bending line L14 with respect to the third bending line L13. The fifth point P15 may be a point on the fourth bending line L14. The slit line (fourth slit line) L18 is a line extending from the fifth point P15 to a point (sixth point) P16, which is the foot of a perpendicular line dropped from the fifth point P15 to one side edge of the metal plate 710. When the metal plate 710 is bent with the valley fold along the third and fourth bending lines L13 and L14, a region 714 surrounded by the third and fourth slit lines L17 and L18, the third bending line L11, and the side edge of the metal plate 710 forms an downwardly protruding portion projecting downward from the valley of the fin 410.

In this manner, start points of the first and third slit lines L15 and L17 may be respectively set at points on the first and third bending lines L11 and L13, or points on the opposite sides of the second and fourth bending lines L12 and L14 with respect to the first and third bending lines L11 and L13, while end points of the first and third slit lines L15 and L17 may be respectively set at points on the second and fourth bending lines L12 and L14, or points on the opposite sides of the first and third bending lines L11 and L13. Accordingly, the lengths of the upwardly protruding portion projecting upward from the fin 410 and the downwardly protruding portion projecting downward from the fin 410 may be increased. In addition, although FIG. 4 illustrates that the first to fourth slit lines L15 to L18 are formed such that the respective lengths of the upwardly protruding portion and the downwardly protruding portion on a side of the second and fourth bending lines L12 and L14 are greater than those on a side of the first and third bending lines L11 and L13, the disclosure is not limited thereto. The first to fourth slit lines L15 to L18 may be formed such that the respective lengths of the upwardly protruding portion and the downwardly protruding portion on the side of the first and third bending lines L11 and L13 are greater than those on the side of the second and fourth bending lines L12 and L14. In air conditioning equipment such as household air conditioners or building multi-air conditioners to which the heat exchanger of the embodiment of the disclosure may be applied, the tubes 300 may have various thicknesses. By using the fin 410 of the embodiment of the disclosure, drainage may be secured without compromising productivity in the heat exchanger 21a using the tubes 300 of various thicknesses.

FIG. 5 is a perspective view illustrating an example in which the fin 410 manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger. For example, FIG. 5 is a perspective view of a region B of FIG. 3.

Referring to FIG. 5, the fin 410 is inserted between the two tubes 300. The fin 410 includes a plurality of ridges 411 and a plurality of valleys 412 repeatedly arranged in the longitudinal direction of the tube 300. Each of the ridges 411 is formed by bending the metal plate 710 illustrated in FIG. 4 with a ridge fold along the first and second bending lines L11 and L12. Each of the valleys 412 is formed by bending the metal plate 710 illustrated in FIG. 4 with a valley fold along the third and fourth bending lines L13 and L14.

On the downstream side of the fin 410 in the air flow direction F1, an upwardly protruding portion 413 projecting upward from the ridge 411 and a downwardly protruding portion 414 projecting downward from the valley 412 are arranged. The upwardly protruding portion 413 is formed by the action of the first and second slit lines L15 and L16 of the metal plate 710 illustrated in FIG. 4. The downwardly protruding portion 414 is formed by the action of the third and fourth slit lines L17 and L18 of the metal plate 710 shown in FIG. 4.

On the downstream side of the fin 410 in the air flow direction F1, a notch 415 is formed adjacent to the valley 412, and a notch 416 is formed adjacent to the ridge 411. In detail, the notch 415 is formed on a surface of the fin 410 opposite to a surface of the fin 410 from which the downwardly protruding portion 414 projects. This is because the region 714 of the metal plate 710 illustrated in FIG. 4 extends beyond the fourth bending line L14. In addition, the notch 416 is formed on a surface of the fin 410 opposite to a surface from which the upwardly protruding portion 413 projects. This is because the region 713 of the metal plate 710 illustrated in FIG. 4 extends beyond the second bending line L12.

FIG. 6 is a front view illustrating an example in which the fin 410 manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger. FIG. 6 is a front view of the fin 410 in the region B of FIG. 3, as viewed from the downstream side in the air flow direction F1.

Referring to FIG. 6, the fins 410 are respectively disposed on an upper surface and a lower surface of each of the tubes 300. The arrangement of the tubes 300 and the fins 410 is described using, as an example, a tube 300a and fins 410U and 410L respectively disposed on an upper surface and a lower surface of the tube 300a. The description of the tube 300a and the fins 410U and 410L equally applies to other tubes 300 and fins 410. The fin 410U may be referred to as a first fin, and the fin 410L may be referred to as a second fin.

An upwardly protruding portion 413 projects upward from a ridge 411 of the fin 410L on a lower side of the tube 300a. In addition, a downwardly protruding portion 414 projects downward from a valley 412 of the fin 410U on an upper side of the tube 300a. Here, the fin 410L on the lower side of the tube 300a and the fin 410U on the upper side of the tube 300a are arranged to be offset from each other in a longitudinal direction of the tube 300a. Accordingly, the upwardly protruding portion 413 and the downwardly protruding portion 414 are also arranged to be offset from each other in the longitudinal direction of the tube 300a. In addition, the upwardly protruding portion 413 and the downwardly protruding portion 414 overlap each other when viewed in the longitudinal direction of the tube 300a.

Hereinafter, a principle of improving drainage implemented by overlapping the upwardly protruding portion 413 and the downwardly protruding portion 414 when viewed in the longitudinal direction of the tube 300a is described.

In a general case where the fin 410 has hydrophilicity, water is guided downward along the downwardly protruding portion 414 of the fin 410U on the upper side.

A general case is considered in which the tube 300a has a cross-sectional shape with both rounded ends in a width direction (the air flow direction F1), for example, arc-shaped ends. In this case, the downwardly protruding portion 414 of the fin 410U on the upper side needs to be in aligned contact with the upwardly protruding portion 413 of the fin 410L on the lower side at a center of the tube 300a in a vertical direction (a thickness direction perpendicular to the longitudinal direction and the air flow direction F1), thereby securing a drainage path. That is, the upwardly protruding portion 413 of the fin 410L on the lower side needs to protrude up to the central position of the tube 300a.

On the other hand, when the downwardly protruding portion 414 of the fin 410U on the upper side extends only to the center position of the tube 300a, the degree of extension may be insufficient. Considering the amount of misalignment in the longitudinal direction due to manufacturing errors, assembly errors, etc. of the tube 300a and the downwardly protruding portion 414, deformation during transportation, and the like, there is an increased risk that a drainage path may not be secured when the downwardly protruding portion 414 protrudes only to the central position of the tube 300a. That is, the robustness of drainage performance may deteriorate. Therefore, the downwardly protruding portion 414 of the fin 410U on the upper side may protrude beyond the central position of the tube 300a, and needs to overlap the upwardly protruding portion 413 of the fin 410L on the lower side when viewed in the longitudinal direction of the tube 300a.

Furthermore, during drainage, water is pulled downward at the downwardly protruding portion 414, and forms an interface that remains upward at other locations. For this reason, when the downwardly protruding portion 414 is made excessively long, the surface tension of the water acts in a direction that causes an interface on a side where the notch 416 near the valley 412 is formed to return upward instead of moving downward. Thus, when drainage of the entire heat exchanger 21a is considered, a longer downwardly protruding portion 414 of the fin 410U on the upper side does not necessarily result in a stronger force for draining water downward.

In this manner, when both ends of the tube 300a in the width direction have a rounded shape, the downwardly protruding portion 414 of the fin 410U on the upper side may extend beyond the center of the tube 300a in the vertical direction. Generalizing this, the downwardly protruding portion 414 may extend beyond the most protruding portion of the tube 300a in the width direction.

In addition, the downwardly protruding portion 414 may extend beyond the lower surface of the tube 300. This is because water can easily reach the lower surface of the tube 300a or the ridge 411 of the fin 410L on the lower side.

Here, a length of a portion of the downwardly protruding portion 414 of the fin 410U below the upper surface of the tube 300a is FP-Ft, where FP is a pitch of the fin 410U and Ft is a thickness of the fin 410. This is because a distance between the first bending line L11 and the second bending line L12 in FIG. 4 is FP, and there is a valley 412 having a thickness Ft below a branch point to the downwardly protruding portion 414 in the fin 410U on the upper side. Therefore, where Tt is a thickness of the tube 300a, it is effective for securing drainage when Tt>FP−Ft.

A length of the downwardly protruding portion 414 of the fin 410U on the upper side may be equal to a length of the upwardly protruding portion 413 of the fin 410L on the lower side, but the disclosure is not limited thereto. For example, the length of the upwardly protruding portion 413 may be less than the length of the downwardly protruding portion 414. A hydrophilic coating may be applied to the fin 410. This is because, when the upwardly protruding portion 413 is shorter than the downwardly protruding portion 414, water easily reaches the lower surface of the tube 300a or the ridge 411 of the fin 410L on the lower side. However, because the amount of overlap between the upwardly protruding portion 413 and the downwardly protruding portion 414 is reduced, there may be cases where it becomes difficult for water to be transferred to the fin 410L on the lower side. On the other hand, when the upwardly protruding portion 413 is longer than the downwardly protruding portion 414, a force for pulling the water upward acts, and thus, the speed at which water is transferred to the lower surface of the tube 300a or the ridge 411 of the fin 410L on the lower side may decrease.

FIG. 7 is a side view illustrating an example in which the fin 410 manufactured by the method illustrated in FIG. 4 is applied to a heat exchanger. FIG. 7 is a side view of the fin 410 as viewed from a side of the liquid-side header 500.

Referring to FIG. 7, the fin 410 has the downwardly protruding portion 414 on the downstream side in the air flow direction F1. In addition, as illustrated in FIGS. 5 and 6, the fin 410 also has the upwardly protruding portion 413 on the downstream side thereof in the air flow direction F1, but the upwardly protruding portion 413 is omitted from the side view of FIG. 7.

In the above-described embodiment of the disclosure, the downwardly protruding portion 414 and the upwardly protruding portion 413 are provided on the downstream side in the air flow direction F1, but the disclosure is not limited thereto. The downwardly protruding portion 414 and the upwardly protruding portion 413 may be provided on an upstream side in the air flow direction F1. That is, the downwardly protruding portion 414 and the upwardly protruding portion 413 may be provided at one end among both ends of the tube 300 in the air flow direction F1.

When the downwardly protruding portion 414 and the upwardly protruding portion 413 are provided at both ends of the tube 300 in the air flow direction F1, a width of the tube 300 is reduced. Accordingly, pressure loss within the tube 300 increases, which may degrade performance of the heat exchanger. In addition, a contact area between the tube 300 and the fin 410 is reduced, which may degrade the performance of the heat exchanger.

The downwardly protruding portion 414 and the upwardly protruding portion 413 may contact one end of the tube 300 in the air flow direction F1. In this case, water needs to be brought into close proximity to the downwardly protruding portion 414 and the upwardly protruding portion 413. Therefore, the downwardly protruding portion 414 and the upwardly protruding portion 413 may be in close planar contact with the tube 300 at portions where they contact the tube 300. In FIG. 7, the downwardly protruding portion 414 is in close contact with a short side end of the tube 300.

With the above-described configuration, condensate water may be bridged between the fin 410U on the upper side of the tube 300 and the fin 410L on the lower side.

FIG. 8 is a diagram illustrating an example of a method of manufacturing a fin 420, according to an embodiment of the disclosure. Referring to FIG. 8, according to an embodiment of the disclosure, the fin 420 is manufactured from a plate-shaped member, for example, a metal plate 720.

Reference numerals L21 to L24 denote virtual bending lines. The fin 420 may be manufactured by bending the metal plate 720 along the virtual bending lines L21 to L24.

In detail, the metal plate 720 is bent with a ridge fold along the bending lines (first and second bending lines) L21 and L22. Then, a region 721 between the first and second bending lines L21 and L22 forms a horizontal portion of a ridge of the fin 420. In addition, the metal plate 720 is bent with a valley fold along the bending lines (third and fourth bending lines) L23 and L24. Then, a region 724 between the third and fourth bending lines L23 and L24 forms a horizontal portion of a valley of the fin 420. Accordingly, the fin 420 has a shape in which ridges and valleys are repeatedly arranged along a longitudinal direction of the tube 300.

The metal plate 720 is also provided with slit lines L25 to L28. Protruding portions are formed on the fin 420 by the action of the slit lines L25 to L28.

In detail, the slit line (first slit line) L25 is a line extending from a point (first point) P21 on the first bending line L21 and passing through the second bending line L22 to a point (second point) P22, parallel to the longitudinal direction of the metal plate 720. The first point P21 may not be a point on the first bending line L21. In this case, the first point P21 may be a point on an opposite side of the second bending line L22 with respect to the first bending line L21. The second point P22 may be a point on the second bending line L22. The slit line (second slit line) L26 is a line extending from the second point P22 to a point (third point) P23, which is an intersection between one side of the metal plate 720 and the first bending line L21. When the metal plate 720 is bent with the ridge fold along the first and second bending lines L21 and L22, a region 723 surrounded by the first and second slit lines L25 and L26 and the first bending line L21 forms an upwardly protruding portion projecting upward from the ridge of the fin 420.

In addition, the slit line (third slit line) L27 is a line extending from a point (fourth point) P24 on the third bending line L23 and passing through the fourth bending line L24 to a point (fifth point) P25, parallel to the longitudinal direction of the metal plate 720. The fourth point P24 may not be a point on the third bending line L23. In this case, the fourth point P24 may be a point on an opposite side of the fourth bending line L24 with respect to the third bending line L23. The fifth point P25 may be a point on the fourth bending line L24. The slit line (fourth slit line) L28 is a line extending from the fifth point P25 to a sixth point P26, which is an intersection between one side edge of the metal plate 720 and the third bending line L23. When the metal plate 720 is bent with the valley fold along the third and fourth bending lines L23 and L24, a region 724 surrounded by the third and fourth slit lines L27 and L28 and the third bending line L23 forms a downwardly protruding portion projecting downward from the valley of the fin 420.

In this manner, start points of the first and third slit lines L25 and L27 may be respectively set at points on the first and third bending lines L21 and L23, or points on the opposite sides of the second and fourth bending lines L22 and L24 with respect to the first and third bending lines L21 and L23, while end points of the first and third slit lines L25 and L27 may be respectively set at points on the second and fourth bending lines L22 and L24, or points on the opposite sides of the first and third bending lines L21 and L23. Accordingly, the lengths of the upwardly protruding portion projecting upward from the fin 420 and the downwardly protruding portion projecting downward from the fin 420 may be increased. In addition, although FIG. 8 illustrates that the first to fourth slit lines L25 to L28 are formed such that the respective lengths of the upwardly protruding portion and the downwardly protruding portion on a side of the second and fourth bending lines L22 and L24 are greater than those on a side of the first and third bending lines L21 and L23, the disclosure is not limited thereto. The first to fourth slit lines L25 to L28 may be formed such that the respective lengths of the upwardly protruding portion and the downwardly protruding portion on the side of the first and third bending lines L21 and L23 are greater than those on the side of the second and fourth bending lines L22 and L24. In air conditioning equipment such as household air conditioners or building multi-air conditioners to which the heat exchanger of the embodiment of the disclosure may be applied, the tubes 300 may have various thicknesses. By using the fin 420 of the embodiment of the disclosure, drainage may be secured without compromising productivity in the heat exchanger 21a using the tubes 300 of various thicknesses.

FIG. 9 is a perspective view illustrating an example in which the fin 420 manufactured by the method illustrated in FIG. 8 is applied to a heat exchanger. For example, FIG. 9 is a perspective view of a region B of FIG. 3.

Referring to FIG. 9, the fin 420 is inserted between the two tubes 300. The fin 420 includes a plurality of ridges 421 and a plurality of valleys 422 repeatedly arranged in the longitudinal direction of the tube 300. Each of the ridges 421 is formed by bending the metal plate 720 illustrated in FIG. 8 with a ridge fold along the first and second bending lines L21 and L22. Each of the valleys 422 is formed by bending the metal plate 720 illustrated in FIG. 8 with a valley fold along the third and fourth bending lines L23 and L24.

On the downstream side of the fin 420 in the air flow direction F1, an upwardly protruding portion 423 projecting upward from the ridge 421 and a downwardly protruding portion 424 projecting downward from the valley 422 are arranged. The upwardly protruding portion 423 is formed by the action of the first and second slit lines L25 and L26 of the metal plate 720 illustrated in FIG. 8. The downwardly protruding portion 424 is formed by the action of the third and fourth slit lines L27 and L28 of the metal plate 720 illustrated in FIG. 8.

On a downstream side of the fin 420 in the air flow direction F1, an uncut portion 425 is formed in the valley 422, and an uncut portion 426 is formed in the ridge 421. In detail, the uncut portion 425 is formed on a surface of the fin 420 on an upper side, which is opposite to a surface from which the downwardly protruding portion 414 projects. This is because the region 724 of the metal plate 720 illustrated in FIG. 8 extends beyond the fourth bending line L24. In addition, the notch 416 is formed on a surface of the fin 420 opposite to a surface from which the upwardly protruding portion 423 projects. This is because the region 723 of the metal plate 720 illustrated in FIG. 8 extends beyond the second bending line L22.

A front view of an example in which the fin 420 according to an embodiment of the disclosure is applied to the heat exchanger is the same as FIG. 6. In this case, the fin 410, the fin 410U on the upper side, and the fin 410L on the lower side in FIG. 6 are respectively replaced with a fin 420, a fin 420U on an upper side, and a fin 420L on a lower side, and the ridge 411, the valley 412, the upwardly protruding portion 413, and the downwardly protruding portion 414 in FIG. 6 are respectively replaced with the ridge 421, the valley 422, the upwardly protruding portion 423, and the downwardly protruding portion 424. The principle of improving drainage by arranging the upwardly protruding portion 423 and the downwardly protruding portion 424 to overlap each other when viewed in the longitudinal direction of the tube 300 is also the same as described above. An effective condition for a length of the downwardly protruding portion 424 and a thickness of the tube 300 is also the same as described above. Furthermore, a relationship between the length of the downwardly protruding portion 424 and the length of the upwardly protruding portion 423 is also the same as described above.

FIG. 10 is a side view illustrating an example in which the fin 420 manufactured by the method illustrated in FIG. 8 is applied to a heat exchanger. FIG. 10 is a side view of the fin 420 as viewed from the side of the liquid-side header 500.

Referring to FIG. 10, the fin 420 has the downwardly protruding portion 424 on the downstream side in the air flow direction F1. In addition, as illustrated in FIG. 9, the fin 420 also has the upwardly protruding portion 423 on the downstream side thereof in the air flow direction F1, but the upwardly protruding portion 423 is omitted from the side view of FIG. 10. As described above, the downwardly protruding portion 424 and the upwardly protruding portion 423 may be provided at one end among both ends of the tube 300 in the air flow direction F1. Furthermore, as described above, the downwardly protruding portion 424 and the upwardly protruding portion 423 may be in contact with one end of the tube 300 in the air flow direction F1, and may be in close planar contact with the tube 300.

With the above-described configuration, condensate water may be bridged between the fin 420 on the upper side of the tube 300 and the fin 420 on the lower side.

FIG. 11 is a side view illustrating an example of a drainage path of the heat exchanger 21a. The heat exchanger 21a is arranged, for example, in an area A1 of the indoor unit 20a illustrated in FIG. 2, in the same direction as shown in FIG. 11.

Referring to FIG. 11, upwardly protruding portions 403 and downwardly protruding portions 404 are provided on a downstream side of the heat exchanger 21a in the air flow direction F1. Here, the upwardly protruding portion 403 corresponds to the upwardly protruding portion 413 in FIGS. 4 to 7 or the upwardly protruding portion 423 in FIGS. 8 to 10. In addition, the downwardly protruding portion 404 corresponds to the upwardly protruding portion 414 in FIGS. 4 to 7 or the upwardly protruding portion 424 in FIGS. 8 to 10. Accordingly, as indicated by an arrow W1, a drainage path is formed on the downstream side of the heat exchanger 21a in the air flow direction F1, i.e., on a leeward side.

FIG. 12 is a cross-sectional view illustrating an example of the indoor unit 20 of the air conditioner 1, according to an embodiment of the disclosure. An indoor unit as an embodiment of the indoor unit 20 is denoted by reference numeral 20b. FIG. 13 is a side view illustrating an example of a drainage path of a heat exchanger 21b shown in FIG. 12. The heat exchanger 21b is arranged, for example, in an area A2 of the indoor unit 20b illustrated in FIG. 12, in the same direction as shown in FIG. 13.

In the indoor unit 20b, the heat exchanger 21b is arranged in an inclined manner. In the embodiment of the disclosure, a 1-way ceiling cassette type indoor unit is described as an example of the indoor unit 20b, but the indoor unit 20b may be another type of indoor unit such as a duct-type indoor unit. Referring to FIG. 12, the indoor unit 20b includes the heat exchanger 21b and a fan 22b. An air flow is generated in a direction indicated by an arrow F1 by rotation of the fan 22a, and the air flow passes through the heat exchanger 21b. Heat exchange between air and a refrigerant is performed in the heat exchanger 21b. The indoor unit 20b may include other general components of the indoor unit 20, such as the expansion valve 23 shown in FIG. 1.

An example of the configuration of the heat exchanger 21b is as shown in FIG. 3. However, unlike in FIG. 3, an upstream side of the heat exchanger 21b in an air flow direction F2 is at the front. A method of manufacturing a fin 400 is as described with reference to FIG. 4 or 8. The configuration of the fin 400 is as shown in FIGS. 5 to 7, or FIGS. 9 and 10. Therefore, the description of the fin 410 or the fin 420 applies equally to the fin 400. However, an upwardly protruding portion 403 and a downwardly protruding portion 404 are provided on the upstream side of the fin 400 in the air flow direction F2.

As described above, the upwardly protruding portions 403 and the downwardly protruding portions 404 are arranged on the upstream side of the heat exchanger 21b in the air flow direction F2. Accordingly, as indicated by an arrow W2, a drainage path is formed on the upstream side of the heat exchanger 21b in the air flow direction F2, i.e., on a windward side. Here, the upstream side in the air flow direction F2 is approximately a lower side in a gravitational direction indicated by an arrow G. Therefore, water naturally moves in the gravitational direction along the drainage path indicated by the arrow W2. As a result, because water easily reaches the upwardly protruding portion 403 from the downwardly protruding portion 404, smooth drainage is achieved even when the amount of overlap therebetween is relatively small.

According to an aspect of the disclosure, an air conditioner includes an outdoor heat exchanger and an indoor heat exchanger. At least one of the outdoor heat exchanger or the indoor heat exchanger includes a first header into which a refrigerant performing heat exchange with a fluid is introduced, a second header from which the refrigerant is discharged, a tube having a flat tube form, through which the refrigerant introduced from the first header is discharged to the second header, and fins respectively provided on an upper surface of the tube, which is parallel to a flow direction of the fluid, and a lower surface opposite to the upper surface, the fins including a plurality of ridges and a plurality of valleys alternately arranged along a longitudinal direction of the tube. The fins include a first fin provided on the upper surface of the tube and a second fin provided on the lower surface of the tube. The first fin includes a downwardly protruding portion that protrudes from a corresponding one of the plurality of valleys toward the lower surface of the tube and contacts one end of the tube in the flow direction of the fluid. The second fin includes an upwardly protruding portion that protrudes from a corresponding one of the plurality of ridges toward the upper surface of the tube and contacts the one end of the tube.

In an embodiment of the disclosure, the downwardly protruding portion may be in close planar contact with the one end of the tube, and the upwardly protruding portion may be in close planar contact with the one end of the tube.

In an embodiment of the disclosure, the first fin and the second fin may be arranged such that the downwardly protruding portion of the first fin and the upwardly protruding portion of the second fin are offset from each other in the longitudinal direction of the tube.

In an embodiment of the disclosure, the downwardly protruding portion of the first fin and the upwardly protruding portion of the second fin may overlap each other when viewed in the longitudinal direction of the tube.

In an embodiment of the disclosure, the downwardly protruding portion may extend beyond the most protruding portion of the one end of the tube in the flow direction of the fluid.

In an embodiment of the disclosure, the downwardly protruding portion may extend beyond the lower surface of the tube.

In an embodiment of the disclosure, a length of the downwardly protruding portion may be greater than a length of the upwardly protruding portion.

In an embodiment of the disclosure, the one end of the tube may have a rounded shape.

In an embodiment of the disclosure, at least one of the outdoor heat exchanger or the indoor heat exchanger may be arranged at an inclination with respect to a gravitational direction. The one end of the tube may be a lower end in the gravitational direction.

According to an aspect of the disclosure, a heat exchanger includes a first header into which a refrigerant performing heat exchange with a fluid is introduced, a second header from which the refrigerant is discharged, a tube having a flat tube form, through which the refrigerant introduced from the first header is discharged to the second header, and fins respectively provided on an upper surface of the tube, which is parallel to a flow direction of the fluid, and a lower surface opposite to the upper surface, the fins including a plurality of ridges and a plurality of valleys alternately arranged along a longitudinal direction of the tube. The fins include a first fin provided on the upper surface of the tube and a second fin provided on the lower surface of the tube. The first fin includes a downwardly protruding portion that protrudes from a corresponding one of the plurality of valleys toward the lower surface of the tube and contacts one end of the tube in the flow direction of the fluid. The second fin includes an upwardly protruding portion that protrudes from a corresponding one of the plurality of ridges toward the upper surface of the tube and contacts the one end of the tube.

In an embodiment of the disclosure, the downwardly protruding portion may be in close planar contact with the one end of the tube, and the upwardly protruding portion may be in close planar contact with the one end of the tube.

In an embodiment of the disclosure, the first fin and the second fin may be arranged such that the downwardly protruding portion of the first fin and the upwardly protruding portion of the second fin are offset from each other in the longitudinal direction of the tube, and the downwardly protruding portion of the first fin and the upwardly protruding portion of the second fin may overlap each other when viewed in the longitudinal direction of the tube.

In an embodiment of the disclosure, the downwardly protruding portion may extend beyond a most protruding portion of the one end of the tube in the flow direction of the fluid.

In an embodiment of the disclosure, the downwardly protruding portion may extend beyond the lower surface of the tube.

In an embodiment of the disclosure, a length of the downwardly protruding portion may be greater than a length of the upwardly protruding portion.

According to an aspect of the disclosure, a heat exchanger includes a first header into which a refrigerant performing heat exchange with a fluid is introduced, a second header from which the refrigerant is discharged, a flat tube through which the refrigerant introduced from the first header is discharged to the second header, a first fin provided on a first surface of the flat tube parallel to a flow direction of the fluid, the first fin including ridges and valleys alternately arranged, and a second fin provided on a second surface of the flat tube opposite to the first surface, the second fin including ridges and valleys alternately arranged. The first fin includes a first protruding portion that protrudes from a corresponding one of the valleys toward the second surface, and the second fin includes a second protruding portion that protrudes from a corresponding one of the ridges toward the first surface.

The first protruding portion and the second protruding portion may be formed by providing, on a plate-shaped member, a virtual first bending line, a virtual second bending line, a first slit line extending, parallel to a longitudinal direction of the plate-shaped member, from a first point on the virtual first bending line or on a side opposite to the virtual second bending line with respect to the virtual first bending line, to a second point on the virtual second bending line or on a side opposite to the virtual first bending line with respect to the virtual second bending line, a second slit line extending from the second point to a third point on a side edge of the plate-shaped member, a virtual third bending line, a virtual fourth bending line, a third slit line extending, parallel to the longitudinal direction of the plate-shaped member, from a fourth point on the virtual third bending line or on a side opposite to the virtual fourth bending line with respect to the virtual third bending line, to a fifth point on the virtual fourth bending line or on a side opposite to the virtual third bending line with respect to the virtual fourth bending line, and a fourth slit line extending from the fifth point to a sixth point on the side edge of the plate-shaped member, and then bending the plate-shaped member along the first bending line and the second bending line with a valley fold and along the third bending line and the fourth bending line with a ridge fold.

According to an aspect of the disclosure, a heat exchanger includes a first header into which a refrigerant performing heat exchange with a fluid is introduced, a second header from which the refrigerant is discharged, a flat tube through which the refrigerant introduced from the first header is discharged to the second header, a first fin provided on a first surface of the flat tube parallel to a flow direction of the fluid, the first fin including ridges and valleys alternately arranged, and a second fin provided on a second surface of the flat tube opposite to the first surface, the second fin including ridges and valleys alternately arranged. The first fin includes a first protruding portion that protrudes from a corresponding one of the valleys toward the second surface, and the second fin includes a second protruding portion that protrudes from a corresponding one of the ridges toward the first surface.

When the first fin and the second fin are expanded into a plate-shaped member in which the ridges and the valleys are not formed, the plate-shaped member is provided with: a virtual first bending line and a virtual second bending line which are to form the valley by being bent with a valley fold; a first slit line extending, parallel to a longitudinal direction of the plate-shaped member, from a first point on the virtual first bending line or on a side opposite to the virtual second bending line with respect to the virtual first bending line, to a second point on the virtual second bending line or on a side opposite to the virtual first bending line with respect to the virtual second bending line; a second slit line extending from the second point to a third point on a side edge of the plate-shaped member; a virtual third bending line and a virtual fourth bending line which form the ridge by being bent with a ridge fold; a third slit line extending, parallel to the longitudinal direction of the plate-shaped member, from a fourth point on the virtual third bending line or on a side opposite to the virtual fourth bending line with respect to the virtual third bending line, to a fifth point on the virtual fourth bending line or on a side opposite to the virtual third bending line with respect to the virtual fourth bending line, and a fourth slit line extending from the fifth point to a sixth point on the side edge of the plate-shaped member.

According to the above-described configuration, drainage of the heat exchanger may be secured. In addition, a heat exchanger with secured drainage, which is applicable to various devices including air conditioners, may be implemented.

Technical effects to be achieved from the disclosure are not limited to the effects described above, and other technical effects not described herein will be apparent to those of ordinary skill in the art from the description of the disclosure.

As described above, although the heat exchanger of the disclosure and the air conditioner employing the same have been described with reference to specific embodiments of the disclosure and drawings, the disclosure is not limited to the embodiments, and various modifications may be made without departing from the spirit of the disclosure.

Claims

1. An air conditioner comprising:

an outdoor heat exchanger; and

an indoor heat exchanger,

wherein at least one of the outdoor heat exchanger or the indoor heat exchanger includes: a first header into which a refrigerant for performing heat exchange with a fluid is introducible, a second header from which the refrigerant is discharged, a tube, having a flat tube form, into which the refrigerant in the first header is introduced such that the refrigerant flows through the tube to be discharged to the second header, wherein the tube has an upper surface which is parallel to a flow direction of the fluid and a lower surface opposite to the upper surface, a first fin on the upper surface of the tube and including: a plurality of ridges and a plurality of valleys alternately arranged along a longitudinal direction of the tube, and downwardly protruding portions that protrude from respectively corresponding valleys of the first fin toward the lower surface of the tube and that contact one end of the tube, and a second fin on the lower surface of the tube and including: a plurality of ridges and a plurality of valleys alternately arranged along the longitudinal direction of the tube, and upwardly protruding portions that protrude from respectively corresponding ridges of the second fin toward the upper surface of the tube and that contact the one end of the tube.

2. The air conditioner of claim 1, wherein

the downwardly protruding portions are in close planar contact with the one end of the tube, and

the upwardly protruding portions are in close planar contact with the one end of the tube.

3. The air conditioner of claim 1, wherein the first fin and the second fin are arranged such that the downwardly protruding portions of the first fin and the upwardly protruding portions of the second fin are offset from each other in the longitudinal direction of the tube.

4. The air conditioner of claim 1, wherein the downwardly protruding portions of the first fin and the upwardly protruding portions of the second fin overlap each other when viewed in the longitudinal direction of the tube.

5. The air conditioner of claim 1, wherein the downwardly protruding portions extends beyond a most protruding portion of the one end of the tube in the flow direction of the fluid.

6. The air conditioner of claim 1, wherein the downwardly protruding portions extend beyond the lower surface of the tube.

7. The air conditioner of claim 1, wherein a length of the downwardly protruding portions is greater than a length of the upwardly protruding portions.

8. The air conditioner of claim 1, wherein the one end of the tube has a rounded shape.

9. The air conditioner of claim 1, wherein

the at least one of the outdoor heat exchanger or the indoor heat exchanger is arranged at an inclination with respect to a gravitational direction, and

the one end of the tube is a lower end in the gravitational direction.

10. A heat exchanger comprising:

a first header into which a refrigerant for performing heat exchange with a fluid is introducible;

a second header from which the refrigerant is discharged;

a tube having a flat tube form, through which the refrigerant in the first header is introduced such that the refrigerant flows through the tube to be discharged to the second header, wherein the tube has an upper surface which is parallel to a flow direction of the fluid and a lower surface opposite to the upper surface;

a first fin on the upper surface of the tube and including: a plurality of ridges and a plurality of valleys alternately arranged along a longitudinal direction of the tube, and downwardly protruding portions that protrude from respectively corresponding valleys of the first fin toward the lower surface of the tube and that contact one end of the tube, and

a second fin on the lower surface of the tube and including: a plurality of ridges and a plurality of valleys alternately arranged along the longitudinal direction of the tube, and upwardly protruding portions that protrude from respectively corresponding ridges of the second fin toward the upper surface of the tube and that contact the one end of the tube.

11. The heat exchanger of claim 10, wherein

the downwardly protruding portions are in close planar contact with the one end of the tube, and

the upwardly protruding portions are in close planar contact with the one end of the tube.

12. The heat exchanger of claim 11, wherein

the first fin and the second fin are arranged such that the downwardly protruding portions of the first fin and the upwardly protruding portions of the second fin are offset from each other in the longitudinal direction of the tube, and

the downwardly protruding portions of the first fin and the upwardly protruding portions of the second fin overlap each other when viewed in the longitudinal direction of the tube.

13. The heat exchanger of claim 10, wherein the downwardly protruding portions extends beyond a most protruding portion of the one end of the tube in the flow direction of the fluid.

14. The heat exchanger of claim 10, wherein the downwardly protruding portions extend beyond the lower surface of the tube.

15. The heat exchanger of claim 10, wherein a length of the downwardly protruding portions is greater than a length of the upwardly protruding portions.