JP3674058B2

JP3674058B2 - Manufacturing method of stacked heat exchanger

Info

Publication number: JP3674058B2
Application number: JP24507794A
Authority: JP
Inventors: 恵津夫長谷川; 聡也長沢
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 1994-10-11
Filing date: 1994-10-11
Publication date: 2005-07-20
Anticipated expiration: 2020-07-20
Also published as: JPH08110189A

Description

【０００１】
【産業上の利用分野】
本発明は流体通路を金属薄板の積層構造により形成する積層型熱交換器において、特に流体通路内を流れる内部流体同志で熱交換を行う副熱交換部を有する積層型熱交換器の製造方法に関する。
【０００２】
【従来の技術】
本出願人は、特開平５−１９６３２１号公報において、流体通路内を流れる内部冷媒同志で熱交換を行う副熱交換部を有する積層型熱交換器を提案している。上記公報記載のものは、具体的には冷凍サイクルの冷媒蒸発器として適用されるものであって、通常の冷媒−空気間の熱交換をおこなう主熱交換部の他に、蒸発器入口側の冷媒と蒸発器出口側の冷媒とを熱交換させて、主熱交換部の入口タンク内に流入する冷媒の乾き度を小さくする、副熱交換部（冷媒−冷媒熱交換部）を設けている。
【０００３】
この副熱交換部の作用により主熱交換部の入口タンク内に流入する冷媒の乾き度を大幅に小さくして、入口タンク内における冷媒を液単相に近い状態にすることにより、入口タンクから多数のチューブに冷媒を分配する際に、各チューブに均一に液冷媒を分配できる。しかも、各チューブ内面が液冷媒で覆われた状態となり、チューブ内面での熱伝達率が向上し、これらのことが相まって蒸発器の冷却性能を向上できるものである。
【０００４】
【発明が解決しようとする課題】
ところで、上記公報記載のものは、冷媒通路を構成する金属薄板を積層してろう付けにより一体構造に接合して製造されるようになっているが、本発明者らの試作、実験検討によれば、通常の蒸発器では具備してない副熱交換部（冷媒−冷媒熱交換部）を持つため、蒸発器の製造に際し、次のごとき問題が発生することが分かった。
【０００５】
すなわち、副熱交換部では、主熱交換部のようなコルゲートフィンが金属薄板相互間に介在されておらず、金属薄板だけで積層しているので、主熱交換部に比して熱容量が大となる。そのため、副熱交換部は、主熱交換部に比して温度上昇に時間がかかり、ろう付け温度まで十分上昇できず、ろう付け不良を起こすことがある。
【０００６】
また、副熱交換部の端板には、前記内部流体の入口管および出口管を有する配管コネクタ部材が備えられているが、この配管コネクタ部材と端板との位置決めを確実に行うためには、この配管コネクタ部材と端板との嵌合部をかしめて、両者の嵌合部分を仮止めする必要が生じ、組付工程が複雑となる。
本発明は上記点に鑑みてなされたもので、流体通路内を流れる内部流体同志で熱交換を行う副熱交換部を有する積層型熱交換器において、副熱交換部の温度上昇不足によるろう付け不良を良好に解消できる製造方法を提供することを目的とする。
【０００７】
また、本発明の他の目的は、配管コネクタ部材の位置決めをかしめ工程なしで、簡単に行うことができる積層型熱交換器の製造方法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
本発明は上記目的を達成するため、以下の技術的手段を採用する。
請求項１記載の発明では、流体通路（７ａ）内を流れる内部流体と前記流体通路（７ａ）の外部を流れる外部流体とを熱交換させる主熱交換部（７）と、
前記主熱交換部（７）の流体通路（７ａ）の入口側に流入する内部流体と、前記主熱交換部（７）の流体通路（７ａ）の出口側から流出する内部流体とを熱交換させる副熱交換部（８）とを有し、
前記主及び副熱交換部（７、８）の流体通路（７ａ、８ａ、８ｂ）は金属薄板（７ｂ、８ｃ）の積層構造により形成されており、
前記主熱交換部（７）には前記外部流体側の伝熱面積を増大するフィン部材（１１）が備えられている積層型熱交換器の製造方法であって、
前記主熱交換部（７）および前記副熱交換部（８）を、それぞれ金属薄板（７ｂ、８ｃ）の積層構造からなる所定構造に仮組付するとともに、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となるようにして、この両熱交換部を治具（Ａ、Ｂ、Ｃ）により一体に保持する組付工程と、
次に、前記両熱交換部（７、８）からなる組付体を、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となる位置関係を維持しながら、炉中にて一体ろう付けするろう付け工程とを具備する積層型熱交換器の製造方法を特徴としている。
【０００９】
請求項２記載の発明では、流体通路（７ａ）内を流れる内部流体と前記流体通路（７ａ）の外部を流れる外部流体とを熱交換させる主熱交換部（７）と、
前記主熱交換部（７）の流体通路（７ａ）の入口側に流入する内部流体と、前記主熱交換部（７）の流体通路（７ａ）の出口側から流出する内部流体とを熱交換させる副熱交換部（８）とを有し、
前記主及び副熱交換部（７、８）の流体通路（７ａ、８ａ、８ｂ）は金属薄板（７ｂ、８ｃ）の積層構造により形成されており、
前記主熱交換部（７）には前記外部流体側の伝熱面積を増大するフィン部材（１１）が備えられており、
前記副熱交換部（８）の端板（１２）には、前記内部流体の入口管（１３ａ）および出口管（１３ｂ）を有する配管コネクタ部材（１３）が備えられている積層型熱交換器の製造方法であって、
前記主熱交換部（７）および前記副熱交換部（８）を、それぞれ金属薄板（７ｂ、８ｃ）の積層構造からなる所定構造に仮組付するとともに、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となるようにして、この両熱交換部（７、８）を治具（Ａ、Ｂ、Ｃ）により一体に保持する組付工程と、
次に、前記両熱交換部（７、８）からなる組付体を、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となる位置関係を維持しながら、炉中にて一体ろう付けするろう付け工程とを具備する積層型熱交換器の製造方法を特徴としている。
【００１０】
請求項３記載の発明では、冷媒通路（７ａ）内を流れる冷媒と前記冷媒通路（７ａ）の外部を流れる被冷却流体とを熱交換させる主熱交換部（７）と、
前記主熱交換部（７）の冷媒通路（７ａ）の入口側に流入する入口側冷媒と、前記主熱交換部（７）の冷媒通路（７ａ）の出口側から流出する出口側冷媒とを熱交換させる副熱交換部（８）とを有し、
前記主及び副熱交換部（７、８）の冷媒通路（７ａ、８ａ、８ｂ）は金属薄板（７ｂ、８ｃ）の積層構造により形成されており、
前記主熱交換部（７）には前記被冷却流体側の伝熱面積を増大するフィン部材（１１）が備えられている積層型冷媒蒸発器の製造方法であって、
前記主熱交換部（７）および前記副熱交換部（８）を、それぞれ金属薄板（７ｂ、８ｃ）の積層構造からなる所定構造に仮組付するとともに、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となるようにして、この両熱交換部（７、８）を治具（Ａ、Ｂ、Ｃ）により一体に保持する組付工程と、
次に、前記両熱交換部（７、８）からなる組付体を、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となる位置関係を維持しながら、炉中にて一体ろう付けするろう付け工程とを具備する積層型冷媒蒸発器の製造方法を特徴としている。
【００１１】
請求項４記載の発明では、冷媒通路（７ａ）内を流れる冷媒と前記冷媒通路（７ａ）の外部を流れる被冷却流体とを熱交換させる主熱交換部（７）と、
前記主熱交換部（７）の冷媒通路（７ａ）の入口側に流入する入口側冷媒と、前記主熱交換部（７）の冷媒通路（７ａ）の出口側から流出する出口側冷媒とを熱交換させる副熱交換部（８）とを有し、
前記主及び副熱交換部（７、８）の冷媒通路（７ａ、８ａ、８ｂ）は金属薄板（７ｂ、８ｃ）の積層構造により形成されており、
前記主熱交換部（７）には前記被冷却流体側の伝熱面積を増大するフィン部材（１１）が備えられており、
前記副熱交換部（８）の端板（１２）には、前記冷媒の入口管（１３ａ）および出口管（１３ｃ）を有する配管コネクタ部材（１３）が備えられている積層型冷媒蒸発器の製造方法であって、
前記主熱交換部（７）および前記副熱交換部（８）を、それぞれ金属薄板（７ｂ、８ｃ）の積層構造からなる所定構造に仮組付するとともに、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となるようにして、この両熱交換部（７、８）を治具（Ａ、Ｂ、Ｃ）により一体に保持する組付工程と、
次に、前記両熱交換部（７、８）からなる組付体を、前記主熱交換部（７）が下方、前記副熱交換部（８）が上方となる位置関係を維持しながら、炉中にて一体ろう付けするろう付け工程とを具備する積層型冷媒蒸発器の製造方法を特徴としている。
【００１２】
請求項５記載の発明では、請求項３または４に記載の積層型冷媒蒸発器の製造方法において、前記治具（Ａ、Ｂ、Ｃ）により一体に保持された前記両熱交換部（７、８）を、前記治具（Ａ、Ｂ、Ｃ）を介して、移動自在なキャリア（Ｄ）の保持棚（Ｅ）上に載置して、前記炉への移動を行うことを特徴とする。
請求項６記載の発明では、請求項３ないし５のいずれか１つに記載の積層型冷媒蒸発器の製造方法において、前記副熱交換部（８）の最上部に前記端板（１２）を組付け、この端板（１２）に設けた穴部（１２ｂ）に前記配管コネクタ部材（１３）を上方から自重により嵌合保持することを特徴とする。
【００１３】
なお、上記各手段の括弧内の符号は、後述する実施例記載の具体的手段との対応関係を示すものである。
【００１４】
【発明の作用効果】
請求項１〜６記載の発明によれば、熱容量の小さい（温度上昇しやすい）主熱交換部（７）を下方にし、熱容量の大きい副熱交換部（８）を上方にして、この両熱交換部（７、８）を一体ろう付けしているから、蒸発器組付体を搬送用キャリア（Ｄ）の保持棚（Ｅ）に載置してろう付け用炉内に搬送し、ろう付けする場合に、この保持棚（Ｅ）に主熱交換部（７）の方が近接するので、主熱交換部（７）の熱が治具（Ａ、Ｂ、Ｃ）を通してキャリア（Ｄ）の保持棚（Ｅ）に伝導する割合よりも、副熱交換部（８）の熱が治具（Ａ、Ｂ、Ｃ）を通してキャリア（Ｄ）の保持棚（Ｅ）に伝導する割合の方を低減でき、その結果ろう付け時に熱容量の大きい副熱交換部（８）の温度上昇の遅れを防止でき、副熱交換部（８）を含めた熱交換器全体を良好にろう付けできる。
【００１５】
また、主熱交換部（７）を下方にし、副熱交換部（８）を上方に配置して組付けることにより、副熱交換部（８）の最上部に端板（１２）を組付けて、この端板（１２）に対して配管コネクタ部材（１３）を上方から自重により嵌合保持することが可能となり、配管コネクタ部材（１３）をかしめ工程なしで簡単に位置決めしてろう付けできる。そのため、ろう付け前の組付工程を簡素化できる。
【００１６】
【実施例】
以下、本発明を図に示す実施例について説明する。図１は本発明方法により製造した冷媒蒸発器を適用した自動車用空調装置の冷凍サイクルを示しており、１は圧縮機で、電磁クラッチ２を介して自動車用エンジン（駆動源、図示せず）により駆動されるものである。３は凝縮器で、圧縮機１から吐出された高温、高圧のガス冷媒を冷却ファン（図示せず）の送風空気と熱交換して冷却し、凝縮するものである。４は凝縮器３で凝縮した液冷媒を溜めて液冷媒のみをサイクル下流側へ導出する受液器、５は冷媒の減圧手段を構成する温度作動式膨張弁で、５ａはその感温筒である。６は本発明による積層型の冷媒蒸発器である。
【００１７】
この蒸発器６は、冷媒通路７ａ内を流れる冷媒と前記冷媒通路７ａの外部を流れる空調用送風空気（被冷却流体）とを熱交換させる主熱交換部７と、
この主熱交換部７の冷媒通路７ａの入口側に流入する冷媒と、前記主熱交換部７の冷媒通路７ａの出口側から流出する冷媒とを熱交換させる副熱交換部８とを有している。
【００１８】
ここで、副熱交換部８において、８ａは前記主熱交換部７の冷媒通路７ａの入口側に流入する冷媒が流れる入口側冷媒通路を示し、８ｂは前記主熱交換部７の冷媒通路７ａの出口側から流出する冷媒が流れる出口側冷媒通路を示す。従って、副熱交換部８は冷媒−冷媒熱交換部を構成することになる。一方、主熱交換部７は送風空気から冷媒が吸熱して蒸発する冷媒蒸発部（冷媒−空気熱交換部）を構成することになる。
【００１９】
９は副熱交換部８の入口側冷媒通路８ａと主熱交換部７の冷媒通路７ａの入口部との間に蛇行状に形成された微小断面積の絞り通路で、一般にキャピラリチューブと称されている減圧手段の役割を果たす。但し、この絞り通路９による減圧度合いは膨張弁５の減圧度合いよりも小さく設定されており、この絞り通路９はその上流側と下流側との間に冷媒の圧力差を設けて、副熱交換部８における入口側冷媒通路８ａの冷媒温度と、出口側冷媒通路８ｂの冷媒温度との間に、高低の温度差をつけることにより、両通路８ａ、８ｂ間の熱交換を良好に行わせるものである。
【００２０】
１０は定圧弁で、冬季の如く冷凍サイクル熱負荷が著しく低下して、その前後の圧力差が設定値以下になると、開弁して受液器４からの液冷媒を所定量減圧して直接主熱交換部７の冷媒通路７ａの入口に流入させるものである。
冬季の低負荷条件時には、凝縮器３における冷媒圧力が低下して、蒸発器６の冷媒圧力との間の圧力差に占める絞り通路９の抵抗が大となって、冷媒流量が小となる。そして、車室内空気を循環させる内気循環モードでは、小流量の冷媒が比較的高温の内気から吸熱して、主熱交換部７の出口冷媒温度が入口冷媒温度より高くなってしまうことがある。その結果、副熱交換部８で、主熱交換部７の出口冷媒により入口側冷媒を加熱するという不具合が生じる。
【００２１】
そこで、このような低負荷条件下では、前記定圧弁１０を開弁して、上記不具合の発生を防止するようにしてある。
前記主及び副熱交換部７、８及び絞り通路９は金属薄板の積層構造により形成されており、その具体的構造は基本的には特開平５−１９６３２１号公報と同じでよいので、以下積層構造の概略を図２、３により説明すると、主熱交換部７では、金属薄板７ｂ、具体的にはアルミニュウム心材の両面にろう材をクラッドした両面クラッド材を所定形状に成形して、これを２枚１組として多数組積層した上で、ろう付けにより接合することにより多数の冷媒通路７ａを並列に形成するものである。
【００２２】
この多数の冷媒通路７ａはそれぞれ図１、２の上方でＵターンするＵ形状のものであり、この各Ｕ形状の冷媒通路７ａの入口部及び出口部はそれぞれ通路下方部に形成された入口側タンク部７ｃ、出口側タンク部７ｄの開口部にて相互にコア奥行き方向で連通するようになっている。
また、主熱交換部７では、隣接する冷媒通路７ａの外面側相互の間隙にコルゲートフィン（フィン手段）１１を接合して空気側の伝熱面積の増大を図るようになっている。
【００２３】
同様に、副熱交換部８においても、金属薄板８ｃ、具体的にはアルミニュウム心材の両面にろう材をクラッドした両面クラッド材を所定形状に成形して、これを多数枚積層してろう付けにより接合することにより、この多数枚の積層構造の金属薄板８ｃの間に、前記入口側冷媒通路８ａと、出口側冷媒通路８ｂを交互に形成するようになっている。
【００２４】
ここで、副熱交換部８の端板１２には配管コネクタ部材１３が接合されるようになっており、この配管コネクタ部材１３には、膨張弁５で減圧された気液２相冷媒が流入する入口管１３ａと、蒸発器６から圧縮機１側へ吸入されるガス冷媒が流出する出口管１３ｂと、絞り通路９の下流側を定圧弁１０の下流側に接続する接続管１３ｃとが配設されている。
【００２５】
また、上記端板１２には、副熱交換部８の入口側冷媒通路８ａと出口側冷媒通路８ｂ相互間での冷媒洩れ（内部洩れ）検査用治具挿入穴１９（図４（ａ）参照）を形成する取付座１８がろう付けで接合されており、そしてこの取付座１８には前記治具挿入穴１９を閉じるための密封部材２０がねじにより脱着自在に装着されている。
【００２６】
そして、上記入口管１３ａからの冷媒は、金属薄板８ｃの上部に形成された、入口側冷媒通路８ａの入口側タンク部８ｄに流入するようになっており、この入口側タンク部８ｄはそれ自身の開口部にてコア奥行き方向に連通している。
一方、金属薄板８ｃの下部に入口側冷媒通路８ａの出口側タンク部８ｅが形成されており、この出口側タンク部８ｅもそれ自身の開口部にてコア奥行き方向に連通している。そして、上部の入口側タンク部８ｄから下部の出口側タンク部８ｅに向かって、入口側冷媒通路８ａが蛇行状に形成されている。
【００２７】
また、前記した絞り通路９は、主熱交換部７のうち最も副熱交換部８寄りの金属薄板７ｂ′と、主、副両熱交換部７、８の中間に介在された肉厚の中間プレート１４との間に形成されるようになっている。
副熱交換部８の入口側冷媒通路８ａの出口側タンク部８ｅから流出した冷媒は中間プレート１４に形成された通路穴（図示せず）を通り、次に絞り通路９の入口部９ａに流入する。そして、この絞り通路９を通過した後、絞り通路９の出口部９ｂから冷媒は中間プレート１４に形成された別の通路穴（図示せず）を通り、再度副熱交換部８側へ流入し、その後、中継タンク部８ｈを通過して中間プレート１４に形成されたさらに別の通路穴を通り、主熱交換部７の入口側タンク部７ｃに流入する。
【００２８】
そして、ここから冷媒は主熱交換部７の各冷媒通路７ａをＵターン状に流れ、その後出口側タンク部７ｄに集合するようになっている。
この出口側タンク部７ｄに集合した冷媒は、中間プレート１４に形成された別の通路穴（図示せず）を通り、副熱交換部８の金属薄板８ｃの下部に形成された、出口側冷媒通路８ｂの入口側タンク部８ｆに流入するようになっており、この入口側タンク部８ｆはそれ自身の開口部にてコア奥行き方向に連通している。一方、金属薄板８ｃの上部に出口側冷媒通路８ｂの出口側タンク部８ｇが形成されており、この出口側タンク部８ｇもそれ自身の開口部にてコア奥行き方向に連通している。そして、下部の入口側タンク部８ｆから上部の出口側タンク部８ｇに向かって、出口側冷媒通路８ｂが形成されている。
【００２９】
副熱交換部８において、入口側冷媒通路８ａと出口側冷媒通路８ｂは多数枚積層された金属薄板８ｃの表裏両側に交互に形成されている。出口側冷媒通路８ｂの出口側タンク部８ｇから冷媒は配管コネクタ部材１３の出口管１３ｂへ流出する。１５は主熱交換部７の端板である。
次に、上記のごとく構成された本実施例の冷媒蒸発器の製造方法について説明する。
【００３０】
本実施例では、蒸発器６をアルミニュウムの一体ろう付けで製造するようにしてあるので、冷間鍛造、切削加工等の必要な厚肉部品である配管コネクタ部材１３及び取付座１８、さらにはろう材の不要なコルゲートフィン１１を除く他の薄板形状の部品は、すべてろう材（Ａ４１０４）を心材（Ａ３００３）の両面にクラッドしたアルミニュウム両面クラッド材から成形されている。
【００３１】
厚肉部品の配管コネクタ部材１３および取付座１８と、コルゲートフィン１１はろう材をクラッドしてないアルミニュウムベア材（Ａ３００３）で成形している。
以下製造方法を工程順に説明する。
１．主熱交換部７及び副熱交換部８のそれぞれ個別の組付工程
主熱交換部７においては、まず、入口タンク部７ｃ、出口タンク部７ｄのバーリング形状部７ｅ（図４（ｃ）参照）をかしめて口拡することによりコルゲートフィン１１を挟む２つの金属薄板７ｂ、７ｂ（７ｂ′）を一体化して、これらの三者１１、７ｂ、７ｂ（７ｂ′）を１ユニットしておく。
【００３２】
しかるのち、図５に示す下治具Ａの上に、端板１５を載せ、その上に、前記１ユニット化した金属薄板７ｂ、７ｂ、絞り通路９を形成する金属薄板７ｂ′、コルゲートフィン１１を必要段数積層することにより、主熱交換部７の組付を終える。
一方、副熱交換部８においては、中間プレート１４を最下方にして、その上に金属薄板８ｃを必要段数積層し、最上段に端板１２を載せる。次に、図４（ａ）、（ｂ）に示すように、端板１２の穴部１２ａ、１２ｂに、取付座１８の円筒状突出部１８ａ、および配管コネクタ部材１３の円筒状突出部１３ｄを嵌合する。ここで、この両突出部１８ａ、１３ｄはかしめることなく、取付座１８および配管コネクタ部材１３の自重で単に嵌合しているだけである。
【００３３】
以上により、副熱交換部８の組付を終える。
２．蒸発器６全体の組付工程
上記のように、それぞれ個別に組付けられた主熱交換部７と副熱交換部８とを、主熱交換部７の上方に副熱交換部８が位置するように、この両者７、８を積層する。従って、副熱交換部８の取付座１８および配管コネクタ部材１３が図５に示すように最上方に位置する。
【００３４】
次に、副熱交換部８の端板１２上に上治具Ｂを載せる。このとき、上治具Ｂには、端板１２上に突出している取付座１８および配管コネクタ部材１３等を回避するように段部Ｂ−１、Ｂ−２（図５参照）が設けてあるので、この段部Ｂ−１、Ｂ−２の下側空間内に取付座１８および配管コネクタ部材１３等が納まるようにして（換言すれば、取付座１８および配管コネクタ部材１３等との干渉を避けるようにして）、上治具Ｂを端板１２上に載せることができる。取付座１８および配管コネクタ部材１３はその自重で端板１２との嵌合状態を維持する。
【００３５】
次に、コ字状に形成された２枚の縦治具Ｃを、所定の間隔を開けて、下治具Ａの下側面と上治具Ｂの上側面の間に組付け、この縦治具Ｃにより下治具Ａと上治具Ｂとの間に所定の押圧力を加えて、蒸発器６全体の積層状態を維持する。
３．蒸発器６全体の一体ろう付け工程
縦治具Ｃにより上記両熱交換部７、８の積層状態を維持しながら、蒸発器６の組付体を図６に示すキャリアＤの保持棚Ｅの上に載置する。このとき、縦治具Ｃの下端部を保持棚Ｅの嵌合穴Ｆに嵌合することにより、組付体の載置姿勢を保つ。
【００３６】
キャリアＤはその上部に配置されたハンガＧにて吊り下げられて移動自在となっているので、キャリアＤを真空炉中に搬入して、組付体をアルミニュウムクラッド材のろう材融点以上に加熱して、組付体各部の接合部分をろう付けにより一体に接合し、蒸発器６全体を一体構造にする。
ここで、キャリアＤの保持棚Ｅは、図６（ａ）に示すように２０〜３０台の蒸発器６の組付体を同時に炉内に搬送できるようにするため、ある程度の強度が必要となり、そして強度を持たせるために、肉厚が大となるので、キャリアＤの熱容量は蒸発器６に比してかなり大きくなる。
【００３７】
従って、炉内にて、キャリアＤの保持棚Ｅは蒸発器６に比してかなり温度上昇の速度が遅れることになり、その結果蒸発器６が受けた輻射熱は縦治具Ｃを通してキャリアＤの保持棚Ｅに移動するため、蒸発器６においては、その上方側から下方側へ向かって温度が次第に低下する、温度勾配（図６（ｃ）参照）が生じることになる。
【００３８】
蒸発器６にこのような温度勾配が生じる点に鑑みて、本発明では、蒸発器６において、熱容量の大きい副熱交換部８を温度上昇しやすい上方側に配置して、主、副の両熱交換部７、８の温度上昇の均一化を図っている。
これにより、熱容量の大きい副熱交換部８が温度上昇遅れによりろう付け不良となるのを防止できる。
４．冷媒の外部洩れ検査工程
次に、蒸発器６を密閉室内に搬入し、洩れ検査用流体（例えばヘリウムガス）を所定圧力に加圧して蒸発器６の主、副両熱交換部７、８の冷媒通路７ａ、８ａ、８ｂ内に供給し、蒸発器６外への流体洩れ（密閉室内への流体洩れ）の有無を検査する。
５．冷媒の内部洩れ検査工程
副熱交換部８においてろう付け不良等により入口側冷媒通路８ａと出口側冷媒通路８ｂとが直接連通する状態が内部洩れ（図１の矢印Ｘはこの内部洩れを模式的に示す）であり、この内部洩れによる連通状態と、入口側冷媒通路８ａと出口側冷媒通路８ｂとが主熱交換部７の冷媒通路７ａを介して連通している正規の連通状態は、蒸発器６の本来の構成のままでは区別することができない。
【００３９】
そこで、本例では、主熱交換部７の冷媒通路７ａの入口部を閉鎖（図１のＹ部はその閉鎖部を示す）することにより、冷媒の内部洩れの検査を可能としている。すなわち、冷媒の外部洩れ検査工程で装着した蓋体２０を取付座１８から取り外して、その代わりに図示しない検査治具の先端の弁体を取付座１８の治具挿入穴１９から副熱交換部８内に挿入して、検査治具の先端の弁体１７により図１のＹ部に相当する冷媒入口穴を閉鎖する。
【００４０】
そして、接続管１３ｃは適宜の盲蓋で閉塞し、出口管１３ｂは開口したままにしておく。
しかるのち、蒸発器６を密閉室内に搬入し、入口管１３ａに洩れ検査用流体（例えばヘリウムガス）の供給装置を接続して、この検査用流体を所定圧力に加圧して入口管１３ａから蒸発器６の副熱交換部８の入口側冷媒通路８ａ内に供給し、副熱交換部８の入口側冷媒通路８ａから出口側冷媒通路８ｂへの流体洩れ（出口管１３ｂを通して密閉室内への流体洩れ）の有無を検査する。
【００４１】
つまり、図１の矢印Ｘのような内部洩れがあるときは、出口管１３ｂを通して密閉室内へ流体が洩れてくるので、内部洩れの発生を検知できる。
６．蓋体装着工程
外部洩れ検査及び内部洩れ検査により、洩れなしと判定された良品については、検査治具を取付座１８から取り外して、その代わりに蓋体２０を取付座１８にねじ込みで装着する。
【００４２】
以上により蒸発器６の骨格構造の製造を終了でき、この後は表面処理等の仕上げを行うことにより、蒸発器６の製造を完了できる。
【図面の簡単な説明】
【図１】本発明方法を適用する蒸発器を含む冷凍サイクル図である。
【図２】本発明方法を適用する蒸発器を示す斜視図である。
【図３】図２の蒸発器の分解斜視図である。
【図４】（ａ）、（ｂ）、（ｃ）は図２、３の蒸発器の要部拡大断面図である。
【図５】図２、３に示す蒸発器の組付体を組付用治具により保持した状態を示す斜視図である。
【図６】（ａ）は蒸発器組付体搬送用キャリアの概要構成図、（ｂ）は（ａ）の一部拡大図、（ｃ）は蒸発器組付体の温度勾配を示す図である。
【符号の説明】
６…蒸発器、７…主熱交換部、７ａ…冷媒通路、７ｂ…金属薄板、
８…副熱交換部、８ａ…入口側冷媒通路、８ｂ…出口側冷媒通路、
８ｃ…金属薄板、１２…端板、１３…配管コネクタ部材、
Ａ…下治具、Ｂ…上治具、Ｃ…縦治具、Ｄ…キャリア、Ｅ…保持棚。[0001]
[Industrial application fields]
The present invention relates to a stacked heat exchanger in which a fluid passage is formed by a laminated structure of thin metal plates, and more particularly to a method for manufacturing a stacked heat exchanger having a sub heat exchange section that exchanges heat between internal fluids flowing in a fluid passage. .
[0002]
[Prior art]
In Japanese Patent Application Laid-Open No. 5-196321, the applicant of the present application has proposed a stacked heat exchanger having a sub heat exchange section that exchanges heat between internal refrigerants flowing in a fluid passage. The above-mentioned publication is specifically applied as a refrigerant evaporator of a refrigeration cycle, and in addition to a main heat exchange unit that performs heat exchange between a normal refrigerant and air, A sub heat exchange unit (refrigerant-refrigerant heat exchange unit) is provided to reduce the dryness of the refrigerant flowing into the inlet tank of the main heat exchange unit by exchanging heat between the refrigerant and the refrigerant at the evaporator outlet side. .
[0003]
By the action of this sub heat exchange part, the dryness of the refrigerant flowing into the inlet tank of the main heat exchange part is greatly reduced, and the refrigerant in the inlet tank is made to be in a state close to a liquid single phase. When distributing the refrigerant to a large number of tubes, the liquid refrigerant can be uniformly distributed to each tube. In addition, the inner surface of each tube is covered with the liquid refrigerant, the heat transfer coefficient on the inner surface of the tube is improved, and these can be combined to improve the cooling performance of the evaporator.
[0004]
[Problems to be solved by the invention]
By the way, although the thing of the said gazette is laminated | stacked and manufactured by laminating | stacking the metal thin plate which comprises a refrigerant path, and joining to integral structure by brazing, it is based on trial manufacture and experiment examination of these inventors. For example, since it has a sub heat exchange part (refrigerant-refrigerant heat exchange part) which is not provided in a normal evaporator, it has been found that the following problems occur when the evaporator is manufactured.
[0005]
That is, in the auxiliary heat exchange section, corrugated fins like the main heat exchange section are not interposed between the thin metal plates, and are laminated only by the thin metal plates, so that the heat capacity is larger than that of the main heat exchange portion. It becomes. For this reason, the sub heat exchange section takes a longer time to rise in temperature than the main heat exchange section, and cannot sufficiently rise to the brazing temperature, which may cause brazing failure.
[0006]
Further, the end plate of the auxiliary heat exchanging section is provided with a pipe connector member having an inlet pipe and an outlet pipe for the internal fluid. In order to reliably position the pipe connector member and the end plate, The fitting portion between the pipe connector member and the end plate needs to be caulked to temporarily fix the fitting portion therebetween, which complicates the assembly process.
The present invention has been made in view of the above points, and in a stacked heat exchanger having a sub heat exchange section that exchanges heat between internal fluids flowing in a fluid passage, brazing due to insufficient temperature rise of the sub heat exchange section. It aims at providing the manufacturing method which can eliminate a defect favorably.
[0007]
Another object of the present invention is to provide a method for manufacturing a laminated heat exchanger that can easily perform positioning of a pipe connector member without a caulking step.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the present invention employs the following technical means.
In the invention according to claim 1, a main heat exchange part (7) for exchanging heat between the internal fluid flowing in the fluid passage (7a) and the external fluid flowing outside the fluid passage (7a),
Heat exchange is performed between the internal fluid flowing into the inlet side of the fluid passage (7a) of the main heat exchanging portion (7) and the internal fluid flowing out from the outlet side of the fluid passage (7a) of the main heat exchanging portion (7). An auxiliary heat exchange section (8)
The fluid passages (7a, 8a, 8b) of the main and auxiliary heat exchange parts (7, 8) are formed by a laminated structure of metal thin plates (7b, 8c),
The main heat exchanging part (7) is a manufacturing method of a laminated heat exchanger provided with a fin member (11) for increasing the heat transfer area on the external fluid side,
The main heat exchanging part (7) and the auxiliary heat exchanging part (8) are temporarily assembled to predetermined structures each having a laminated structure of metal thin plates (7b, 8c), and the main heat exchanging part (7) An assembling step for holding the two heat exchanging portions integrally with the jigs (A, B, C) so that the sub heat exchanging portion (8) is on the lower side;
Next, the assembly composed of both the heat exchange parts (7, 8) is maintained while maintaining the positional relationship in which the main heat exchange part (7) is downward and the auxiliary heat exchange part (8) is upward. The present invention is characterized by a method for manufacturing a laminated heat exchanger including a brazing step of integrally brazing in a furnace.
[0009]
In the invention according to claim 2, the main heat exchange section (7) for exchanging heat between the internal fluid flowing in the fluid passage (7a) and the external fluid flowing outside the fluid passage (7a),
Heat exchange is performed between the internal fluid flowing into the inlet side of the fluid passage (7a) of the main heat exchanging portion (7) and the internal fluid flowing out from the outlet side of the fluid passage (7a) of the main heat exchanging portion (7). An auxiliary heat exchange section (8)
The fluid passages (7a, 8a, 8b) of the main and auxiliary heat exchange parts (7, 8) are formed by a laminated structure of metal thin plates (7b, 8c),
The main heat exchange part (7) is provided with a fin member (11) that increases the heat transfer area on the external fluid side,
The laminated heat exchanger is provided with a pipe connector member (13) having an inlet pipe (13a) and an outlet pipe (13b) for the internal fluid on the end plate (12) of the auxiliary heat exchange section (8). A manufacturing method of
The main heat exchanging part (7) and the auxiliary heat exchanging part (8) are temporarily assembled to predetermined structures each having a laminated structure of metal thin plates (7b, 8c), and the main heat exchanging part (7) An assembly step of holding both the heat exchange parts (7, 8) together with jigs (A, B, C) so that the sub heat exchange part (8) is on the lower side,
Next, the assembly composed of both the heat exchange parts (7, 8) is maintained while maintaining the positional relationship in which the main heat exchange part (7) is downward and the auxiliary heat exchange part (8) is upward. The present invention is characterized by a method for manufacturing a laminated heat exchanger including a brazing step of integrally brazing in a furnace.
[0010]
In the invention according to claim 3, the main heat exchange section (7) for exchanging heat between the refrigerant flowing in the refrigerant passage (7a) and the fluid to be cooled flowing outside the refrigerant passage (7a);
An inlet side refrigerant flowing into the inlet side of the refrigerant passage (7a) of the main heat exchange part (7) and an outlet side refrigerant flowing out from the outlet side of the refrigerant path (7a) of the main heat exchange part (7). A secondary heat exchange section (8) for heat exchange,
The refrigerant passages (7a, 8a, 8b) of the main and auxiliary heat exchange parts (7, 8) are formed by a laminated structure of metal thin plates (7b, 8c),
The main heat exchanging part (7) is a manufacturing method of a laminated refrigerant evaporator provided with a fin member (11) that increases a heat transfer area on the cooled fluid side,
The main heat exchanging part (7) and the auxiliary heat exchanging part (8) are temporarily assembled to predetermined structures each having a laminated structure of metal thin plates (7b, 8c), and the main heat exchanging part (7) An assembly step of holding both the heat exchange parts (7, 8) together with jigs (A, B, C) so that the sub heat exchange part (8) is on the lower side,
Next, the assembly composed of both the heat exchange parts (7, 8) is maintained while maintaining the positional relationship in which the main heat exchange part (7) is downward and the auxiliary heat exchange part (8) is upward. The present invention is characterized by a method for manufacturing a laminated refrigerant evaporator including a brazing step of integrally brazing in a furnace.
[0011]
In the invention according to claim 4, the main heat exchanging part (7) for exchanging heat between the refrigerant flowing in the refrigerant passage (7a) and the fluid to be cooled flowing outside the refrigerant passage (7a),
An inlet side refrigerant flowing into the inlet side of the refrigerant passage (7a) of the main heat exchange part (7) and an outlet side refrigerant flowing out from the outlet side of the refrigerant path (7a) of the main heat exchange part (7). A secondary heat exchange section (8) for heat exchange,
The refrigerant passages (7a, 8a, 8b) of the main and auxiliary heat exchange parts (7, 8) are formed by a laminated structure of metal thin plates (7b, 8c),
The main heat exchange part (7) is provided with a fin member (11) that increases the heat transfer area on the cooled fluid side,
An end plate (12) of the auxiliary heat exchanger (8) includes a pipe connector member (13) having an inlet pipe (13a) and an outlet pipe (13c) for the refrigerant. A manufacturing method comprising:
The main heat exchanging part (7) and the auxiliary heat exchanging part (8) are temporarily assembled to predetermined structures each having a laminated structure of metal thin plates (7b, 8c), and the main heat exchanging part (7) An assembly step of holding both the heat exchange parts (7, 8) together with jigs (A, B, C) so that the sub heat exchange part (8) is on the lower side,
Next, the assembly composed of both the heat exchange parts (7, 8) is maintained while maintaining the positional relationship in which the main heat exchange part (7) is downward and the auxiliary heat exchange part (8) is upward. The present invention is characterized by a method for manufacturing a laminated refrigerant evaporator including a brazing step of integrally brazing in a furnace.
[0012]
According to a fifth aspect of the present invention, in the method for manufacturing a stacked refrigerant evaporator according to the third or fourth aspect, the two heat exchange parts (7, 7) held together by the jig (A, B, C). 8) is placed on a holding shelf (E) of a movable carrier (D) via the jig (A, B, C), and moved to the furnace. .
According to a sixth aspect of the present invention, in the method for manufacturing a stacked refrigerant evaporator according to any one of the third to fifth aspects, the end plate (12) is placed on the uppermost portion of the auxiliary heat exchange section (8). The pipe connector member (13) is fitted and held from above by its own weight in a hole (12b) provided in the end plate (12).
[0013]
In addition, the code | symbol in the bracket | parenthesis of each said means shows a corresponding relationship with the specific means of the Example description described later.
[0014]
[Effects of the invention]
According to the first to sixth aspects of the present invention, the main heat exchanging portion (7) having a small heat capacity (the temperature is likely to rise) is directed downward, and the auxiliary heat exchanging portion (8) having a large heat capacity is directed upward. Since the replacement parts (7, 8) are integrally brazed, the evaporator assembly is placed on the holding shelf (E) of the carrier (D) for conveyance and conveyed into the brazing furnace for brazing. In this case, since the main heat exchanging part (7) is closer to the holding shelf (E), the heat of the main heat exchanging part (7) passes through the jigs (A, B, C) of the carrier (D). Compared to the rate of conduction to the holding shelf (E), the rate at which the heat of the auxiliary heat exchange section (8) is conducted to the holding shelf (E) of the carrier (D) through the jig (A, B, C) is reduced. As a result, it is possible to prevent a delay in temperature rise of the auxiliary heat exchange section (8) having a large heat capacity during brazing, and the entire heat exchanger including the auxiliary heat exchange section (8) It can be good Jiro with.
[0015]
Moreover, the end plate (12) is assembled | attached to the uppermost part of a sub heat exchange part (8) by arrange | positioning and mounting a main heat exchange part (7) below and a sub heat exchange part (8) upward. Thus, the pipe connector member (13) can be fitted and held to the end plate (12) by its own weight from above, and the pipe connector member (13) can be easily positioned and brazed without a caulking step. . Therefore, the assembly process before brazing can be simplified.
[0016]
【Example】
The present invention will be described below with reference to embodiments shown in the drawings. FIG. 1 shows a refrigeration cycle of an automobile air conditioner to which a refrigerant evaporator manufactured by the method of the present invention is applied. Reference numeral 1 denotes a compressor, which is an automobile engine (drive source, not shown) via an electromagnetic clutch 2. It is driven by. Reference numeral 3 denotes a condenser, which cools and condenses the high-temperature and high-pressure gas refrigerant discharged from the compressor 1 by exchanging heat with blown air from a cooling fan (not shown). 4 is a liquid receiver that stores the liquid refrigerant condensed in the condenser 3 and leads only the liquid refrigerant to the downstream side of the cycle, 5 is a temperature-actuated expansion valve that constitutes a pressure reducing means for the refrigerant, and 5a is a temperature sensing cylinder. is there. Reference numeral 6 denotes a stacked refrigerant evaporator according to the present invention.
[0017]
The evaporator 6 includes a main heat exchanging unit 7 for exchanging heat between the refrigerant flowing in the refrigerant passage 7a and the air-conditioning blown air (cooled fluid) flowing outside the refrigerant passage 7a.
A sub heat exchanging portion 8 for exchanging heat between the refrigerant flowing into the inlet side of the refrigerant passage 7a of the main heat exchanging portion 7 and the refrigerant flowing out from the outlet side of the refrigerant passage 7a of the main heat exchanging portion 7; ing.
[0018]
Here, in the auxiliary heat exchange unit 8, 8 a denotes an inlet side refrigerant passage through which refrigerant flows into the inlet side of the refrigerant passage 7 a of the main heat exchange unit 7, and 8 b denotes the refrigerant passage 7 a of the main heat exchange unit 7. 2 shows an outlet side refrigerant passage through which refrigerant flowing out from the outlet side of the refrigerant flows. Accordingly, the auxiliary heat exchange unit 8 constitutes a refrigerant-refrigerant heat exchange unit. On the other hand, the main heat exchange unit 7 constitutes a refrigerant evaporation unit (refrigerant-air heat exchange unit) in which the refrigerant absorbs heat from the blown air and evaporates.
[0019]
9 is a narrow passage having a minute cross-sectional area formed in a meandering manner between the inlet side refrigerant passage 8a of the auxiliary heat exchange section 8 and the inlet portion of the refrigerant passage 7a of the main heat exchange section 7, and is generally called a capillary tube. Serves as a decompression means. However, the degree of pressure reduction by the throttle passage 9 is set to be smaller than the degree of pressure reduction of the expansion valve 5, and this throttle passage 9 provides a pressure difference of the refrigerant between the upstream side and the downstream side so that sub heat exchange is performed. By making a difference in temperature between the refrigerant temperature of the inlet side refrigerant passage 8a in the section 8 and the refrigerant temperature of the outlet side refrigerant passage 8b, heat exchange between both the passages 8a and 8b is favorably performed. It is.
[0020]
10 is a constant pressure valve. When the heat load of the refrigeration cycle is significantly reduced as in winter, and the pressure difference before and after that is less than a set value, the valve is opened and the liquid refrigerant from the liquid receiver 4 is depressurized by a predetermined amount directly. It is made to flow into the inlet of the refrigerant passage 7a of the main heat exchange part 7.
Under low load conditions in winter, the refrigerant pressure in the condenser 3 decreases, the resistance of the throttle passage 9 occupying the pressure difference from the refrigerant pressure in the evaporator 6 increases, and the refrigerant flow rate decreases. In the inside air circulation mode in which the passenger compartment air is circulated, a small flow amount of refrigerant may absorb heat from the relatively high temperature inside air, and the outlet refrigerant temperature of the main heat exchange unit 7 may become higher than the inlet refrigerant temperature. As a result, the sub heat exchange unit 8 has a problem that the inlet side refrigerant is heated by the outlet refrigerant of the main heat exchange unit 7.
[0021]
Therefore, under such a low load condition, the constant pressure valve 10 is opened to prevent the occurrence of the above problem.
The main and auxiliary heat exchanging portions 7 and 8 and the throttle passage 9 are formed by a laminated structure of thin metal plates, and the specific structure may be basically the same as that of JP-A-5-196321. 2 and 3, the main heat exchanging unit 7 forms a metal thin plate 7b, specifically, a double-sided clad material in which a brazing material is clad on both sides of an aluminum core material into a predetermined shape. A large number of refrigerant passages 7a are formed in parallel by laminating a large number of two sheets as one set and joining them by brazing.
[0022]
Each of the plurality of refrigerant passages 7a has a U-shape that makes a U-turn in the upper direction in FIGS. 1 and 2, and the inlet portion and the outlet portion of each U-shaped refrigerant passage 7a are respectively formed on the inlet side formed in the lower portion of the passage. The tank portion 7c and the outlet side tank portion 7d communicate with each other in the core depth direction.
In the main heat exchanging section 7, corrugated fins (fin means) 11 are joined to the gaps between the outer surfaces of the adjacent refrigerant passages 7a to increase the heat transfer area on the air side.
[0023]
Similarly, in the auxiliary heat exchanging section 8, a thin metal plate 8c, specifically, a double-sided clad material in which a brazing material is clad on both sides of an aluminum core is formed into a predetermined shape, and a large number of these are laminated and brazed. By joining, the inlet side refrigerant passages 8a and the outlet side refrigerant passages 8b are alternately formed between the multiple thin metal plates 8c having a laminated structure.
[0024]
Here, a pipe connector member 13 is joined to the end plate 12 of the auxiliary heat exchange unit 8, and the gas-liquid two-phase refrigerant decompressed by the expansion valve 5 flows into the pipe connector member 13. An inlet pipe 13a, an outlet pipe 13b from which the gas refrigerant sucked from the evaporator 6 to the compressor 1 flows out, and a connection pipe 13c that connects the downstream side of the throttle passage 9 to the downstream side of the constant pressure valve 10 are arranged. It is installed.
[0025]
The end plate 12 has a jig insertion hole 19 for inspection of refrigerant leakage (internal leakage) between the inlet-side refrigerant passage 8a and the outlet-side refrigerant passage 8b of the auxiliary heat exchange section 8 (see FIG. 4A). A mounting seat 18 is formed by brazing, and a sealing member 20 for closing the jig insertion hole 19 is detachably attached to the mounting seat 18 with a screw.
[0026]
The refrigerant from the inlet pipe 13a flows into the inlet side tank portion 8d of the inlet side refrigerant passage 8a formed in the upper part of the thin metal plate 8c. The inlet side tank portion 8d itself The opening communicates in the core depth direction.
On the other hand, an outlet side tank portion 8e of the inlet side refrigerant passage 8a is formed in the lower part of the thin metal plate 8c, and this outlet side tank portion 8e is also communicated in the core depth direction at its own opening. An inlet-side refrigerant passage 8a is formed in a meandering manner from the upper inlet-side tank portion 8d toward the lower outlet-side tank portion 8e.
[0027]
Further, the throttle passage 9 described above is formed between the thin metal plate 7 b ′ closest to the sub heat exchanging portion 8 in the main heat exchanging portion 7 and the intermediate thickness between the main and sub heat exchanging portions 7, 8. It is formed between the plate 14.
The refrigerant flowing out from the outlet side tank portion 8e of the inlet side refrigerant passage 8a of the auxiliary heat exchange portion 8 passes through a passage hole (not shown) formed in the intermediate plate 14, and then flows into the inlet portion 9a of the throttle passage 9. To do. After passing through the throttle passage 9, the refrigerant flows from the outlet portion 9 b of the throttle passage 9 through another passage hole (not shown) formed in the intermediate plate 14 and again flows into the auxiliary heat exchange portion 8 side. After that, it passes through the relay tank portion 8h, passes through another passage hole formed in the intermediate plate 14, and flows into the inlet side tank portion 7c of the main heat exchange portion 7.
[0028]
And from here, a refrigerant | coolant flows through each refrigerant path 7a of the main heat exchange part 7 in the shape of a U-turn, and it collects in the outlet side tank part 7d after that.
The refrigerant gathered in the outlet side tank portion 7d passes through another passage hole (not shown) formed in the intermediate plate 14 and is formed in the lower portion of the thin metal plate 8c of the auxiliary heat exchanging portion 8. It flows into the inlet side tank part 8f of the passage 8b, and this inlet side tank part 8f communicates in the core depth direction at its own opening. On the other hand, an outlet side tank portion 8g of the outlet side refrigerant passage 8b is formed on the upper part of the thin metal plate 8c, and this outlet side tank portion 8g is also communicated in the core depth direction at its own opening. An outlet side refrigerant passage 8b is formed from the lower inlet side tank portion 8f toward the upper outlet side tank portion 8g.
[0029]
In the auxiliary heat exchanging section 8, the inlet side refrigerant passages 8a and the outlet side refrigerant passages 8b are alternately formed on both front and back sides of the laminated metal thin plates 8c. The refrigerant flows out from the outlet side tank portion 8g of the outlet side refrigerant passage 8b to the outlet pipe 13b of the pipe connector member 13. Reference numeral 15 denotes an end plate of the main heat exchange unit 7.
Next, the manufacturing method of the refrigerant evaporator of the present Example configured as described above will be described.
[0030]
In this embodiment, the evaporator 6 is manufactured by integrally brazing aluminum, so that the pipe connector member 13 and the mounting seat 18 which are thick parts necessary for cold forging, cutting, etc. All of the thin plate-like components other than the corrugated fins 11 that do not require the material are formed from an aluminum double-sided clad material in which a brazing material (A4104) is clad on both sides of the core material (A3003).
[0031]
The thick-walled pipe connector member 13 and mounting seat 18 and the corrugated fin 11 are formed of an aluminum bare material (A3003) that is not clad with a brazing material.
Hereinafter, the production method will be described in the order of steps.
1. In the individual assembly process main heat exchange section 7 for each of the main heat exchange section 7 and the sub heat exchange section 8, first, the burring shape section 7e of the inlet tank section 7c and the outlet tank section 7d (see FIG. 4C) The two thin metal plates 7b and 7b (7b ') sandwiching the corrugated fin 11 are integrated by caulking and the three members 11, 7b and 7b (7b') are united.
[0032]
Thereafter, the end plate 15 is placed on the lower jig A shown in FIG. 5, and the thin metal plates 7b and 7b formed as one unit, the thin metal plate 7b ′ forming the throttle passage 9, and the corrugated fin 11 Assembling of the main heat exchange section 7 is completed by stacking the required number of steps.
On the other hand, in the auxiliary heat exchanging section 8, the intermediate plate 14 is placed at the lowermost position, the required number of thin metal plates 8c are stacked thereon, and the end plate 12 is placed on the uppermost stage. Next, as shown in FIGS. 4A and 4B, the cylindrical protrusion 18 a of the mounting seat 18 and the cylindrical protrusion 13 d of the pipe connector member 13 are inserted into the holes 12 a and 12 b of the end plate 12. Mating. Here, the two projecting portions 18a and 13d are merely fitted by their own weights of the mounting seat 18 and the pipe connector member 13 without being caulked.
[0033]
Thus, the assembly of the auxiliary heat exchange unit 8 is completed.
2. Assembling process of the entire evaporator 6 As described above, the main heat exchanging part 7 and the sub heat exchanging part 8 that are individually assembled are positioned above the main heat exchanging part 7. Thus, both these 7 and 8 are laminated | stacked. Accordingly, the mounting seat 18 and the pipe connector member 13 of the auxiliary heat exchanging portion 8 are located at the uppermost position as shown in FIG.
[0034]
Next, the upper jig B is placed on the end plate 12 of the auxiliary heat exchange unit 8. At this time, the upper jig B is provided with stepped portions B-1 and B-2 (see FIG. 5) so as to avoid the mounting seat 18 and the pipe connector member 13 protruding on the end plate 12. Therefore, the mounting seat 18 and the pipe connector member 13 are accommodated in the lower space of the step portions B-1 and B-2 (in other words, the interference with the mounting seat 18 and the pipe connector member 13 is prevented. The upper jig B can be placed on the end plate 12. The mounting seat 18 and the pipe connector member 13 maintain the fitted state with the end plate 12 by their own weight.
[0035]
Next, the two vertical jigs C formed in a U-shape are assembled between the lower side surface of the lower jig A and the upper side surface of the upper jig B at a predetermined interval. A predetermined pressing force is applied between the lower jig A and the upper jig B by the tool C, and the entire laminated state of the evaporator 6 is maintained.
3. The assembly of the evaporator 6 is mounted on the holding shelf E of the carrier D shown in FIG. 6 while maintaining the stacked state of the heat exchange parts 7 and 8 by the vertical brazing process vertical jig C of the entire evaporator 6. Placed on. At this time, the mounting posture of the assembly is maintained by fitting the lower end portion of the vertical jig C into the fitting hole F of the holding shelf E.
[0036]
Since the carrier D is suspended by a hanger G disposed on the top thereof and is movable, the carrier D is loaded into a vacuum furnace and the assembly is heated to the melting point of the brazing material of the aluminum clad material or higher. Then, the joint portions of the respective parts of the assembly are joined together by brazing, and the entire evaporator 6 is made into an integral structure.
Here, the holding shelf E of the carrier D needs to have a certain degree of strength so that the assembly of 20 to 30 evaporators 6 can be simultaneously transported into the furnace as shown in FIG. And, in order to give strength, the thickness is increased, so that the heat capacity of the carrier D is considerably larger than that of the evaporator 6.
[0037]
Accordingly, in the furnace, the temperature of the holding shelf E for the carrier D is considerably delayed as compared with the evaporator 6, and as a result, the radiant heat received by the evaporator 6 passes through the vertical jig C to the carrier D. Since it moves to the holding shelf E, in the evaporator 6, a temperature gradient (see FIG. 6C) is generated in which the temperature gradually decreases from the upper side to the lower side.
[0038]
In view of the point that such a temperature gradient is generated in the evaporator 6, in the present invention, in the evaporator 6, the auxiliary heat exchanging portion 8 having a large heat capacity is arranged on the upper side where the temperature easily rises, and both the main and the auxiliary are arranged. The temperature increase of the heat exchange parts 7 and 8 is made uniform.
Thereby, it can prevent that the sub heat exchange part 8 with a large heat capacity becomes brazing defect by a temperature rise delay.
4). Step of inspecting external leakage of refrigerant Next, the evaporator 6 is carried into a sealed chamber, and a leakage inspection fluid (for example, helium gas) is pressurized to a predetermined pressure so that the main and sub heat exchangers 7 and 8 of the evaporator 6 The refrigerant is supplied into the refrigerant passages 7a, 8a and 8b, and the presence or absence of fluid leakage to the outside of the evaporator 6 (fluid leakage into the sealed chamber) is inspected.
5. Internal refrigerant leakage inspection process In the secondary heat exchange section 8, the state where the inlet side refrigerant passage 8a and the outlet side refrigerant passage 8b are in direct communication due to poor brazing or the like is an internal leakage (the arrow X in FIG. 1 schematically shows this internal leakage). And the normal communication state in which the inlet-side refrigerant passage 8a and the outlet-side refrigerant passage 8b communicate with each other via the refrigerant passage 7a of the main heat exchanging portion 7 is an evaporation state. The original configuration of the vessel 6 cannot be distinguished.
[0039]
Therefore, in this example, the internal leakage of the refrigerant can be inspected by closing the inlet portion of the refrigerant passage 7a of the main heat exchanging portion 7 (the Y portion in FIG. 1 indicates the closed portion). That is, the lid 20 mounted in the refrigerant external leakage inspection process is removed from the mounting seat 18, and instead, the valve body at the tip of the inspection jig (not shown) is inserted from the jig insertion hole 19 of the mounting seat 18 into the auxiliary heat exchange section. The refrigerant inlet hole corresponding to the Y portion in FIG. 1 is closed by the valve body 17 at the tip of the inspection jig.
[0040]
The connecting pipe 13c is closed with an appropriate blind lid, and the outlet pipe 13b is left open.
After that, the evaporator 6 is carried into the sealed chamber, a leakage inspection fluid (for example, helium gas) supply device is connected to the inlet pipe 13a, and the inspection fluid is pressurized to a predetermined pressure and evaporated from the inlet pipe 13a. The fluid leaks from the inlet side refrigerant passage 8a of the auxiliary heat exchange unit 8 to the outlet side refrigerant passage 8b (fluid into the sealed chamber through the outlet pipe 13b). Check for leaks.
[0041]
That is, when there is an internal leak as indicated by an arrow X in FIG. 1, the fluid leaks into the sealed chamber through the outlet pipe 13b, so that the occurrence of the internal leak can be detected.
6). Lid Installation Step For a non-defective product determined as having no leakage by the external leakage inspection and the internal leakage inspection, the inspection jig is removed from the mounting seat 18 and the lid 20 is mounted on the mounting seat 18 by screwing.
[0042]
The manufacture of the skeleton structure of the evaporator 6 can be completed as described above, and thereafter the manufacture of the evaporator 6 can be completed by finishing the surface treatment or the like.
[Brief description of the drawings]
FIG. 1 is a refrigeration cycle diagram including an evaporator to which the method of the present invention is applied.
FIG. 2 is a perspective view showing an evaporator to which the method of the present invention is applied.
FIG. 3 is an exploded perspective view of the evaporator of FIG.
FIGS. 4A, 4B, and 4C are enlarged cross-sectional views of main parts of the evaporator shown in FIGS.
5 is a perspective view showing a state where the assembly of the evaporator shown in FIGS. 2 and 3 is held by an assembly jig. FIG.
6A is a schematic configuration diagram of a carrier for transporting an evaporator assembly, FIG. 6B is a partially enlarged view of FIG. 6A, and FIG. 6C is a diagram showing a temperature gradient of the evaporator assembly. is there.
[Explanation of symbols]
6 ... Evaporator, 7 ... Main heat exchange part, 7a ... Refrigerant passage, 7b ... Metal thin plate,
8 ... Sub heat exchange part, 8a ... Inlet side refrigerant passage, 8b ... Outlet side refrigerant passage,
8c ... Metal thin plate, 12 ... End plate, 13 ... Pipe connector member,
A ... Lower jig, B ... Upper jig, C ... Vertical jig, D ... Carrier, E ... Holding shelf.

Claims

A main heat exchanging section for exchanging heat between the internal fluid flowing in the fluid passage and the external fluid flowing outside the fluid passage;
An auxiliary fluid exchanging portion that exchanges heat between the internal fluid flowing into the inlet side of the fluid passage of the main heat exchanging portion and the internal fluid flowing out from the outlet side of the fluid passage of the main heat exchanging portion, And the fluid passage of the auxiliary heat exchange part is formed by a laminated structure of thin metal plates,
The main heat exchanging part is a manufacturing method of a laminated heat exchanger provided with a fin member that increases a heat transfer area on the external fluid side,
The main heat exchange part and the sub heat exchange part are each temporarily assembled in a predetermined structure composed of a laminated structure of thin metal plates, and the main heat exchange part is at the bottom and the sub heat exchange part is at the top. , An assembly process for holding both the heat exchange parts together with a jig,
Next, a brazing process of brazing the assembly composed of the two heat exchange parts integrally in a furnace while maintaining a positional relationship in which the main heat exchange part is downward and the sub heat exchange part is upward. The manufacturing method of the laminated heat exchanger characterized by comprising.

A main heat exchanging section for exchanging heat between the internal fluid flowing in the fluid passage and the external fluid flowing outside the fluid passage;
A sub heat exchange part that exchanges heat between the internal fluid flowing into the inlet side of the fluid passage of the main heat exchange part and the internal fluid flowing out from the outlet side of the fluid path of the main heat exchange part,
The fluid passages of the main and auxiliary heat exchange parts are formed by a laminated structure of thin metal plates,
The main heat exchange part is provided with a fin member that increases the heat transfer area on the external fluid side,
The end plate of the auxiliary heat exchange unit is a manufacturing method of a laminated heat exchanger provided with a pipe connector member having an inlet pipe and an outlet pipe of the internal fluid,
The main heat exchange part and the sub heat exchange part are each temporarily assembled in a predetermined structure composed of a laminated structure of thin metal plates, and the main heat exchange part is at the bottom and the sub heat exchange part is at the top. , An assembly process for holding both the heat exchange parts together with a jig,
Next, a brazing process of brazing the assembly composed of the two heat exchange parts integrally in a furnace while maintaining a positional relationship in which the main heat exchange part is downward and the sub heat exchange part is upward. The manufacturing method of the laminated heat exchanger characterized by comprising.

A main heat exchanging section for exchanging heat between the refrigerant flowing in the refrigerant passage and the cooled fluid flowing outside the refrigerant passage;
An inlet-side refrigerant that flows into the inlet side of the refrigerant passage of the main heat exchange unit, and an auxiliary heat exchange unit that exchanges heat between the outlet-side refrigerant that flows out from the outlet side of the refrigerant path of the main heat exchange unit,
The refrigerant passages of the main and sub heat exchange parts are formed by a laminated structure of metal thin plates,
The main heat exchanging part is a method for manufacturing a laminated refrigerant evaporator, comprising a fin member that increases a heat transfer area on the cooled fluid side,
The main heat exchange part and the sub heat exchange part are each temporarily assembled in a predetermined structure composed of a laminated structure of thin metal plates, and the main heat exchange part is at the bottom and the sub heat exchange part is at the top. , An assembly process for holding both the heat exchange parts together with a jig,
Next, a brazing process of brazing the assembly composed of the two heat exchange parts integrally in a furnace while maintaining a positional relationship in which the main heat exchange part is downward and the sub heat exchange part is upward. A method for producing a stacked refrigerant evaporator, comprising:

A main heat exchanging section for exchanging heat between the refrigerant flowing in the refrigerant passage and the cooled fluid flowing outside the refrigerant passage;
An inlet-side refrigerant that flows into the inlet side of the refrigerant passage of the main heat exchange unit, and an auxiliary heat exchange unit that exchanges heat between the outlet-side refrigerant that flows out from the outlet side of the refrigerant path of the main heat exchange unit,
The refrigerant passages of the main and sub heat exchange parts are formed by a laminated structure of metal thin plates,
The main heat exchange part is provided with a fin member that increases the heat transfer area on the cooled fluid side,
The end plate of the auxiliary heat exchanging unit is a manufacturing method of a laminated refrigerant evaporator provided with a pipe connector member having an inlet pipe and an outlet pipe of the refrigerant,
The main heat exchange part and the sub heat exchange part are each temporarily assembled in a predetermined structure composed of a laminated structure of thin metal plates, and the main heat exchange part is at the bottom and the sub heat exchange part is at the top. The assembly step of holding both the heat exchange parts integrally with a jig, and then the assembly comprising the both heat exchange parts, the main heat exchange part is at the bottom and the sub heat exchange part is at the top And a brazing step of brazing integrally in a furnace while maintaining the positional relationship.

The both heat exchanging parts held integrally by the jig are placed on a holding shelf of a movable carrier via the jig and moved to the furnace. Item 5. The method for producing a stacked refrigerant evaporator according to Item 3 or 4.

6. The end plate is assembled to the uppermost part of the sub heat exchange part, and the pipe connector member is fitted and held from above by its own weight in a hole provided in the end plate. The manufacturing method of the laminated | stacked refrigerant | coolant evaporator as described in any one.