JP3973271B2 - Liquid receiver integrated refrigerant condenser and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a liquid receiver-integrated refrigerant condenser and a method for manufacturing the same, and can be used, for example, as a refrigerant condenser for an automotive air conditioner and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, for example, as disclosed in Japanese Patent Application Laid-Open No. 8-35744, a receiver in which a liquid receiver is integrally joined to a header of a refrigerant condenser is known. In this refrigerant condenser, a pair of curved plates face each other to form a cylindrical header, and a flat portion formed on the header and a flat portion formed on the liquid receiver are joined together. . The pair of curved plates constituting this header is formed into a curved shape by pressing a single strip-shaped material, and the curved plate 100 on the side to be joined to the liquid receiver is further subjected to pressing as shown in FIG. By applying this, the plane portion 101 is formed. In order to prevent the occurrence of “wrinkles” when the flat surface portion 101 is press-molded, the flat surface portion 101 is formed with ribs 103 extending in the vertical direction. Further, communication holes 105 and 107 for communicating the interior of the liquid receiver and the interior of the header are formed in the flat portion 101 by pressing.
[0003]
[Problems to be solved by the invention]
However, when forming the header of such a refrigerant condenser, no problem occurs as long as it is pressed from a strip material cut to a predetermined length and finished to the final shape. When a curved plate is formed by a press working method (hereinafter referred to as sequential processing) as disclosed in Japanese Patent Publication No. 6-340331, the die of the press device interferes with the rib of the curved plate, and the material cannot be fed. There's a problem.
[0004]
That is, in this sequential processing, as shown in FIG. 4, a continuous belt-like material is continuously fed into a press device, and an outer shape is punched out from a flat plate-like material, a bending bending process, a corner shaping process, a flat surface / rib forming process, and a communication hole punching. -The shaping process is sequentially performed, and finally, it is divided to form a curved plate having a predetermined length. 5 and 6 are longitudinal sectional views showing the communication hole punching process. The communication holes 12 and 14 are sequentially drilled by a pair of punches 18 and a die 20. FIG. 5 shows a state in which the communication hole 14 is punched out after the communication hole 12 is formed. Here, the punch 14 moves up and down, but the die 20 remains fixed in that position. Therefore, as shown in FIG. 6, when the material 10 moves in the direction of the arrow X in the figure (after forming the communication hole 14, the material 10 is lifted up, conveyed by one pitch, and lifted down), the rib 16 and the die 20 Interfere with each other at a position indicated by S in the figure, and the material 10 cannot be sent satisfactorily. When the rib 16 rides on the die 20, the horizontal position of the material changes, and there is a problem that the work in other processes is hindered.
[0005]
In view of such a problem, the present invention can keep the horizontal position of the material constant without causing “wrinkles” when the header is pressed by sequential processing. It is an object of the present invention to obtain a liquid receiver integrated refrigerant condenser and a method for manufacturing the same.
[0006]
[Means for achieving the object]
In order to achieve this object, in the invention described in claim 1, a concave portion recessed in the cylindrical body is formed in the flat portion formed in the header which is the longer cylindrical body of the header or the liquid receiver. Was divided into a plurality of pieces along the vertical direction. In the manufacturing method according to the second aspect, after the communication hole is formed, the die for forming the communication hole is positioned between the plurality of recesses. By having this structure, even if the communication holes are sequentially formed with the punch and the die in the plane portion, the die is located between the recesses divided into a plurality of portions after the communication holes are formed. Interference can be avoided and the material can be sent well. Further, when the flat portion is press-molded, surplus material escapes into the plurality of concave portions, so that “wrinkles” do not occur in the flat portion.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments shown in the drawings will be described below.
1 and 2 show an embodiment in which the receiver-integrated condenser of the present invention is applied to an air conditioner for an automobile. FIG. 1 is a perspective view of a curved plate (tank plate) constituting the header. FIG. 3 is a front view of a condenser with an integrated receiver.
[0008]
The receiver-integrated condenser has a pair of left and right tanks 24 and 26 and a plurality of tubes 28 that communicate with the tanks 24 and 26. Corrugated fins 30 bent in a wave shape are joined between the plurality of tubes 28. A liquid receiver 70 is joined to one tank 24 of the pair of tanks 24, 26, and the other tank 26 has an inlet pipe 32 for receiving refrigerant from a compressor (not shown), an expansion valve ( An outlet pipe 34 for connecting the refrigerant to the savings) is connected.
[0009]
The core part which consists of the tube 28 and a corrugated fin consists of the condensation part CO and the supercooling part SU. The condensing unit CO is connected to the discharge side of the compressor via the inlet pipe 32, and exchanges heat with the outdoor air sent by a fan (not shown) or the like from the superheated gaseous refrigerant flowing into the inside from the compressor. Works as a means to condense and liquefy the refrigerant.
The liquid receiver 70 functions as gas-liquid separation means that separates the refrigerant that has flowed into the interior from the condenser CO into a gas-phase refrigerant and a liquid-phase refrigerant, and supplies only the liquid-phase refrigerant to the supercooling unit SU. The supercooling unit SU is provided adjacent to the lower side of the condensing unit CO disposed on the upper side, and heat-exchanges the liquid-phase refrigerant flowing into the interior from the liquid receiver 70 with the outdoor air sent by a fan or the like. It works as a supercooling means for supercooling the liquid phase refrigerant.
[0010]
The first header 26 includes a header plate 38 having a substantially U-shaped cross section and a tank plate 36 having a semicircular arc in cross section. The first header 26 has a substantially cylindrical shape extending in the vertical direction by joining the two face to face. . The plates 36 and 38 of the first header 26 are each formed into a predetermined shape by pressing a metal plate clad with brazing material on both sides with aluminum or aluminum alloy having excellent corrosion resistance and thermal conductivity. ing.
[0011]
The upper end of the first header 26 is connected to the upstream ends of a plurality of condensing tubes 28 constituting the condensing unit CO, and the lower end is connected to the downstream ends of the subcooling tubes 28 constituting the supercooling unit SU. Has been. A cap 40 is fitted into the end opening of the first header 26 in the vertical direction (cylindrical axial direction). A partition plate 42 that partitions the condensing unit and the subcooling unit is disposed in the first header 26.
[0012]
The second header 24 includes a header plate 44 having a substantially U-shaped cross-section, and a tank plate having a flat portion 11 at the center in the longitudinal direction and an arc portion 13 having a substantially arc-shaped cross section at both ends 46. In the lower part of the flat portion 11 of the tank plate 46, communication holes 12 and 14 are provided for communicating the second header 24 and the liquid receiver 70. Further, the flat portion 11 is formed with a concave portion 22 which is divided into a plurality along the longitudinal direction. Both plates 44 and 46 of the second header 24 are each formed into a predetermined shape by pressing a metal plate clad with brazing material on both sides with aluminum or aluminum alloy having excellent corrosion resistance and thermal conductivity. .
[0013]
The liquid receiver 70 is shorter in the vertical direction than the second header 24 and has a substantially cylindrical shape in which the flat surface portion 21 corresponding to the flat surface portion 11 is formed over the entire length in the vertical direction as shown in FIG. It is comprised from the cylindrical body. The liquid receiver 70 is for brazing the flange 23 after forming a plate into a substantially cylindrical shape. In addition, communication holes 25 and 27 are formed in the plane portion 21 at positions that match the communication holes 12 and 14 when joined to the second header 24.
[0014]
The upper end of the second header 24 is connected to the downstream ends of a plurality of condensing tubes 28 constituting the condensing unit CO, and the lower end is connected to the upstream end of the supercooling tube 28 constituting the supercooling unit SU. ing. A cap 50 is fitted into the opening at the upper and lower ends of the second header 24. A partition plate 52 that divides the second header 24 into a condensing part and a supercooling part is disposed in the second header 24 at a position between the communication hole 25 and the communication hole 27.
[0015]
Since the tank plate 46 has a shape in which the flat surface portion 11 is formed at the center in the longitudinal direction and the arc portions 13 are formed at both ends, the cross-sectional shape length in the circumferential direction is large in the longitudinal direction of the tank plate 46. There are two different parts. Therefore, when the flat portion 11 is formed by pressing, an extra material is generated, but the extra material escapes to the plurality of recesses 22 and no “wrinkle” is generated.
[0016]
FIG. 10 is a schematic diagram showing a state in which a plurality of recesses 22 are formed in the flat portion 11 by a pair of punches 60 and a die 62. The position of the die 62 is fixed, and the punch 60 is lifted up and down. When the punch 60 is lowered once, a plurality of (three in FIG. 10) recesses 22 are formed simultaneously. The material is conveyed one pitch at a time in the direction of the arrow X in the figure, and the downward movement of the punch 60 is repeated, whereby a plurality of recesses 22 are continuously formed in the flat surface portion 11.
[0017]
When the concave portion 22 is formed in the vicinity of both end portions of the flat portion 11, a portion for receiving the arc portion 13 of the tank plate 46 is also necessary for the die 62. Therefore, the die 62 is formed with a portion where the recess forming hole 62a is formed in the flat portion and portions where the arc portion 13 is received on both sides thereof, but the right side portion 63 is a mechanism capable of moving up and down. . And when forming the recessed part 22 in parts other than the right end in the figure of the plane part 11, the right side part 63 is the state which fell.
[0018]
FIG. 8 is a transverse cross-sectional view in FIG. 10, and the left half shows a state before the punch 60 is lowered, and the right half shows a state in which the punch 60 is lowered and the flat portion 11 and the recess 22 are formed. The inner surface of the punch 60 is substantially U-shaped. When the punch 60 is lowered, the material is deformed along the die, and a recess 22 is formed in a portion facing the recess forming hole 62a.
[0019]
Further, an escape space 61 is formed between the shoulder portion of the material and the corner portion of the punch 60, and surplus space when the flat portion 11 is formed also escapes into this space 61. Therefore, the material has a shape in which the material protrudes slightly in the escape space 61, and the protruding shoulder portion has a smaller radius of curvature than the shoulder portion of the arc-shaped portion 13.
In this way, after the concave portion 22 is formed in the flat portion 11, the communication holes 12 and 14 are further drilled in the flat portion 11 by a pair of punches and dies. FIG. 7 is a longitudinal sectional view showing a state in which the material is conveyed by 1 pitch after the communication holes 12 and 14 are formed. The punch 18 is in the raised position and has no effect on the transport of the material. The die 20 is positioned between the recesses 22 after passing over one recess 22, and in this state, there is no change in the horizontal position of the material, and there is no influence on processing in other processes.
[0020]
The operation as a refrigerant condenser is exactly the same as that disclosed in Japanese Patent Laid-Open No. 8-35744, and a description thereof will be omitted.
[Brief description of the drawings]
FIG. 1 is a perspective view of a tank plate showing an embodiment of the present invention.
FIG. 2 is a front view when the present invention is used as a condenser of an automotive air conditioner.
FIG. 3 is a perspective view showing a conventional tank plate.
FIG. 4 is a perspective view for explaining a process of forming a tank plate by sequential processing.
FIG. 5 is a cross-sectional view for explaining a conventional method of forming a tank plate.
FIG. 6 is a cross-sectional view for explaining a conventional method of forming a tank plate.
FIG. 7 is a cross-sectional view showing a tank plate forming step according to an embodiment of the present invention.
FIG. 8 is a cross-sectional view showing a flat plate portion forming step of a tank plate according to an embodiment of the present invention.
FIG. 9 is a perspective view for explaining a joined state of a header and a liquid receiver as an embodiment of the present invention.
FIG. 10 is a perspective view for explaining a flat part forming step of the tank plate in the embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 Plane part 12 Communication hole 13 Arc part 14 Communication hole 22 Recess 24 Header 26 Header 46 Tank plate 70 Liquid receiver

Claims (2)

A core portion having a condensing portion for condensing refrigerant flowing in the horizontal direction;
A header that is extended in the vertical direction at one end of the core and connected to the downstream end of the condensing unit;
A communication chamber provided inside the header and communicating with the downstream end of the condensing unit;
A liquid receiver that is provided on a side of the communication chamber of the header and has a gas-liquid separation chamber for gas-liquid separation of the refrigerant;
A first communication hole formed in the header and the liquid receiver to allow the refrigerant in the communication chamber to flow into the gas-liquid separation chamber;
A second communication hole that is located below the first communication hole and is formed in the header and the liquid receiver to allow the liquid refrigerant in the gas-liquid separation chamber to flow out of the separation chamber;
Both the header and the liquid receiver are formed of a cylindrical body extending in the vertical direction, and the vertical length of the header and the liquid receiver is configured such that one of them is long and the other is short,
The liquid receiver, which is a tubular body having a shorter vertical direction, has a flat portion extending over the entire length in the vertical direction,
The header , which is a cylindrical body having a longer vertical direction, has a flat portion corresponding to the flat portion at a part of the vertical direction, and the flat portion has a recess recessed inside the cylindrical body. Is divided into a plurality along the vertical direction,
The liquid receiver integrated refrigerant condenser, wherein the header and the liquid receiver are integrally joined at the flat portion. A liquid receiver comprising a pair of header tanks formed into a cylindrical body by joining a pair of plates, a plurality of tubes communicating with the header tank, and a liquid receiver integrally joined to the header tank In the manufacturing method of the condenser-integrated refrigerant condenser,
Of the pair of plates, the plate to be joined to the liquid receiver is formed through a plurality of processing steps while conveying a continuous strip at a predetermined interval.
Bending process of press-molding from a flat plate shape into a circular arc shape,
A planar molding step of forming a planar portion having a concave portion divided into a plurality of parts by pressing;
Punching step of thus forming a communication hole communicating with the said receiver on said plane portion and a pair of punch and die,
A cutting process for dividing the strip material into a predetermined length is sequentially performed,
A receiver-integrated refrigerant condenser characterized in that when the material is shifted to a predetermined pitch after the hole punching step, the die used in the hole punching step is positioned between the plurality of recesses to perform the next step. Manufacturing method.

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