JP4861844B2 - Heat exchanger and manufacturing method thereof - Google Patents

Description

  The present invention relates to a heat exchanger suitably used as, for example, a heater core incorporated in a car air conditioner of a vehicle and a method for manufacturing the same.

  As a heater core for a car air conditioner that heats the vehicle interior using warm water for cooling the engine, a pair of header tanks spaced apart from each other and a width direction between the header tanks are directed to the ventilation direction. A plurality of flat heat exchange tubes arranged at intervals in the length direction of the header tank and having both ends connected to both header tanks, and corrugated fins arranged between adjacent heat exchange tubes The provided heat exchanger is widely used.

  Each header tank of this type of heat exchanger has conventionally been a rectangular parallelepiped box-shaped tank body that opens to the other header tank side, and a header that is brazed to the opening end of the tank body and closes the opening of the tank body. The tank body and the header plate are each formed by folding a metal blank, and the tank body is connected to a rectangular top wall and a pair of parallel sides of the top wall. And a pair of second side walls connected to a pair of other side portions parallel to each other on the top wall, and the second side walls of the tank body are adjacent to the first side wall and the second side wall. A mating portion along the inner surface of the side wall is integrally formed via a rounded connecting portion, and the header plate is a rectangular closing wall having a plurality of pipe insertion holes, and a pair of sides of the closing wall parallel to each other Or A pair of first side walls along the opening side end outer surface of the first side wall of the tank main body, and an opening side end outer surface of the second side wall of the tank main body connected to another pair of parallel sides of the closing wall There is known one composed of a pair of second side walls extending along the line (see Patent Document 1).

However, since the header tank described in Patent Document 1 is formed by bending a metal plate, a relatively large recess is formed between the outer surface of the rounded connecting portion of the tank body and the front end surface of the bent portion. Is inevitable. As a result, there is a relatively large gap between the first and second side walls of the tank body and the first and second side walls of the header plate in the portion where the recess is present, and the tank body There is a possibility that a brazing defect may occur between the header plate and the header plate, and there is a need to repair them later, which is troublesome.
JP-A-8-226786

  An object of the present invention is to provide a heat exchanger that solves the above-described problems and can suppress the occurrence of defective brazing between a tank body and a header plate, and a method for manufacturing the same.

  In order to achieve the above object, the present invention comprises the following aspects.

  In order to achieve the above object, the present invention comprises the following aspects.

1) A pair of header tanks arranged at a distance from each other, and between the header tanks, the header tanks are arranged at intervals in the length direction of the header tank so that the width direction faces the ventilation direction, and both end portions are A box-shape that has a plurality of flat heat exchange tubes connected to both header tanks and fins arranged between adjacent heat exchange tubes, each header tank opening to the other header tank side The tank body and a header plate joined to the opening end of the tank body and closing the opening of the tank body. The tank body and the header plate are each formed by bending a metal blank, and the tank body is rectangular. A top wall, a pair of first side walls connected to a pair of parallel sides of the top wall, and a pair of second side walls connected to a pair of other parallel sides of the top wall; Tank book In the first side wall and the second side wall adjacent to each other, a mating portion along the inner surface of the second side wall is formed integrally with the inner surface of the second side wall, and the header plate includes a plurality of tubes. A rectangular closed wall having an insertion hole, a pair of first side walls that are connected to a pair of parallel sides of the closed wall and extend along the outer surface of the opening side end of the first side wall of the tank body; It consists of a pair of second side walls that are connected to a pair of sides that are parallel to each other and that extend along the outer surface of the opening side end of the second side wall of the tank body, and both ends of the heat exchange pipes are inserted into the header plates of both header tanks. A heat exchanger inserted into the hole and joined to the header plate,
The first side wall end of the second side wall of the tank body is bent along the outer surface of the rounded connecting portion to form a first bent portion, and the first side wall end of the second side wall of the header plate is formed. Is bent along the first bent portion of the tank body to form a second bent portion, and the first side wall of the header plate is formed between the outer surface of the tank-shaped articulated portion and the front end surface of the first bent portion. The heat exchanger in which the deformation | transformation part which enters in the recess formed in is formed.

  2) The heat exchanger according to 1) above, wherein mating portions are formed at both ends of each first side wall of the tank body.

  3) The heat according to 1) or 2) above, wherein the brazing material outflow prevention portion straddling between the end portions of the first and second side walls adjacent to each other on the closing wall side is formed integrally with the closing wall. Exchanger.

  4) At least one through hole is formed in a portion of the second side wall of the tank body that overlaps the mating portion, and the top wall of the tank body is located at a position corresponding to the through hole of the tank body on the second side wall of the header plate. The heat exchanger according to any one of the above 1) to 3), wherein a claw portion that protrudes to the side and has a tip portion bent and fitted into a through hole of the tank body is integrally formed.

  5) The heat exchanger according to 4) above, wherein a plurality of through holes are formed in the second side walls of the tank body at intervals in the length direction of the second side walls.

6) From the metal base plate, a rectangular top wall forming portion, a pair of first side wall forming portions integrally formed on mutually parallel side portions of the top wall forming portion, and other parallel sides of the top wall forming portion Cutting out a first blank for a tank body having a pair of second side wall forming portions formed integrally with each other and a mating portion forming portion formed integrally with both ends of the first side wall forming portion;
From the metal base plate, the rectangular closed wall forming portion, the pair of first side wall forming portions integrally formed on the parallel side portions of the closing wall forming portion, and the other parallel side portions of the closing wall forming portion Cutting out a second blank for a header plate having a pair of second side wall forming portions formed integrally, and forming a plurality of tube insertion holes in the closing wall forming portion;
The first blank forming portion is bent with respect to the first side wall forming portion, the first side wall forming portion is bent with respect to the top wall forming portion, and the second side wall forming portion is further bent with respect to the top wall forming portion. In addition, by bending both end portions of the second side wall forming portion along the rounded connecting portion of the first side wall forming portion and the mating portion forming portion, a pair of sides parallel to each other of the rectangular top wall and the top wall A pair of first side walls that are continuous with each other, a pair of second side walls that are connected to a pair of other parallel sides of the top wall, and a first side wall that are integrally formed via a round-shaped connecting portion; Producing a tank body material having a mating portion along the inner surface of the second side wall and a first bent portion formed integrally with the second side wall;
The first side wall forming portion and the second side wall forming portion of the second blank are bent with respect to the closing wall forming portion, and both end portions of the second side wall forming portion are bent into a shape along the first bent portion of the tank body material. Further, by transforming both ends of the first side wall forming portion into a shape that can enter into a recess formed between the outer surface of the rounded connecting portion of the tank body material and the front end surface of the first bent portion, A closing wall, a pair of first side walls connected to a pair of parallel sides of the closing wall, a pair of second side walls connected to a pair of other parallel sides of the closing wall, a second side wall A second bent portion that can be formed along the first bent portion of the tank body material, and an outer surface of the rounded connecting portion of the tank body material and a distal end surface of the bent portion. Deformation part that can enter into the recess formed between To create a header plate material having,
The header plate material is fitted over the opening side end of the tank body material, the first and second side walls of the header plate material are aligned with the outer surfaces of the first and second side walls of the tank body material, and the header plate material Making the second bent part along the first bent part of the tank body material and making the deformed part of the header plate material enter the recess of the tank body material to make a combination of both materials,
Arranging the two combinations at intervals so that the header plate materials face each other;
A plurality of heat exchange tubes and fins are alternately combined, and both end portions of the heat exchange tubes are respectively inserted into the tube insertion holes of the header plate material of both combinations,
In addition, the tank body material is brazed to the second side wall to form the tank body, and the first side wall and the second side wall of the header plate material are brazed to the first side wall and the second side wall of the tank body. A method of manufacturing a heat exchanger, comprising forming a header plate, brazing both ends of the heat exchange pipe to the header plate, and brazing fins to the heat exchange pipe.

  7) A brazing material outflow prevention portion forming portion straddling between the first side wall forming portion and the second side wall forming portion on the closing wall forming portion side of the second blank is formed integrally with the closing wall forming portion. When the header plate material is made, the brazing material outflow prevention portion forming portion integrally forms the brazing material outflow prevention portion straddling the end portions of the adjacent first and second side walls on the closing wall side. The method for producing a heat exchanger according to 6) above.

  8) At least one through hole is formed in a portion that should overlap with the mating portion forming portion in the second sidewall forming portion of the first blank, and corresponds to the through hole of the first blank in the second sidewall forming portion of the second blank. The above-mentioned 6) or 7 is formed by integrally forming an outwardly projecting claw portion at a position where the tank body material and header plate material are combined, and bending the claw portion into the through hole. ) Manufacturing method of the heat exchanger.

  9) Manufacture of a heat exchanger as described in 8) above, wherein a plurality of through-holes are formed at intervals in the length direction in a portion that should overlap with the mating portion forming portion in the second side wall forming portion of the first blank. Method.

  According to the heat exchangers of 1) and 2) above, the first side wall end of the second side wall of the tank body is bent along the outer surface of the round connection portion to form the first bent portion, An end of the second side wall of the header plate on the side of the first side wall is bent along the first bent portion of the tank body to form a second bent portion, and the round shape of the tank body is formed on the first side wall of the header plate. Since the deformed portion is formed to enter into the recess formed between the outer surface of the connecting portion and the tip surface of the first bent portion, the first and second side walls of the tank body also in the portion where the recess exists. The gap formed between the first and second side walls of the header plate is smaller than that of the header tank described in the above publication. Therefore, it is possible to suppress the occurrence of defective brazing between the tank body and the header plate.

  According to the heat exchanger of 3) above, the brazing material outflow prevention portion straddling between the end portions on the closing wall side of the adjacent first and second side walls of the header plate is formed integrally with the closing wall. Therefore, when the tank body and the header plate are brazed, the function of the brazing material outflow prevention portion prevents the molten brazing material from flowing out between the first side wall and the second side wall. Therefore, it is possible to more effectively suppress the occurrence of defective brazing between the tank body and the header plate.

  According to the heat exchangers 4) and 5) above, the tank body and the header plate can be reliably positioned in the state before brazing.

  According to the method for producing a heat exchanger of 6), when the tank body material is produced, the mating portion forming portion of the first blank is bent with respect to the first side wall forming portion, and the first side wall forming portion is the top wall. The second side wall forming portion is bent with respect to the top wall forming portion, and both end portions of the second side wall forming portion are rounded connection portions between the first side wall forming portion and the mating portion forming portion. The first side wall forming portion and the second side wall forming portion of the second blank are bent with respect to the closed wall forming portion when the first bent portion is formed by bending along the first wall portion and the header plate material is formed. Both ends of the side wall forming portion are bent into a shape along the first bent portion of the tank body material to form a second bent portion, and both ends of the first side wall forming portion are further connected to the rounded connecting portion of the tank body material. Between the outer surface and the tip of the bent part Since the deformed part is deformed into a shape that can enter into the formed recess, the outer surface of the tank-shaped connecting part of the tank body and the front end surface of the first bent part are formed during brazing in the subsequent process. The gap formed between the first and second side walls of the tank body and the first and second side walls of the header plate is also smaller than that of the header tank described in the above publication, even in the portion where the recess is formed. Become smaller. Therefore, in the manufactured heat exchanger, it is possible to suppress the occurrence of brazing failure between the tank body and the header plate.

  According to the heat exchanger manufacturing method of 7) above, the brazing material outflow prevention portion forming portion straddling between the first side wall forming portion and the end portion of the second side wall forming portion on the closed wall forming portion side in the second blank. Is formed integrally with the closing wall forming portion, and when the header plate material is made, the brazing material outflow prevention portion forming portion causes the closing wall side end portions of the adjacent first and second side walls to be adjacent to each other. Since the brazing material outflow prevention part straddling is formed integrally with the closed wall, the melted brazing material is caused by the function of the brazing material outflow prevention part when the tank body material and the header plate material are brazed. And the second side wall are prevented from flowing out. Therefore, in the manufactured heat exchanger, it is possible to more effectively suppress the occurrence of defective brazing between the tank body and the header plate.

  According to the heat exchanger manufacturing methods of 8) and 9) above, when the tank main body material and the header plate material are combined, both can be reliably positioned.

  Embodiments of the present invention will be described below with reference to the drawings. In this embodiment, the heat exchanger according to the present invention is applied to a heater core of a car air conditioner.

  In the description of the heater core with reference to FIGS. 1 to 4, the top, bottom, left, and right in FIG. 1 are referred to as the top, bottom, left and right, the back side of FIG. 1 (upper side in FIG. 2) is the front, and the opposite side is the back. To do.

  FIG. 1 shows the overall configuration of a heater core for a car air conditioner to which a heat exchanger according to the present invention is applied, and FIGS.

  In FIG. 1, the heater core (1) has an aluminum upper header tank (2) and a lower header tank (3) which are spaced apart in the vertical direction and are long in the horizontal direction, and both upper and lower header tanks (2) (3 ) Between the upper and lower header tanks (2) and (3) are protruded to the left of the heat exchange core (4) An outlet pipe (5) is connected to the left protruding portion of the header tank (2), and an inlet pipe (6) is connected to the left protruding portion of the lower header tank (3).

  The upper header tank (2) is joined to the box body (10), which is a rectangular parallelepiped box that is open at the bottom, and the opening end of the tank body (10), and the opening of the tank body (10) is closed. And header plate (11). The tank body (10) is formed by brazing a metal base plate made of an aluminum brazing sheet having a brazing material layer on one side so that the brazing material layer comes to the outer surface side, and brazing a required portion, and a header plate ( 11) is formed by bending a metal base plate made of an aluminum brazing sheet having a brazing filler metal layer on one side so that the brazing filler metal layer is on the outer surface side and brazing the required part to the tank body (10). Yes.

  As shown in FIGS. 2 to 4, the tank body (10) has a rectangular top wall (12) that is long in the left-right direction, and a pair of short side walls (13) connected to both the left and right short sides of the top wall (12). ), And a pair of long side walls (14) connected to the front and rear long sides of the top wall (12). One of the short side wall (13) and the long side wall (14) adjacent to each other in the tank body (10), here, the front and rear ends of the short side wall (13) are superimposed on the inner surface of the long side wall (14). The mating portion (15) is integrally formed via the rounded connecting portion (16), and the mating portion (15) is brazed to the inner surface of the long side wall (14). Therefore, in this embodiment, the short side wall (13) of the tank body (10) is the first side wall, and the long side wall (14) is the second side wall. The left and right end portions of the long side wall (14) of the tank body (10) are bent along the outer surface of the rounded connecting portion (16), thereby the outer side surface of the rounded connecting portion (16) on the long side wall (14). The 1st bending part (14a) along is formed. A recess (20) is formed between the outer surface of the rounded connecting portion (16) of the tank body (10) and the tip surface of the first bent portion (14a). In addition, through holes (17) are respectively formed below the portions of the long side walls (14) of the tank body (10) that overlap the mating portions (15) at the left and right ends.

  The header plate (11) has a rectangular closing wall (18) that is long in the left-right direction, is connected to the left and right short sides of the closing wall (18), and is open at the end of the short side wall (13) of the tank body (10) ( Lower end) A pair of short side walls (19) brazed along the outer surface, and the opening side of the long side wall (14) of the tank body (10) connected to the front and rear long sides of the closing wall (18) It consists of a pair of long side walls (21) brazed along the outer surface of the end. A plurality of long tube insertion holes (22) in the front-rear direction are formed in the closing wall (18) at intervals in the left-right direction. Has been. In this embodiment, the short side wall (19) of the header plate (11) is the first side wall, and the long side wall (21) is the second side wall. The left and right ends of the long side wall (21) of the header plate (11) are bent along the first bent portion (14a) of the tank body (10), thereby the first bent portion ( A second bent portion (21a) is formed along the outer surface of 14a). In the front and rear ends of the short side wall (19) of the header plate (11), a recess formed between the outer surface of the rounded joint (16) of the tank body (10) and the front end surface of the bent portion (14a) ( 20) An inwardly projecting deforming portion (23) that enters the inside is formed. The brazing material outflow prevention part (24) is closed so as to straddle the lower ends of both front and rear ends of each short side wall (19) of the header plate (11) and the lower ends of both left and right ends of each long side wall (21). It is integrally formed with the wall (18). In addition, the left and right ends of each long side wall (21) of the header plate (11) protrude toward the top wall (12) side of the tank body (10), and the front end is bent inward in the front-rear direction. A claw portion (25) fitted into the through hole (17) of the long side wall (14) of 10) is integrally formed.

  The lower header tank (3) is obtained by turning the upper header tank (2) upside down, and the same components and the same parts are denoted by the same reference numerals.

  The heat exchange core part (4) is arranged with a space in the left-right direction so that the width direction faces the front-rear direction (ventilation direction), and the upper and lower ends are connected to the upper and lower header tanks (2) (3). A plurality of flat aluminum heat exchange pipes (26) and adjacent heat exchange pipes (26) and outside the heat exchange pipes (26) at both the left and right sides are connected to the heat exchange pipe (26). It comprises an aluminum corrugated fin (27) attached and a side plate (28) that is disposed outside the corrugated fins (27) at the left and right ends and brazed to the corrugated fins (27). The heat exchange pipe (26) is formed by brazing a brazed aluminum brazing sheet having a brazing filler metal layer on at least one side so that the brazing filler metal layer comes outside and brazing. The upper and lower ends of the exchange pipe (26) are both inserted into the pipe insertion holes (22) formed in the closing wall (18) of the header plate (11) of the upper and lower header tanks (2) and (3). It is brazed to the header tank (2) (3). The outlet pipe (5) and the inlet pipe (6) are formed in a through-shaped refrigerant passage hole (29) formed in the closing wall (18) of the header plate (11) of the upper and lower header tanks (2) and (3) (FIG. 6). Inserted into the header tanks (2) and (3).

  Next, a method for manufacturing the heater core (1) will be described with reference to FIGS. In the description of the method for manufacturing the heater core (1), the left and right sides in FIGS. 5 and 6 are referred to as the left and right sides, the upper side in both figures is the front, and the opposite side is the rear.

  First, from a metal base plate made of an aluminum brazing sheet having a brazing material layer on one side, it is integrally formed on both short sides of a rectangular top wall forming part (31) and top wall forming part (31) that are long in the left-right direction. A pair of short side wall forming portions (32), a pair of long side wall forming portions (33) integrally formed on both long sides of the top wall forming portion (31), and a short side wall forming portion (32) A first blank (30) for the tank body (10) having a mating portion forming portion (34) formed integrally at both front and rear ends is cut out (see FIG. 5). A through hole (17) is formed in each of the left and right ends of the long side wall forming portion (33) near the outer end in the front-rear direction simultaneously with the cutting of the first blank (30). The through hole (17) is formed in a portion that should overlap the mating portion forming portion (34) in the long side wall forming portion (33) when the first blank (30) described later is bent. The width in the front-rear direction of the short side wall forming part (32) is narrower by twice the thickness of the first blank (30) than the width in the front-rear direction of the top wall forming part (31). The front and rear ends of the portion (32) are positioned inward in the front-rear direction by the thickness of the first blank (30) relative to the front and rear side edges of the top wall forming portion (31).

  In addition, it is integrally formed on both short sides of the rectangular wall-closing portion (36) and the wall-closing portion (36) that are long in the left-right direction, from a metal base plate made of an aluminum brazing sheet having a brazing material layer on one side. A pair of short side wall forming portions (37), a pair of long side wall forming portions (38) integrally formed on both long sides of the closed wall forming portion (36), The claw portion (25) projecting outward in the front-rear direction formed integrally at the left and right ends, and the closure wall forming portion (36) are formed integrally, and the short side wall forming portion (37) is closed at both the front and rear ends. Header having brazing material outflow prevention part forming part (39) straddling the end part on the wall forming part (36) side and the end part on the closed wall forming part (36) side at the left and right ends of the long side wall forming part (38) A second blank (35) for the plate (11) is cut out (see FIG. 6). A plurality of pipe insertion holes (22) and a refrigerant passage hole (29) are formed in the closed wall forming part (36) simultaneously with the cutting of the second blank (35). The claw portion (25) is formed in a portion corresponding to the through hole (17) when a tank body material (10A) and a header plate material (11A) described later are combined.

  Next, as shown in FIGS. 7 and 8, the mating portion forming portion (34) of the first blank (30) is bent with respect to the short side wall forming portion (32) so that the brazing material layer is on the outer surface side. The short side wall forming part (32) is bent with respect to the top wall forming part (31), and the long side wall forming part (33) is set with respect to the top wall forming part (31) so that the brazing material layer comes to the outer surface side. And bending both ends of the long side wall forming portion (33) along the rounded connection portion (16) between the short side wall forming portion (32) and the mating portion forming portion (34). A pair of short side walls (13) connected to both short sides of the wall (12), top wall (12), a pair of long side walls (14) connected to both long sides of the top wall (12), short The first bend formed integrally with the side wall (13) via the rounded connecting portion (16) and along the inner surface of the long side wall (14), and integrally formed with the long side wall (14) A tank body material (10A) having a portion (14a) is produced. A recess (20) is formed between the outer surface of the rounded connecting portion (16) of the tank body material (10A) and the front end surface of the first bent portion (14a).

  Moreover, as shown in FIGS. 9-11, the short side wall formation part (37) and long side wall formation part (38) of a 2nd blank (35) are made into a closed wall formation part so that a brazing material layer may come to an outer surface side. (36), the brazing material outflow prevention portion forming portion (39) is squeezed, and the left and right ends of the long side wall forming portion (38) are along the first bent portion (14a) of the tank body material (10A). By bending the front and rear ends of the short side wall forming portion (37) into a shape that can enter the recess (20) of the tank body material (10A), the rectangular closed wall (18) A pair of short side walls (19) connected to both short sides of the closed wall (18), a pair of long side walls (21) connected to both long sides of the closed wall (18), a long side wall (21) A second bent portion (21a) which can be formed integrally with the first bent portion (14a), a rounded connecting portion (16) outer surface of the tank body material (10A) and a distal end surface of the bent portion (14a). Can enter the recess (20) between And a brazing material outflow prevention portion (24) straddling between the end portions on the closed wall (18) side of the short side wall (19) and the long side wall (21) of the shape portion (23) and the header plate material (11) Make the header plate material (11A).

  Next, the header plate material (11A) is fitted over the opening end of the tank body material (10A), and the short side wall (19) and the long side wall (21) of the header plate material (11A) are attached to the tank body material (10A). ) Along the outer surface of the short side wall (13) and the long side wall (14), and the deformed portion (23) of the header plate material (11A) enters the recess (20) of the tank body material (10A) ( 12), and by bending the claw portion (25) of the header plate material (11A) inward and fitting it into the through hole (17) of the tank body material (10A), both the materials (10A) (11A) Create a combination.

  Next, the two combined bodies are arranged with an interval so that the header plate materials (11A) face each other. Further, a plurality of heat exchange tubes (26) and corrugated fins (27) are alternately combined so that the corrugated fins (27) come to both ends, and the side plates (28) are arranged outside the corrugated fins (27) at both ends. Then, both ends of the heat exchange pipe (26) are inserted into the pipe insertion holes (22) of the header plate material (11A) of both combinations. Further, the outlet pipe (5) and the inlet pipe (6) are inserted into the refrigerant passage hole (29) of the combined header plate material (11A). Then, all parts are temporarily fixed using an appropriate jig.

  After that, all the temporarily fixed parts are heated to a predetermined temperature, the joining portion (15) of the tank body material (10A) is brazed to the long side wall (14), and the bent portion (14a) is connected to the rounded connection portion. (16) The tank body (10) is formed by brazing to the outer surface, and the short side wall (19) and the long side wall (21) of the header plate material (11A) are further connected to the short side wall (13) and the tank body (10). The header plate (11) is formed by brazing the long side wall (14), brazing the bent portion (21a) to the bent portion (14a), and the deformed portion (23) to the outer surface of the round connection portion (16). To do. At the same time, both ends of the heat exchange pipe (26) are brazed to the header plate (11), the corrugated fin (27) is brazed to the heat exchange pipe (26), and the side plate (28) is further corrugated. Braze the fin (27). Thus, the heater core (1) is manufactured.

  When the tank body material (10A) and the header plate material (11A) are brazed, the brazing material outflow prevention part (24) causes the molten brazing material to flow into the short side wall (19A) of the header plate material (11A). ) And the long side wall (21).

  In the above embodiment, the mating portion (15) is integrally formed with the short side wall (13) of the tank body (10), so that the short side wall (13) is the first side wall and the long side wall (14) is the second side. The header plate (11) has a short side wall (19) as a first side wall and a long side wall (21) as a second side wall. By forming the mating part integrally with the side wall (14), the long side wall (14) becomes the first side wall, the short side wall (13) becomes the second side wall, and the header plate (11) also has the long side wall (21) as the first side wall. One side wall and the short side wall (19) may be the second side wall.

It is a front view which shows the whole structure of the heater core for car air conditioners to which the heat exchanger by this invention is applied. It is an AA line expanded sectional view of FIG. FIG. 3 is an enlarged sectional view taken along line B-B in FIG. 2. It is a partial expansion perspective view which shows the corner part of an upper header tank. It is a top view which shows the 1st blank for tank main bodies. It is a top view which shows the 2nd blank for header plates. It is a perspective view which shows the method of forming a tank main body raw material from a 1st blank. It is a partial expanded horizontal sectional view which shows the method of forming a tank main body raw material from a 1st blank. It is a perspective view which shows the method of forming a header plate raw material from a 2nd blank. FIG. 10 is a partially enlarged view of FIG. 9. It is a partial expanded horizontal sectional view which shows the method of forming a header plate raw material from a 2nd blank. It is a partial expanded horizontal sectional view which shows a part of combination body of a tank main body raw material and a header plate raw material.

Explanation of symbols

(1): Heater core (heat exchanger)
(2) (3): Header tank
(10): Tank body
(10A): Tank body material
(11): Header plate
(11A): Header plate material
(12): Top wall
(13): Short side wall (first side wall)
(14): Long side wall (second side wall)
(14a): 1st bending part
(15): Matching section
(16): Earl connection
(17): Through hole
(18): Closed wall
(19): Short side wall (first side wall)
(21): Long side wall (second side wall)
(22): Pipe insertion hole
(23): Deformation part
(24): Brazing material spill prevention part
(25): Claw
(26): Heat exchange pipe
(27): Corrugated fin
(30): 1st blank
(31): Top wall forming part
(32): Short side wall forming part (first side wall forming part)
(33): Long side wall forming part (second side wall forming part)
(34): Matching part forming part
(35): Second blank
(36): Closure wall forming part
(37): Short side wall forming part (first side wall forming part)
(38): Long side wall forming part (second side wall forming part)
(39): Brazing material outflow prevention part formation part

Claims (9)

A pair of header tanks arranged at a distance from each other and between the header tanks, the header tank is arranged at intervals in the length direction of the header tank so that the width direction faces the ventilation direction, and both headers are at both ends. A box-shaped tank body with a plurality of flat heat exchange tubes connected to the tank and fins arranged between adjacent heat exchange tubes, each header tank opening to the other header tank side And a header plate that is joined to the opening end of the tank body and closes the opening of the tank body, and the tank body and the header plate are each formed by bending a metal blank, and the tank body has a rectangular top wall A tank body comprising a pair of first side walls connected to a pair of parallel sides of the top wall and a pair of second side walls connected to a pair of other parallel sides of the top wall A mating portion along the inner surface of the second side wall is integrally formed on the first side wall of the first and second side walls adjacent to each other via a round-shaped connecting portion, and the header plate includes a plurality of tubes. A rectangular closed wall having an insertion hole, a pair of first side walls that are connected to a pair of parallel sides of the closed wall and extend along the outer surface of the opening side end of the first side wall of the tank body; It consists of a pair of second side walls that are connected to a pair of sides that are parallel to each other and that extend along the outer surface of the opening side end of the second side wall of the tank body, and both ends of the heat exchange pipes are inserted into the header plates of both header tanks. A heat exchanger inserted into the hole and joined to the header plate,
The first side wall end of the second side wall of the tank body is bent along the outer surface of the rounded connecting portion to form a first bent portion, and the first side wall end of the second side wall of the header plate is formed. Is bent along the first bent portion of the tank body to form a second bent portion, and the first side wall of the header plate is formed between the outer surface of the tank-shaped articulated portion and the front end surface of the first bent portion. The heat exchanger in which the deformation | transformation part which enters in the recess formed in is formed. The heat exchanger according to claim 1, wherein a mating portion is formed at each end of each first side wall of the tank body. The heat exchanger according to claim 1 or 2, wherein a brazing material outflow prevention portion straddling between the end portions of the first and second side walls adjacent to each other on the closing wall side is formed integrally with the closing wall. At least one through hole is formed in a portion of the second side wall of the tank body that overlaps the mating portion, and is located on the top wall side of the tank body at a position corresponding to the through hole of the tank body on the second side wall of the header plate. The heat exchanger according to any one of claims 1 to 3, wherein a claw portion that protrudes and has a tip portion bent and fitted into a through hole of the tank body is integrally formed. The heat exchanger according to claim 4, wherein a plurality of through holes are formed in both second side walls of the tank body at intervals in the length direction of the second side walls. From the metal base plate, a rectangular top wall forming part, a pair of first side wall forming parts integrally formed on mutually parallel side parts of the top wall forming part, and other parallel side parts of the top wall forming part Cutting out a first blank for a tank body having a pair of integrally formed second side wall forming portions and a mating portion forming portion formed integrally at both ends of the first side wall forming portion;
From the metal base plate, the rectangular closed wall forming portion, the pair of first side wall forming portions integrally formed on the parallel side portions of the closing wall forming portion, and the other parallel side portions of the closing wall forming portion Cutting out a second blank for a header plate having a pair of second side wall forming portions formed integrally, and forming a plurality of tube insertion holes in the closing wall forming portion;
The first blank forming portion is bent with respect to the first side wall forming portion, the first side wall forming portion is bent with respect to the top wall forming portion, and the second side wall forming portion is further bent with respect to the top wall forming portion. In addition, by bending both end portions of the second side wall forming portion along the rounded connecting portion of the first side wall forming portion and the mating portion forming portion, a pair of sides parallel to each other of the rectangular top wall and the top wall A pair of first side walls that are continuous with each other, a pair of second side walls that are connected to a pair of other parallel sides of the top wall, and a first side wall that are integrally formed via a round-shaped connecting portion; Producing a tank body material having a mating portion along the inner surface of the second side wall and a first bent portion formed integrally with the second side wall;
The first side wall forming portion and the second side wall forming portion of the second blank are bent with respect to the closing wall forming portion, and both end portions of the second side wall forming portion are bent into a shape along the first bent portion of the tank body material. Further, by transforming both ends of the first side wall forming portion into a shape that can enter into a recess formed between the outer surface of the rounded connecting portion of the tank body material and the front end surface of the first bent portion, A closing wall, a pair of first side walls connected to a pair of parallel sides of the closing wall, a pair of second side walls connected to a pair of other parallel sides of the closing wall, a second side wall A second bent portion that can be formed along the first bent portion of the tank body material, and an outer surface of the rounded connecting portion of the tank body material and a distal end surface of the bent portion. Deformation part that can enter into the recess formed between To create a header plate material having,
The header plate material is fitted over the opening side end of the tank body material, the first and second side walls of the header plate material are aligned with the outer surfaces of the first and second side walls of the tank body material, and the header plate material Making the second bent part along the first bent part of the tank body material and making the deformed part of the header plate material enter the recess of the tank body material to make a combination of both materials,
Arranging the two combinations at intervals so that the header plate materials face each other;
A plurality of heat exchange tubes and fins are alternately combined, and both end portions of the heat exchange tubes are respectively inserted into the tube insertion holes of the header plate material of both combinations,
In addition, the tank body material is brazed to the second side wall to form the tank body, and the first side wall and the second side wall of the header plate material are brazed to the first side wall and the second side wall of the tank body. A method of manufacturing a heat exchanger, comprising forming a header plate, brazing both ends of the heat exchange pipe to the header plate, and brazing fins to the heat exchange pipe. The brazing material outflow prevention part forming part straddling between the first side wall forming part and the end part on the closed wall forming part side of the second side wall forming part in the second blank is formed integrally with the closing wall forming part, When making the header plate material, the brazing material outflow prevention portion forming portion integrally forms the brazing material outflow prevention portion straddling between the end portions of the adjacent first and second side walls on the closing wall side. The manufacturing method of the heat exchanger of Claim 6. A position corresponding to the through hole of the first blank in the second side wall forming portion of the second blank, and at least one through hole is formed in the portion that should overlap the mating portion forming portion in the second side wall forming portion of the first blank. 8. A claw portion protruding outward is integrally formed, and the claw portion is bent and fitted into the through hole when a combination body of the tank body material and the header plate material is formed. Manufacturing method of heat exchanger. The method for manufacturing a heat exchanger according to claim 8, wherein a plurality of through holes are formed at intervals in the length direction in a portion that should overlap with the mating portion forming portion in the second side wall forming portion of the first blank.

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