JP7361887B2 - Heat exchanger header, heat exchanger, method for manufacturing heat exchanger header, and method for manufacturing heat exchanger - Google Patents

Description

The present disclosure relates to a heat exchanger header, a heat exchanger, a method for manufacturing a heat exchanger header, and a method for manufacturing a heat exchanger.

As a heat exchanger used in air conditioners, refrigerators, etc., a fin-tube heat exchanger is known, which exchanges heat by circulating a heat medium through a heat transfer tube equipped with radiation fins. The fin-tube heat exchanger includes a heat exchanger header that distributes and circulates a heat medium to a plurality of heat exchanger tubes.

Patent Document 1 discloses a header for a heat exchanger in which an elongated plate is adjacent to an insertion hole of a heat exchanger tube formed by burring. This elongated plate can bear part of the force when internal pressure acts on the heat exchanger header, so it suppresses the stress applied around the insertion hole of the heat exchanger tube. Thereby, the pressure resistance performance of the heat exchanger header can be improved.

Patent No. 4533374

However, the insertion hole disclosed in Patent Document 1 is formed in a planar portion. Therefore, a configuration for improving the pressure resistance of the header is also provided in the planar portion. On the other hand, when providing an insertion hole in a curved portion of a heat exchanger header, it is difficult to directly apply the configuration disclosed in Patent Document 1, which assumes that the insertion hole is provided in a flat portion.

The present disclosure has been made in order to solve the above-mentioned problems, and provides a heat exchanger tube that can secure the joint strength with the heat exchanger tube joined to the curved part and improve the pressure resistance performance. The present invention aims to provide a header for an exchanger, a heat exchanger, a method for manufacturing a header for a heat exchanger, and a method for manufacturing a heat exchanger.

A header for a heat exchanger according to the present disclosure includes a first header member having a pipe forming portion that is a part of a pipe in which a flow path for circulating a heat medium is formed, and a first header member that is joined to the pipe forming portion and is connected to the pipe forming portion. a second header member forming a pipe. The second header member has a curved portion, and an insertion hole into which the heat exchanger tube is inserted is formed in the curved portion, and the hole wall of the insertion hole extends along the entire circumference of the insertion hole. A cut surface is formed on the edge of the insertion hole on the outer surface of the second header member over the entire circumference. has flanges along the insertion direction of the heat exchanger tube at both ends in the longitudinal direction of the insertion hole .

According to the present disclosure, the hole wall of the insertion hole formed in the curved portion is formed along the entire circumference of the heat exchanger tube to be inserted. Thereby, the bonding strength with the heat exchanger tube to be bonded to the curved portion can be ensured, and the pressure resistance performance can be improved.

A plan view of a heat exchanger according to Embodiment 1 A perspective view of a heat exchanger tube according to Embodiment 1 An exploded perspective view of a heat exchanger header according to Embodiment 1 It is a diagram showing a heat exchanger header according to Embodiment 1, and is an exploded diagram of the heat exchanger header. It is a figure showing the header for heat exchangers concerning Embodiment 1, and is a sectional view of the header for heat exchangers. A diagram focusing on the insertion hole formed in the second header member as seen from arrow V in FIG. 3 6 is a diagram of the second header member according to Embodiment 1, and is a cross-sectional view taken along cutting line VIA-VIA in FIG. 5. FIG. 6 is a diagram of the second header member according to Embodiment 1, and is a cross-sectional view taken along cutting line VIB-VIB in FIG. 5. FIG. Explanatory diagram showing the flow of heat medium in the heat exchanger according to Embodiment 1 It is a figure for explaining the manufacturing process of the 2nd header member based on Embodiment 1, and is an explanatory view shown in process order. It is a figure for explaining the manufacturing process of the 2nd header member based on Embodiment 1, and is an explanatory view shown in process order. 8B is a diagram for explaining the manufacturing process of the second header member according to Embodiment 1, and is a diagram seen from arrow C in FIG. 8B. An explanatory diagram showing the steps of manufacturing the second header member according to the first embodiment following FIGS. 8A and 8B in order of steps An explanatory diagram showing the steps of manufacturing the second header member according to the first embodiment following FIGS. 8A and 8B in order of steps A sectional view showing a state in which a heat exchanger tube is inserted into the second header member according to Embodiment 1. A front view of the second header member according to the second embodiment, focusing on the insertion hole. 12 is a diagram of a second header member according to Embodiment 2, and is a cross-sectional view taken along cutting line XIIA-XIIA in FIG. 11. 12 is a diagram of a second header member according to Embodiment 2, and is a cross-sectional view taken along cutting line XIIB-XIIB in FIG. 11. Cross-sectional view of the second header member according to Embodiment 3 It is a figure of the 2nd header member concerning Embodiment 3, and is a figure showing the state where burring processing is carried out. Explanatory diagram showing another example of the process of manufacturing the second header member according to Embodiment 1 in order of process Explanatory diagram showing another example of the process of manufacturing the second header member according to Embodiment 1 in order of process

Hereinafter, a heat exchanger header, a heat exchanger, a method for manufacturing a heat exchanger header, and a method for manufacturing a heat exchanger according to preferred embodiments of the present disclosure will be described with reference to the drawings.

(Embodiment 1)
The heat exchanger 1 according to the first embodiment performs heat exchange between air flowing outside the heat exchanger 1 and a heat medium flowing inside the heat exchanger 1. As shown in FIG. 1, the heat exchanger 1 includes a heat exchanger tube 20 through which a heat medium flows, a heat exchanger header 500 that is connected to the heat exchanger tube 20 and causes the heat medium to flow into the heat exchanger tube 20, and a heat exchanger tube A heat exchanger header 100 that is connected to the heat exchanger tube 20 and causes the heat medium to flow out from the heat exchanger tube 20, a joint tube 130 that causes the heat medium to flow out from the heat exchanger header 100, and a heat radiation fin 30 that is attached to the heat exchanger tube 20.

As shown in FIG. 2, the heat exchanger tube 20 is a piping member having a flat cross-section and having short arcuate sides and long straight sides. That is, the heat exchanger tube 20 has a shape in which semi-cylindrical portions 20b are connected to both sides of a rectangular parallelepiped portion 20a. Moreover, the heat exchanger tube 20 has a communication hole 20c formed therein, and allows the heat medium to flow through the communication hole 20c. By forming the heat exchanger tubes 20 to have a flat cross-sectional shape in this manner, the ventilation resistance around the heat exchanger tubes 20 can be reduced and the heat exchange efficiency can be improved.

The heat exchanger tube 20 is formed by a known processing technique such as extrusion or drawing. The heat exchanger tube 20 is made of an aluminum alloy whose outer surface is sprayed with zinc to form a sacrificial anode layer. By forming the sacrificial anode layer on the outer surface in this manner, leakage of the heat medium due to corrosion of the heat transfer tube 20 can be prevented.

One end of the heat exchanger tube 20 is inserted into an insertion hole 50 formed in the heat exchanger header 100 shown in FIGS. 1 and 3, and is welded and fixed to the heat exchanger header 100 by brazing. Moreover, the other end of the heat exchanger tube 20 is inserted into the insertion hole 550 formed in the heat exchanger header 500 shown in FIG. 1, and is welded and fixed to the heat exchanger header 500 by brazing.

The radiation fins 30 are flat members that increase cooling efficiency by increasing the contact area with air. As shown in FIG. 1, a plurality of heat radiation fins 30 are attached to the heat transfer tube 20. The material of the radiation fins 30 is, for example, a clad material in which a brazing material is rolled and bonded to the surface of an aluminum plate. Further, the thickness of the radiation fins 30 is approximately 0.09 to 0.2 mm.

As shown in FIG. 1, the heat radiation fins 30 include a plurality of through holes 30a through which the heat exchanger tubes 20 are inserted. The through hole 30a is a flat hole or notch into which the flat heat exchanger tube 20 can be inserted. The heat exchanger tube 20 is inserted into each through hole 30a, respectively. The heat-radiating fins 30 and the heat-radiating tubes 20 are then joined by brazing the connecting portions between the inserted heat-transfer tubes 20 and the heat-radiating fins 30.

As shown in FIG. 1, a plurality of heat radiation fins 30 are attached in the longitudinal direction of the heat exchanger tube 20, that is, in the direction in which the heat medium flows.

The heat exchanger headers 100 and 500 are a pair of piping members for supplying and discharging a fluid heat medium to the heat exchanger 1. A plurality of insertion holes 50 and 550 are formed in the heat exchanger headers 100 and 500, respectively. The heat exchanger tubes 20 are inserted into the respective insertion holes 50 and 550, and the heat exchanger headers 100 and 500 and the heat exchanger tubes 20 are connected.

The heat exchanger header 100 includes a first header member 110, a second header member 120, and a cap 140, as shown in FIGS. 3, 4A, and 4B.

The first header member 110 includes a first pipe 111 in which a bypass flow path Bf is formed, and a pipe forming portion 112 that forms a second pipe 150 in which a main flow path Mf is formed together with the second header member 120 to be combined. have. The first header member 110 is an aluminum alloy member in which a first pipe 111 and a pipe forming portion 112 are integrally formed by extrusion processing. A sacrificial anode layer is formed on the outer surface of the first header member 110 by spraying zinc. Thereby, leakage of the heat medium due to corrosion of the heat exchanger header 100 can be prevented.

The first pipe 111 is formed with a through hole 111a having a circular cross section and extending in the longitudinal direction. This through hole 111a forms a bypass flow path Bf through which the heat medium flows. Further, as shown in FIG. 3, the first pipe 111 is formed with a joint pipe connecting portion 111b to which a joint pipe 130, which will be described later, is connected. The joint pipe connection part 111b is a part obtained by cutting out a part of the middle part of the first pipe 111. The joint pipe connecting portion 111b is cut out in a shape and size into which the joint pipe 130 can be inserted.

As shown in FIG. 3, the pipe forming portion 112 forms a part of the main flow path Mf that is parallel to the bypass flow path Bf. The pipe forming portion 112 is integrally formed with the first pipe 111 over the entire length of the first pipe 111. The pipe forming portion 112 has a semicircular cross section. Furthermore, as shown in FIGS. 3 and 7, the pipe forming portion 112 has a joint pipe insertion hole 112a formed at a position corresponding to the joint pipe connecting portion 111b. The diameter of the joint tube insertion hole 112a is equal to or smaller than the outer diameter of the joint tube 130. Therefore, the joint pipe 130 can be temporarily fixed to the first header member 110 by being press-fitted into the joint pipe insertion hole 112a.

Moreover, as shown in FIG. 3, the joint parts 113 joined to the second header member 120 are both edges of the pipe forming part 112, and are formed along the direction in which the main flow path Mf is formed. The joint portion 113 is formed over the entire length of the pipe forming portion 112.

Furthermore, as shown in FIG. 7, the first header member 110 is formed with a bypass hole 110a that communicates the main flow path Mf and the bypass flow path Bf. This bypass hole 110a and a through hole 130a formed in the joint pipe 130, which will be described later, constitute a bypass circuit for the heat medium flowing out from the joint pipe 130.

As shown in FIGS. 3, 4A, and 4B, the second header member 120 has a U-shaped cross section that is joined to the first header member 110 and forms a part of the main flow path Mf of the heat exchanger header 100. This is a long member. That is, the second header member 120 is joined to the pipe forming part 112 to form the second pipe 150 together with the pipe forming part 112 . The second header member 120 is made of a clad material made by rolling and bonding a brazing material to an aluminum plate. As shown in FIG. 4A, the second header member 120 includes a semicircular portion 121 having a semicircular cross section and two planar portions 122 connected to the ends of the semicircular portion 121. There is.

Further, the second header member 120 includes a joining recess 120a, as shown in FIGS. 4A and 4B. The joining recess 120a is a recess formed by press working on the inner surface of the second header member 120 having a U-shaped cross section, and is formed over the entire length of the second header member 120 in the longitudinal direction. The joining recesses 120a are formed at two locations on the inner surface of the second header member 120. The joint portion 113 of the first header member 110 fits into the joint recess 120a when the first header member 110 and the second header member 120 are combined. At this time, the tip portion of the planar portion 122 of the second header member 120 beyond the joining recess 120a protrudes to the side of the first header member 110. The protruding portion of the second header member 120 is caulked to temporarily fix the first header member 110 and the second header member 120. Then, by heating the temporarily fixed first header member 110 and second header member 120 in a heating furnace, the brazing material layer of the second header member 120 melts, and the first header member 110 and the second header member 120 are brazed.

Further, as shown in FIG. 3, a plurality of insertion holes 50 for attaching the heat exchanger tubes 20 are formed in the second header member 120. The insertion hole 50 is formed in a semicircular portion 121, which is an example of a curved portion of the second header member 120, as shown in FIG. 6B. As shown in FIG. 5, the insertion hole 50 is a flat long hole that matches the outer shape of the heat exchanger tube 20 shown in FIG. 2 when viewed from the front in the direction of arrow V in FIG. It extends along the circumferential direction of the circular portion 121. The insertion hole 50 is defined by a pair of plane walls 50a facing the rectangular parallelepiped part 20a of the heat exchanger tube 20 shown in FIG. 2, and a pair of curved walls 50b facing the semicylindrical part 20b of the heat exchanger tube 20 shown in FIG. has been done.

The plane wall 50a is formed along the heat exchanger tube 20 inserted into the insertion hole 50, as shown in FIG. 6A. The direction along this heat exchanger tube 20 corresponds to the X direction in which the heat exchanger tube 20 is inserted. Moreover, the curved wall 50b is formed along the heat exchanger tube 20 inserted into the insertion hole 50, as shown in FIG. 6B. Note that the X direction, which is the direction in which the heat exchanger tubes 20 are inserted, corresponds to the direction in which the heat exchanger tubes 20 that connect the heat exchanger header 100 on the left side and the heat exchanger header 500 on the right side in FIG. 1 extend.

As shown in FIGS. 3 and 7, the cap 140 has a first protrusion 141 inserted into the main flow path Mf and a second protrusion 142 inserted into the bypass flow path Bf. The caps 140 are attached to both longitudinal ends of the first header member 110 and the second header member 120, respectively. Thereby, the cap 140 closes the main flow path Mf and the bypass flow path Bf formed in the heat exchanger header 100. The cap 140 is made of a clad material in which a brazing material is rolled and bonded to the surface of an aluminum plate, and is formed by press working.

As shown in FIG. 3, the joint pipe 130 is an L-shaped piping member for discharging the heat medium from the heat exchanger header 100. The joint pipe 130 is inserted into the joint pipe insertion hole 112a formed in the first header member 110. Thereby, the inside of the joint pipe 130 communicates with the main flow path Mf. Further, the joint pipe 130 is formed with a through hole 130a that communicates the inside of the joint pipe 130 with the bypass flow path Bf. The through holes 130a are holes that penetrate in the diametrical direction of the circular cross section of the joint pipe 130, and are formed at two locations in the joint pipe 130, as shown in FIG.

As shown in FIG. 1, the heat exchanger header 500 is connected to the end opposite to the end where the heat exchanger tube 20 is connected to the heat exchanger header 100. The basic configuration of the heat exchanger header 500 is the same as that of the heat exchanger header 100, and includes a first header member 510, a second header member 520, and a cap 540.

The heat exchanger header 500 is connected to an inflow pipe (not shown), and distributes the heat medium that has flowed in to the heat exchanger tubes 20 .

Next, the movement of the heat medium flowing through the heat exchanger 1 will be explained with reference to FIG. 7. Note that in FIG. 7, the movement of the heat medium is illustrated by arrows. After heat exchange is performed, the heat medium distributed to the heat exchanger tubes 20 by the heat exchange header 500 flows into the main flow path Mf of the heat exchanger header 100, as shown by arrow Y1. A part of the heat medium that has flowed into the main flow path Mf flows into the joint pipe 130 as shown by arrow Y2, and the rest flows into the bypass flow path Bf through the bypass hole 110a as shown by arrow Y3. The heat medium that has flowed into the bypass flow path Bf flows into the joint pipe 130 through the through hole 130a, as shown by arrow Y4. The heat medium that has flowed into the joint pipe 130 is discharged from the joint pipe 130 as shown by arrow Y5.

In this way, by providing the bypass passage Bf into which the heat exchanger tube 20 is not inserted, the pressure loss within the heat exchanger header 100 is suppressed, and the oil return property of the refrigerating machine oil used in the compressor (not shown) is improved. becomes possible. Furthermore, by similarly providing the bypass flow path Bf in the heat exchanger header 500, the heat medium can evenly flow into the main flow path Mf, thereby eliminating variations in the amount of heat medium flowing through each heat transfer tube 20. be able to.

Next, a method for manufacturing the second header member 120 included in the heat exchanger header will be described. First, a plate 200 for manufacturing the second header member 120 is cut from a flat plate made of aluminum alloy, and a joining recess 120a shown in FIG. 8A is formed by press working. Next, as shown in FIG. 8A, the cut plate 200 is placed in a die (not shown), and punched out in a direction perpendicular to the main surface 200a using a long hole punch 300 with curved side surfaces. As a result, a through hole 250 is formed in the plate 200, as shown in FIG. 8B. The through hole 250 is a long hole having a flat wall 250a and a curved wall 250b, as shown in FIGS. 8B and 8C. The plane wall 250a and the curved wall 250b of the through hole 250 formed in this way are perpendicular to the main surface 200a of the plate 200. The through hole 250 then becomes the insertion hole 50 shown in FIG. 5 through a manufacturing process that will be described later.

Next, as shown in FIG. 9A, the plate 200 with the through holes 250 is bent to form a semicircular portion 221 having a semicircular cross section. At this time, the plate 200 is bent while aligning the circumferential direction of the semicircular portion 221 with the longitudinal direction of the through hole 250. Note that the bent plate 200 is flat in the direction perpendicular to FIG. 9A and has no bends.

Note that the curved wall 250b, which was perpendicular to the main surface 200a before the plate 200 was bent, remains close to perpendicular without significantly changing the angle to the main surface 200a even after the plate 200 is bent. Relationships are maintained. Therefore, as shown in FIG. 9A, after the plate 200 is bent, the curved wall 250b inclines inward to narrow the through hole 250 and is no longer parallel to the X direction. On the other hand, the plate 200 does not have any bend in the direction perpendicular to FIG. 9A as described above. Therefore, after the plate 200 is bent, the plane wall 250a shown in FIG. 9A is parallel to the X direction.

Subsequently, as shown in FIG. 9A, the bent plate 200 is placed in a die (not shown). Then, the punch 301 whose side surface is curved is moved in parallel to the X direction to perform a shaving process in which the curved wall 250b is scraped off. Note that the punch 301 used when performing the shaving process is longer than the punch 300 shown in FIG. 8A, which forms the through hole 250, by the amount of scraping off the curved walls 250b on both sides. As a result, as shown in FIG. 9B, the punched portion 210 is removed from the second header member 120, and a curved wall 50b parallel to the X direction is formed. In this way, the hole wall of the insertion hole 50 formed in the second header member 120 can be made parallel to the X direction over the entire circumference. The second header member 120 is manufactured through such steps.

The heat exchanger tube 20 is inserted into the insertion hole 50 formed in the second header member 120, as shown in FIG. Then, by heating in a heating furnace (not shown), the brazing material melts from the brazing material layer of the second header member 120, and the heat transfer tube 20 is brazed to the second header member 120.

(effect)
According to the embodiment described above, the hole wall of the insertion hole 50 formed in the curved semicircular portion 121 is formed along the entire circumference in the direction along the heat exchanger tube 20, that is, the direction in which the heat exchanger tube 20 is inserted. has been done. Thereby, as shown in FIG. 10, the joining length L between the second header member 120 and the semi-cylindrical portion 20b of the heat exchanger tube 20 can be made longer than the plate thickness t of the second header member 120. In this way, since the bonding length L can be increased, the bonding strength between the second header member 120 and the heat exchanger tubes 20 can be increased, and the pressure resistance performance can be improved.

Moreover, as shown in FIG. 10, the distance between the hole wall of the insertion hole 50 and the outer surface of the heat exchanger tube 20 can be made constant over the joint length L. Therefore, the cooled and solidified solder can be uniformly formed between the hole wall of the insertion hole 50 and the outer surface of the heat exchanger tube 20. As a result, the quality of brazing can be improved, and the strength of the joint portion can be increased, that is, the pressure resistance can be improved.

Further, as shown in FIG. 10, since the distance between the hole wall of the insertion hole 50 and the outer surface of the heat exchanger tube 20 can be made close to each other over the bonding length L, the amount of brazing material to be supplied can be reduced. As a result, it is possible to suppress erosion that tends to occur due to excessive supply of solder, and it is possible to improve the quality of brazing.

Furthermore, a long punch 301 was used during the shaving process to shave off both ends of the insertion hole 50 of the U-shaped second header member 120. Thereby, both ends of the insertion hole 50 can be cut off in one punch using the punch 301, and the manufacturing process can be simplified. Furthermore, since the through holes 250 are formed in the plate 200 in advance, the amount of shaving performed by the punch 301 can be reduced. Thereby, deformation of the second header member 120 having a U-shaped cross section can be suppressed, and it can be combined with the first header member 110 with high accuracy.

(Embodiment 2)
Next, a second embodiment will be described. As shown in FIG. 11, the second header member 320 is formed with an insertion hole 350 that matches the outer shape of the heat exchanger tube 20 shown in FIG. The insertion hole 350 is a flat long hole. The insertion hole 350 has a pair of flat walls 350a facing the rectangular parallelepiped part 20a of the heat exchanger tube 20 shown in FIG. 2, and a pair of curved walls 350b facing the semicylindrical part 20b of the heat exchanger tube 20 shown in FIG. are doing.

The plane wall 350a is formed along the heat exchanger tube 20 inserted into the insertion hole 350, as shown in FIG. 12A. Further, the plane wall 350a is parallel to the X direction, which is the direction in which the heat exchanger tube 20 is inserted. Moreover, the curved wall 350b is formed along the heat exchanger tube 20 inserted into the insertion hole 350, as shown in FIG. 12B. Further, the curved wall 350b is parallel to the X direction, which is the direction in which the heat exchanger tube 20 is inserted.

Further, as shown in FIG. 11, a cut surface 360 is formed on the outer surface 320a of the second header member 320 along the edge of the insertion hole 350. The cut surface 360 connects the hole wall of the insertion hole 350 and the outer surface 320a of the second header member 320, as shown in FIGS. 12A and 12B. Here, the hole walls of the insertion hole 350 are a flat wall 350a and a curved wall 350b. The cut surface 360 is inclined in a direction that enlarges the insertion hole 350 toward the outer surface 320a of the second header member 320.

Next, a method for forming the cut surface 360 on the second header member 320 will be described. First, as shown in FIG. 8B, the process of forming the joining recess 120a and the through hole 250 in the plate 200 for the second header member 320 is the same as in the above embodiment. Next, the edge of the through hole 250 on one surface of the plate 200 shown in FIG. 8B is chamfered by tapping with a tool having an inclined surface. Note that one surface of the plate 200 is a surface opposite to the surface on which the joint recess 120a is formed. Next, the plate 200 is bent so that one side of the chamfered edge of the through hole 250 faces outward. Finally, similar to the step shown in FIG. 9B, the punch 301 is moved in parallel to the X direction to perform a shaving process in which the curved wall 250b is shaved off. Through the above steps, a cut surface 360 can be formed at the edge of the insertion hole 350, as shown in FIGS. 12A and 12B.

Although it has been described that the process of chamfering the edge of the insertion hole 350 is performed before bending the plate 200, it may be performed after the plate 200 is bent. In this case, after bending the plate 200 in which the joining recess 120a and the through hole 250 are formed, the edge of the through hole 250 is chamfered, and finally the end of the through hole 250 is shaved off.

According to the second embodiment, the cut surface 360 is an inclined surface that enlarges the insertion hole 350 toward the outer surface 320a of the second header member 320. Therefore, the heat exchanger tube 20 can be inserted into the insertion hole 350 by bringing it into contact with the cut surface 360 and sliding it along the cut surface 360. Thereby, the heat exchanger tube 20 can be easily inserted into the insertion hole 350, and the assembly work can be performed smoothly.

Further, the area between the heat exchanger tube 20 inserted into the insertion hole 350 and the cut surface 360 can function as a dead body for storing the brazing material overflowing from the joint. Thereby, it is possible to prevent the brazing material from flowing out from the joint between the second header member 320 and the heat exchanger tube 20.

(Embodiment 3)
As shown in FIG. 13A, flanges 460 are formed at both longitudinal ends of the insertion hole 450 in the second header member 420 according to the third embodiment. The second header member 120 according to the first embodiment does not have such a flange, and is different from the first embodiment in this point. The flange 460 is formed to protrude inside the second header member 420.

A method of manufacturing the second header member 420 according to the third embodiment will be described. First, as shown in FIG. 8B, the joining recess 120a and the through hole 250 are formed in the plate 200 for the second header member 420, and then the plate 200 is bent as shown in FIG. 9A. The steps up to this point are the same as in the first embodiment. Subsequently, as shown in FIG. 13B, the punch 302 is moved in the X direction to perform burring on the curved walls 250b formed at both ends of the through hole 250. As a result, as shown in FIG. 13A, a curved wall 450b parallel to the X direction is formed, and a flange 460 extending in the X direction is formed to protrude toward the inside of the second header member 420.

According to the third embodiment, as shown in FIG. 13A, the joining length L1 between the second header member 420 and the semi-cylindrical portion 20b of the heat exchanger tube 20 is made longer than the plate thickness t of the second header member 420. I can do it. In addition to this bonding length L1, a bonding length L2 corresponding to the length of the flanges 460 formed at both ends of the insertion hole 450 in the longitudinal direction can be secured. Thereby, the bonding strength between the second header member 420 and the heat exchanger tube 20 can be increased, and the pressure resistance performance can be improved.

This disclosure is not limited to the above embodiments, and various modifications and applications are possible. In the above embodiment, the through holes 250 are formed before the plate 200 is bent as shown in FIG. 8A, but the through holes 250 may be formed after the plate 200 is bent. As shown in FIG. 14A, the through hole 250 is formed by pressing the plate 200 in which the joining recess 120a is formed with a punch 303 from multiple directions. At this time, the punch 303 is rotated each time the plate 200 is pressed, and the through holes 250 are formed in a plurality of times. Alternatively, as another method, the U-shaped plate 200 may be rotated each time the punch 303 is pressed, and the through holes 250 may be formed in a plurality of times. In this way, a through hole 250 shown in FIG. 14B is formed in the U-shaped plate 200. Subsequently, as shown in FIG. 14B, the punch 301 is moved in parallel to the X direction to scrape off the curved walls 250b formed at both ends of the through hole 250. Thereby, the second header member 120 shown in FIG. 9B in which the curved wall 50b parallel to the X direction is formed can be manufactured.

Note that the punch 303 shown in FIG. 14A that makes the through hole 250 is smaller than the punch 300 shown in FIG. 8A that makes the through hole 250 in the flat plate 200. Therefore, deformation of the plate 200 bent into a U-shape can be suppressed.

Further, the heat exchanger tubes 20 connected to the heat exchanger headers 100, 500 are not limited to those having a flat cross section. For example, heat exchanger tubes having other cross-sectional shapes such as circular, square, or triangular shapes may be connected to the heat exchanger headers 100, 500.

In addition, the second header member 120 is made of a clad material made by rolling and bonding a brazing metal to an aluminum plate, and the heat exchanger tubes 20 are bonded with the brazing metal melted from the second header member 120, but the joining method used is arbitrary. It is. For example, the second header member 120 and the heat exchanger tube 20 may be brazed using paste brazing, wire brazing, or the like.

Further, the configuration of the joint portion between the first header member 110 and the second header member 120 described above is one example, and other joint portion configurations may be used. For example, both edges of the first header member 110 and both edges of the second header member 120 may be joined in abutted state.

In addition, in the above embodiment, a case has been described in which the basic configurations of the heat exchanger header 100 and the heat exchanger header 500, which are a pair of piping members, are the same, but a pair of heat exchanger headers with different basic configurations may also be used.

Further, as described with reference to FIG. 13A, the flange 460 was made to protrude inside the second header member 420 by burring, but the flange may be made to protrude outside the second header member 420.

Furthermore, the process of cutting off the end of the through hole 250 to make it parallel to the X direction, and the process of forming the cut surface 360 on the edge of the insertion hole 350 are not limited to the above-mentioned processing method, but can be performed using any known process. Any method can be selected from among the methods. For example, the end of the through hole 250 may be filed down to align with the X direction. Moreover, the cut surface 360 may be formed by filing the edge of the insertion hole 350, or may be formed by cutting the corner. Alternatively, the insertion holes 50 may be formed in the U-shaped plate 200 by laser processing. Thereby, an insertion hole can be formed in the U-shaped plate 200, the hole wall of which extends along the heat exchanger tube 20.

Although the insertion hole 50 has been described as being formed in the semicircular portion 121 of the second header member 120 having a semicircular cross section, it may be formed in a portion having another cross-sectional shape. For example, it may be formed in a bow-shaped portion of the second header member 120, or it may be formed in a convex portion with a rounded tip.

Furthermore, although it has been described that each component of the heat exchanger 1 such as the heat exchanger header 100 and the heat exchanger tubes 20 is made of aluminum, they may be made of other metals such as stainless steel, steel, and copper.

This disclosure is capable of various embodiments and modifications without departing from its broad spirit and scope. Further, the embodiments described above are for explaining the present disclosure, and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is indicated by the claims rather than the embodiments. Various modifications made within the scope of the claims and the meaning of the disclosure equivalent thereto are considered to be within the scope of the present disclosure.

This application is based on Japanese Patent Application No. 2020-061786, filed on March 31, 2020. The entire specification, claims, and drawings of Japanese Patent Application No. 2020-061786 are incorporated herein by reference.

1 Heat exchanger, 20 Heat exchanger tube, 20a Rectangular parallelepiped part, 20b Semi-cylindrical part, 20c Distribution hole, 30 Radiation fin, 30a Through hole, 50 Insertion hole, 50a Plane wall, 50b Curved wall, 100 Header for heat exchanger, 110 First header member, 110a Bypass hole, 111 First pipe, 111a Through hole, 111b Joint pipe connection part, 112 Pipe forming part, 112a Joint pipe insertion hole, 113 Joint part, 120 Second header member, 120a Joint recess, 121 Semicircular part, 122 Planar part, 130 Joint pipe, 130a Through hole, 140 Cap, 141 First convex part, 142 Second convex part, 150 Second pipe, 200 Plate, 200a Main surface, 210 Punching part, 221 semicircular part, 250 through hole, 250a plane wall, 250b curved wall, 300, 301, 302, 303 punch, 320 second header member, 320a outer surface, 350 insertion hole, 350a plane wall, 350b curved wall, 360 cut surface, 420 second header member, 450 insertion hole, 450b curved wall, 460 flange, 500 header for heat exchanger, 510 first header member, 520 second header member, 540 cap, 550 insertion hole.

Claims (18)

a first header member having a pipe forming part that is a part of a pipe in which a flow path for circulating a heat medium is formed;
a second header member joined to the pipe forming part to form the pipe together with the pipe forming part;
The second header member has a curved part, and an insertion hole into which the heat exchanger tube is inserted is formed in the curved part,
The hole wall of the insertion hole is along the entire circumference of the heat exchanger tube to be inserted,
A cut surface is formed on the edge of the insertion hole on the outer surface of the second header member over the entire circumference,
The insertion hole is a long hole whose longitudinal direction is along the circumferential direction of the pipe,
The curved portion has flanges along the insertion direction of the heat exchanger tube at both ends in the longitudinal direction of the insertion hole.
Header for heat exchanger. The hole wall of the insertion hole is parallel to the insertion direction of the heat exchanger tube over the entire circumference,
The header for a heat exchanger according to claim 1. The cut surface is inclined in a direction that enlarges the insertion hole toward the outer surface of the second header member.
A header for a heat exchanger according to claim 1 or 2. The insertion hole is defined by a pair of flat walls along the longitudinal direction and a pair of curved walls connecting the ends of the pair of flat walls,
Of the pair of flat walls and the pair of curved walls that partition the insertion hole, the flange is formed only on the pair of curved walls.
A header for a heat exchanger according to any one of claims 1 to 3. A recess into which an edge of the pipe forming part fits is formed along the flow path on an inner surface of the second header member to which the pipe forming part is joined;
A header for a heat exchanger according to any one of claims 1 to 4. a first header member having a pipe forming part that is a part of a pipe in which a flow path for circulating a heat medium is formed;
a second header member joined to the pipe forming part to form the pipe together with the pipe forming part;
The second header member has a curved part, and an insertion hole into which the heat exchanger tube is inserted is formed in the curved part,
The hole wall of the insertion hole is along the entire circumference of the heat exchanger tube to be inserted,
A cut surface is formed on the edge of the insertion hole on the outer surface of the second header member over the entire circumference,
At both ends of the insertion hole in the circumferential direction of the pipe, the length along the heat exchanger tube of the portion where the hole wall of the insertion hole and the outer surface of the heat exchanger tube are joined is equal to the length of the second header member. longer than the plate thickness,
Header for heat exchanger. A heat exchanger header according to any one of claims 1 to 6 ,
the heat exchanger tube inserted into the insertion hole and connected to the flow path;
fins attached to the heat exchanger tube,
Heat exchanger. The heat exchanger tube is inserted into the insertion hole and joined to the heat exchanger header,
At both ends of the insertion hole in the circumferential direction of the pipe, the length along the heat exchanger tube of the portion where the hole wall of the insertion hole and the outer surface of the heat exchanger tube are joined is equal to the length of the second header member. longer than the plate thickness,
The heat exchanger according to claim 7 . At both ends of the insertion hole in the circumferential direction of the pipe, the distance between the hole wall of the insertion hole and the outer surface of the heat exchanger tube is constant in the direction along the heat exchanger tube.
The heat exchanger according to claim 7 or 8 . forming an insertion hole in the second header member into which the heat exchanger tube is inserted;
forming a cut surface on an edge of the insertion hole that becomes the outer surface of the second header member;
bending the second header member in which the insertion hole is formed, with the edge portion forming the cut surface facing outward;
Processing a part of the hole wall of the insertion hole that is not along the insertion direction of the heat exchanger tube while leaving the cut surface so as to align it with the insertion direction of the heat exchanger tube;
a step of joining the second header member whose hole wall has been processed and the first header member to form a flow path through which a heat medium flows therein;
A method of manufacturing a header for a heat exchanger. a step of bending the second header member;
drilling a plurality of holes in the bent second header member to form an insertion hole into which the heat exchanger tube is inserted;
forming a cut surface on the outer edge of the second header member in the insertion hole;
Processing a part of the hole wall of the insertion hole that is not along the insertion direction of the heat exchanger tube while leaving the cut surface so as to align it with the insertion direction of the heat exchanger tube;
a step of joining the second header member whose hole wall has been processed and the first header member to form a flow path through which a heat medium flows therein;
A method of manufacturing a header for a heat exchanger. The processing performed on the hole wall is a shaving process in which a portion not along the insertion direction of the heat exchanger tube is shaved off.
A method for manufacturing a header for a heat exchanger according to claim 10 or 11 . The processing performed on the hole wall is burring processing to form a flange in the insertion direction of the heat exchanger tube,
A method for manufacturing a header for a heat exchanger according to claim 10 or 11 . processing performed on the hole wall to make the hole wall parallel to the insertion direction of the heat exchanger tube over the entire circumference;
A method for manufacturing a header for a heat exchanger according to any one of claims 10 to 13 . further comprising the step of forming a recess along the longitudinal direction of the second header member,
arranging the recess on the curved inner surface of the second header member by bending the second header member;
When joining the second header member and the first header member, temporarily fixing the second header member and the first header member with the edge of the first header member fitted into the recess;
A method for manufacturing a header for a heat exchanger according to any one of claims 10 to 14 . Each step included in the method for manufacturing a heat exchanger header according to any one of claims 10 to 15 ,
a step of inserting a heat transfer tube into a through hole formed in the fin;
inserting the heat exchanger tube into the insertion hole formed in the second header member and connecting the heat exchanger tube to the flow path through which the heat medium flows;
a step of heating and joining the assembled second header member, the heat exchanger tube, and the fin;
Method of manufacturing a heat exchanger. At both ends of the insertion hole in the circumferential direction of the second header member, the length along the heat exchanger tube of the portion where the hole wall of the insertion hole and the outer surface of the heat exchanger tube are joined is equal to longer than the plate thickness of the header member,
A method for manufacturing a heat exchanger according to claim 16 . At both ends of the insertion hole in the circumferential direction of the second header member, the distance between the hole wall of the insertion hole and the outer surface of the heat exchanger tube is constant in the direction along the heat exchanger tube.
The method for manufacturing a heat exchanger according to claim 16 or 17 .

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