CN101501436A - 塑料换热器及其制造方法 - Google Patents

塑料换热器及其制造方法 Download PDF

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CN101501436A
CN101501436A CNA200780029912XA CN200780029912A CN101501436A CN 101501436 A CN101501436 A CN 101501436A CN A200780029912X A CNA200780029912X A CN A200780029912XA CN 200780029912 A CN200780029912 A CN 200780029912A CN 101501436 A CN101501436 A CN 101501436A
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heat exchanger
fusion
melted material
exchanger tube
plastic heat
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CN101501436B (zh
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李彦锡
柳浩根
崔斗淳
韩相勋
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LG Corp
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/182—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding the heat-exchange conduits having ends with a particular shape, e.g. deformed; the heat-exchange conduits or end plates having supplementary joining means, e.g. abutments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
    • F28D1/05316—Assemblies of conduits connected to common headers, e.g. core type radiators
    • F28D1/05333—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/06—Constructions of heat-exchange apparatus characterised by the selection of particular materials of plastics material
    • F28F21/062—Constructions of heat-exchange apparatus characterised by the selection of particular materials of plastics material the heat-exchange apparatus employing tubular conduits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/187—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding at least one of the parts being non-metallic, e.g. heat-sealing plastic elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
    • F28D2021/007—Condensers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
    • F28F2255/14—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes molded
    • F28F2255/143—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes molded injection molded
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
    • F28F2255/16—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes extruded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4935—Heat exchanger or boiler making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49401—Fluid pattern dispersing device making, e.g., ink jet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49428—Gas and water specific plumbing component making
    • Y10T29/49432—Nozzle making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49428—Gas and water specific plumbing component making
    • Y10T29/49432—Nozzle making
    • Y10T29/49433—Sprayer

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)

Abstract

本发明公开了一种塑料换热器，其中当该塑料换热器的换热管与集管连接时，通过包括熔融部和熔融槽的热熔模将该换热管和集管的接头部同时熔融并挤压以确保防止制冷剂泄漏的可靠性；以及公开了该塑料换热器的制造方法，使用该方法可以通过简单的工艺以低制造成本大量生产所述塑料换热器。本发明提供了一种制造塑料换热器的方法，其包括通过使用热熔模将塑料换热管和集管的接头熔融并连接的步骤；以及用该方法制造的塑料换热器，由此确保了防止制冷剂泄漏的可靠性，具有比金属换热器更优异或者相同的换热性能，以及通过简单的工艺以低制造成本大量生产所述塑料换热器。

Description

塑料换热器及其制造方法
技术领域
本发明涉及一种塑料换热器(plastic heat exchanger)及其制造方法，并且具体而言，涉及一种塑料换热器，其中当该塑料换热器的换热管与集管(header)连接时，通过包括熔融部和熔融槽(fusion valley)的热熔模(heat fusion jig)将该换热管和集管的接头部熔融并同时挤压，以确保防止制冷剂泄漏的可靠性，由此使该塑料换热器具有比金属换热器更优异或者目同的换热性能；以及涉及该塑料换热器的制造方法，使用该方法可以通过简单的工艺以低制造成本大量生产所述塑料换热器。
背景技术
如图1所示，在常规换热器中，将换热片3连接到包括制冷剂入口管1和制冷剂出口管2的金属换热管的外侧以改善热交换，并且将由金属材料制成的集管连接到该金属换热管的左侧和右侧以固定该换热器。该换热器用昂贵的金属材料例如铝合金、铜等制造并通过复杂的工艺制成，由此增加了制造时间和成本。所以，难于大规模生产这种换热器。
同时，为了解决这个问题，有人提出了在用于塑料换热器的换热管和集管之间的连接方法(韩国专利N0.10-0366430)，其中所述换热器用塑料材料制造，并且通过使用热熔的反转三角模子将换热管和集管彼此熔合。但是，在该方法中，因为换热管和集管并非通过其最初形状的变形而彼此整体熔合，而只是通过用热熔加热模子的方式来简单接合，所以难于保持在换热器中必需的制冷剂的气密性，并且由此因为不可能保持在制冷循环中冷凝器的制冷剂气压以及不能正常完成制冷循环，从而劣化了所述换热器的性能。
发明内容
技术问题
本发明的一个目的是提供一种塑料换热器，其中，当该塑料换热器的换热管与集管连接时，通过一个包括熔融部和熔融槽的热熔模将该换热管和集管的接头部同时熔融并挤压以确保防止制冷剂泄漏的可靠性，由此使该塑料换热器具有比金属换热器更优异或者相同的换热性能；以及提供该塑料换热器的制造方法，使用该方法可以通过简单的工艺以低制造成本大量生产所述塑料换热器。
技术方案
为了实现这个目的，本发明提供了一种制造塑料换热器的方法，包括：换热管连接步骤，用于将换热器连接到集管；热熔步骤，用于用加热熔融和挤压连接到集管的换热管；和集管连接步骤，用于将集管盖(header cap)连接到与塑料换热管连接的集管，其中通过使用热熔模将塑料换热管和集管的接头熔融并连接。
优选地，所述集管的接头包括：熔融环，其连接到塑料换热管然后用加热熔融；和熔融材料入流槽，其沿着所述熔融环的外周表面形成以便熔融材料流入其中。这样，所述塑料换热管和集管就可以彼此牢固地连接在一起，由此确保了制冷剂的气密性。
优选地，使所述熔融材料入流槽形成为预定宽度w和预定角度θ，以防止熔融材料的泄漏并牢固地结合该熔融材料，以及在熔合处理后牢固地形成一种形状。
优选地，所述热熔模包括：插入部，其成形为圆锥形以便可以被顺利地插入到所述塑料换热管中；模体，其具有相应于塑料换热管的内径的外径以便在热熔处理时保持塑料换热管的内部形状；熔融部，其形成在模体的上部并以预定角度倾斜以便换热管和熔融环的熔融材料可以顺利地流入熔融材料入流槽中；和熔融槽，其连接到熔融材料入流槽以防止熔融材料的泄漏，并且其在连接处理后形成一种形状。
优选地，通过使用热熔模将塑料换热管和集管进行热熔合而制造的塑料换热器包括：熔融环，其连接到集管的接头上，然后通过加热与所述换热管的一端熔合在一起；和熔融材料入流槽，其沿着所述熔融环的外周表面形成以便熔融材料流入其中。
优选地，根据权利要求5所述的塑料换热器，其中所述热熔模包括：插入部，其成形为圆锥形；圆柱形模体，其具有相应于换热管的内径的外径；熔融部，其形成在模体的上部并以预定角度倾斜；和熔融槽，其连接到集管的熔融材料入流槽以防止熔融材料的泄漏。
有益效果
根据本发明，因为可以将换热管和集管牢固地连接，所以存在以下优点：确保了防止制冷剂泄漏的可靠性；具有比金属换热器更优异或者相同的换热性能；以及通过简单的工艺以低制造成本大量生产所述塑料换热器。
附图说明
从下文结合附图给出的对优选实施方式的描述中，本发明的上述和其他目的、特征和优点将更显而易见，其中：
图1是显示由金属材料制成的常规换热器的结构的视图；
图2是根据本发明的塑料换热管的透视图；
图3是根据本发明的集管和集管盖的透视图；
图4是根据本发明的集管的接头部的透视图和横截面视图；
图5是根据本发明的热熔模的透视图；
图6是组装根据本发明的塑料换热器的视图；以及
图7是用本发明方法制造的塑料换热器的透视图。
主要元件的简要描述：
1：制冷剂入口管            2：制冷剂出口管
3：换热片                  4：铜换热管
5：塑料换热管              6：集管
6a：熔融环                 6b：熔融材料入流槽
7：集管盖                  8：热熔模
8a：插入部                 8b：模身
8c：熔融部            8d：熔融槽
具体实施方式
以下，将参考附图详细描述本发明的实施方式。
图2是根据本发明的塑料换热管的透视图，而图3是根据本发明的集管和集管盖的透视图，其中由塑料材料制成的换热管5用挤压工艺形成，而集管6和集管盖7用注塑工艺形成。在挤压工艺中，将原材料加入到挤出机中然后用具有将要塑造的预定形状和直径的模具挤压成具有所需成形部分的连续管体。该挤压工艺适于大规模生产并且具有可形成各种形状的优点。
进而，在注塑工艺中，首先制备具有预定形状的注塑模具，并将树脂状的熔融塑料填入其中，然后固化形成产品。该注塑工艺也适于以低制造成本大规模生产。
图4是根据本发明的集管的接头部的透视图和横截面视图，而图5是根据本发明的热熔模的透视图。这些附图显示了在熔化之前将塑料换热管5连接到集管6的接头部的状态，使用热熔模8的熔化和连接工艺以及所述热熔模8的具体结构。也即是说，这些附图用于帮助解释本发明的塑料换热器及其制造方法，该方法包括用于将换热器连接到集管上的换热管连接步骤B和用于通过加热将连接到集管上的换热管加热和挤压的热熔步骤C。在根据本发明的换热管连接步骤B和热熔步骤C中，将由挤压工艺形成的塑料换热管5连接到由注塑工艺形成的集管6的接头部，并且通过热熔模8将该接头部同时熔化并挤压。这样，将换热管5和集管6彼此完全热熔合。
集管6的接头部成形为带有熔融环6a，通过加热熔融环与塑料换热管5熔合在一起。因此，当将集管6的接头部和换热管5用热熔模8熔合时，它们之间的连接变得牢固。在上述工艺中，在换热管5和集管6之间的接头部的熔融材料流入到沿着熔融环6a的外周表面形成的熔融材料入流槽6b中。此时，通过热熔模8的熔融部8c引导该熔融材料以使其容易地流入到熔融材料入流槽6b中。通过连接到熔融材料入流槽6b的热熔模8的熔融槽8d，防止了泄漏并且可以形成在熔合工艺后的形状。这样，可以牢固地连接塑料换热管5和集管6，由此完美地保持了制冷剂的气密性。
另外，如图4所示，优选熔融材料入流槽6b具有预定宽度w和预定角度θ以防止熔融材料的泄漏并牢固地结合该熔融材料，以及牢固地形成在该熔合工艺后的形状。
如图4和5所示，将用于将塑料换热管5和集管6的接头部同时热熔合的热熔模8成形为整体形成的插入部8a、模体8b、熔融部8c和熔融槽8d。所述插入部8a成形为圆锥形以便当将塑料换热管5和集管6的接头部彼此热熔合时可被顺利地插入到塑料换热管5中。
所述模体8b被成形为圆柱形，其具有相应于塑料换热管5的内径的外径以便于在热熔合工艺中保持塑料换热管5的内部形状。
所述熔融部8c成形在模体8b的上部并朝向熔融材料入流槽6b倾斜，以便换热管5和集管6的熔融环6a的熔融材料可以顺利地流入熔融材料入流槽6b中。优选，倾斜角度θ对应于熔融材料入流槽6b的角度。
进而，所述熔融槽8d连接到熔融材料入流槽6b以防止熔融材料的泄漏，并且也在连接工艺后形成形状。在这里，在塑料换热管5和集管6的接头之间进行热熔工艺之后的连接形状由熔融槽8d的内部槽的形状确定。
图6是组装根据本发明的塑料换热器的视图，而图7是用本发明方法制造的塑料换热器的透视图。也即是说，这些附图是为了帮助解释用于将集管盖7连接到与本发明的塑料换热管5连接的集管6上的集管连接步骤D。在这里，在将塑料换热管5和集管6的接头部彼此连接然后用热熔模8同时热熔合以后，将用注塑工艺形成的集管盖7与集管6熔合。例如震动熔合、高频熔合、热熔等的多种方法都可以应用在集管盖7与集管6之间的熔合工艺中。
图7是用本发明方法制造的塑料换热器的透视图。该图显示了具有制冷剂入口管10和制冷剂出口管20的塑料换热器，该塑料换热器是用上述方法制造的。当用注塑工艺成形集管盖时，制冷剂入口管10和制冷剂出口管20也用注塑工艺成形。因此，将制冷剂入口管10和制冷剂出口管20与集管盖7一起整体成形，由此确保了防止制冷剂的泄漏。
工业实用性
根据本发明，因为换热管和集管可以牢固地连接在一起，所以存在以下优点：确保了防止制冷剂泄漏的可靠性；具有比金属换热器更优异或者相同的换热性能；以及通过简单的工艺以低制造成本大量生产所述塑料换热器。
本领域中的技术人员将理解，在上述说明书中公开的概念和具体实施方式可以被容易地用作改进或者设计用于实现本发明的相同目的的其他实施方式的基础。本领域中的技术人员还将理解，这些等价实施方式并没有脱离在所附权利要求书中提出的本发明的实质和范围。

Claims (6)

1、一种制造塑料换热器的方法，其包括通过使用热熔模熔融和挤压塑料换热管和集管的接头的步骤。
2、根据权利要求1所述的方法，其中所述集管的接头包括：
熔融环，其连接到塑料换热管然后用加热熔融；和
熔融材料入流槽，其沿着所述熔融环的外周表面形成以便熔融材料流入其中。
3、根据权利要求2所述的方法，其中所述熔融材料入流槽成形为预定宽度w和预定角度，以防止熔融材料的泄漏并牢固地结合该熔融材料，以及牢固地形成在熔合处理后的形状。
4、根据权利要求1所述的方法，其中所述热熔模包括：
插入部，其成形为圆锥形以便被顺利地插入到所述塑料换热管中；
模体，其具有相应于所述塑料换热管的内径的外径，以便在热熔处理时保持该塑料换热管的内部形状；
熔融部，其在所述模体的上部形成并以预定角度倾斜，以便所述换热管和熔融环的熔融材料顺利地流入所述熔融材料入流槽中；和
熔融槽，其连接到所述熔融材料入流槽，以防止熔融材料的泄漏，并且其在连接处理后形成一种形状。
5、一种塑料换热器，其通过使用热熔模将塑料换热管和集管进行热熔合而制造，包括：
熔融环，其连接到所述集管的接头上，然后通过加热与所述换热管的一端一起熔融；和
熔融材料入流槽，其沿着所述熔融环的外周表面形成，以便熔融材料流入其中。
6、根据权利要求5所述的塑料换热器，其中所述热熔模包括：
插入部，其成形为圆锥形；
圆柱形模体，其具有相应于所述换热管的内径的外径；
熔融部，其在所述模体的上部形成并以预定角度倾斜；和
熔融槽，其连接到所述集管的熔融材料入流槽，以防止熔融材料的泄漏。
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