CN111344530A - Aluminum fin having excellent hydrophilicity after soldering treatment, heat exchanger, and method for manufacturing same - Google Patents
Aluminum fin having excellent hydrophilicity after soldering treatment, heat exchanger, and method for manufacturing same Download PDFInfo
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- CN111344530A CN111344530A CN201880075212.2A CN201880075212A CN111344530A CN 111344530 A CN111344530 A CN 111344530A CN 201880075212 A CN201880075212 A CN 201880075212A CN 111344530 A CN111344530 A CN 111344530A
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Abstract
The aluminum fin is welded to an aluminum tube having a refrigerant flow path inside, and is characterized by having a hydrophilic coating film comprising a boehmite coating film having a thickness of 100 to 10000 Å on at least one of a front surface and a back surface.
Description
Technical Field
The present invention relates to an aluminum fin and a heat exchanger having excellent hydrophilicity after welding treatment, and a method for manufacturing the same.
The present application claims priority based on japanese patent application No. 2017-226238, filed in japanese application at 11/24/2017, and japanese patent application No. 2018-144415, filed in japanese application at 31/7/2018, and the contents thereof are incorporated herein by reference.
Background
Heat exchangers formed by mechanically joining copper tubes and aluminum fins are widely used for air conditioning heat exchangers such as air conditioning equipment.
However, due to the recent increase in the price of copper ingots, there is an increasing need to replace all parts including tubes with inexpensive aluminum. Aluminum is excellent in lightweight properties, workability, and thermal conductivity, can be recycled, and is characterized by being inexpensive.
As an example of such an air conditioning heat exchanger, as described in patent document 1 below, there is known a heat exchanger in which a plurality of flat tubes made of an aluminum alloy are provided between a 1 st header collecting tube and a 2 nd header collecting tube which are disposed on the left and right, and are disposed in parallel in the vertical direction with a certain interval therebetween, and corrugated fins which are bent in the vertical direction are provided between the upper and lower flat tubes.
In the heat exchanger described in patent document 1, heat transfer portions of fins are arranged between vertically arranged flat tubes, air passages are defined between the flat tubes, and heat is exchanged between air flowing through the air passages and fluid flowing inside the flat tubes.
Patent document 2 below describes a flat tube for a heat exchanger in which a surface of the flat tube is coated with a flux composition composed of a synthetic resin containing a polymer or copolymer of methacrylic acid ester as a main component, a soldering flux, and an organic solvent in order to suppress dew condensation water from remaining in an extruded porous flat tube made of an aluminum alloy.
Prior art documents
Patent document
Patent document 1: japanese patent laid-open publication No. 2012-163317 (A)
Patent document 2: japanese patent laid-open No. 11-239867 (A).
Disclosure of Invention
Technical problem to be solved by the invention
In the conventional heat exchanger in which copper and aluminum are combined, a precoated fin in which an organic coating is applied to a fin in advance is used in order to improve the hydrophilicity of the aluminum fin. However, in the aluminum heat exchanger, it is necessary to perform a welding heat treatment in an oven at about 600 ℃ for joining the members, and the organic coating material is decomposed during the heat treatment, so that there is a problem that sufficient hydrophilicity cannot be secured to the fins.
Further, when a water glass-based inorganic paint is used for the precoated fin, although hydrophilicity after the welding heat treatment can be secured to some extent, there is a problem that discoloration occurs on the surface of the fin, which causes defects in appearance.
In view of the above circumstances, the present invention has been made and as a result, it is an object of the present invention to provide a fin which exhibits hydrophilicity required for the fin after welding heating and does not cause a problem such as discoloration in appearance, even if the fin is of a type in which a hydrophilic coating film is formed in advance before welding.
In the present invention, the following is found: by providing a boehmite film having a predetermined thickness to the aluminum fin, excellent hydrophilicity can be imparted to the fin even after the welding heat treatment; no discoloration is generated.
The invention aims to provide an aluminum fin and a heat exchanger with excellent hydrophilicity after welding treatment and a manufacturing method thereof.
Means for solving the technical problem
The aluminum fin is welded to an aluminum tube having a refrigerant flow path inside, and is characterized by having a hydrophilic coating film comprising a boehmite coating film having a thickness of 100 to 10000 Å on at least one of a front surface and a back surface.
In the aluminum fin of the present invention, the color value of the surface provided with the hydrophilic coating film is preferably L: 70-100, a: -3 to +5, b: -3 to + 10.
In the aluminum fin of the present invention, the water contact angle after the welding heat treatment is preferably 40 ° or less on the surface on which the hydrophilic coating is provided.
The heat exchanger of the present invention can adopt the following structure: the aluminum fin of any one of the above is welded in a tube made of aluminum or an aluminum alloy.
The heat exchanger of the present invention can adopt the following structure: the aluminum fins of any one of the above-described embodiments are arranged at a predetermined interval from each other, and a plurality of tubes made of aluminum or an aluminum alloy into which the aluminum fins are inserted or penetrated are welded to the aluminum fins, and the tubes are welded to a header pipe, respectively.
The heat exchanger of the present invention can have the following structure: a coating film for soldering containing Si powder and a Zn-containing flux is formed on the outer surface of a pipe body constituting the pipe before soldering, and the solder layer is formed from the coating film for soldering after soldering.
The heat exchanger of the present invention can have the following structure: a sacrificial anode layer is formed on the surface of the tube by the diffusion of Zn contained in the welding coating film.
A method for manufacturing a heat exchanger according to the present invention is a method for manufacturing a heat exchanger by welding the aluminum fin to a tube having a refrigerant flow path therein, characterized in that a welding coating film containing Si powder and a Zn-containing flux is formed on an outer surface of a tube body constituting the tube, Si and Zn in the welding coating film are diffused to a tube side by heat treatment at the time of welding, and a sacrificial anode layer for diffusing Zn to an outer surface side of the tube body is formed.
Effects of the invention
In the aluminum fin according to the present invention, the boehmite film having a predetermined thickness is formed as the hydrophilic film before welding, whereby excellent hydrophilicity can be imparted to the aluminum fin even after welding, and the surface of the hydrophilic film is not discolored even by heating by welding, whereby the aluminum fin having a beautiful appearance can be provided.
In the heat exchanger according to the present invention, since the aluminum fins of the type in which the hydrophilic coating corresponding to the precoated fins is provided in advance are joined to the tubes by welding, the heat exchanger can be manufactured in the same process as the manufacturing process using the precoated fins, and can provide a heat exchanger having good appearance of the fins by including the aluminum fins to which good hydrophilicity is imparted even after welding.
Drawings
Fig. 1 is a perspective view showing a heat exchanger according to embodiment 1.
Fig. 2 is a cross-sectional view of the heat exchanger shown in fig. 1, taken along a plane orthogonal to the longitudinal direction of the tube.
Fig. 3 is a cross-sectional view of the heat exchanger shown in fig. 1, taken along a longitudinal section of the tube in the longitudinal direction thereof, and shows a state before the welding process.
Fig. 4 is a cross-sectional view of the heat exchanger shown in fig. 1, taken along a longitudinal section of the tube in the longitudinal direction thereof, and shows a state after the welding process.
Fig. 5 is a front view showing a heat exchanger according to embodiment 2.
Fig. 6 is a partially enlarged sectional view of the heat exchanger of embodiment 2.
Fig. 7 is a partial sectional view showing a heat exchanger package before welding the heat exchanger of embodiment 2.
Detailed Description
Hereinafter, an example of an embodiment of the present invention will be described in detail with reference to the drawings. For convenience of understanding of features, the drawings used in the following description are sometimes enlarged, and the dimensional ratios of the components are not necessarily the same as those of the actual heat exchanger.
Fig. 1 is a perspective view showing a heat exchanger 11 according to embodiment 1.
The heat exchanger 11 according to embodiment 1 is an all-aluminum heat exchanger used for applications such as a heat exchanger for indoor/outdoor units of an indoor Air conditioner, an outdoor unit for HVAC (Heating ventilation Air Conditioning), and a heat exchanger for automobiles.
As shown in fig. 1, the heat exchanger 11 includes: a pair of header pipes 14 arranged in parallel with a left-right separation; a plurality of flat tubes 22 which are vertically parallel to each other with a space therebetween and are joined at substantially right angles to the header pipes 14; and a plurality of fins (aluminum fins) 13 welded to an outer surface (upper surface or lower surface) 12b of the tube body 12 constituting the tubes 22 and radiating heat to the outside air. A supply pipe 15 for supplying the refrigerant to the tubes 22 via the header pipe 14 is connected to an upper end portion of one of the pair of left and right header pipes 14. A recovery pipe 16 for recovering the refrigerant via a pipe 22 is connected to the lower end of the other header pipe 14. The tubes 22, fins 13, header tubes 14, supply tubes 15, and recovery tubes 16 are each made of aluminum or an aluminum alloy.
Fig. 2 is a partial sectional view of the heat exchanger 11 taken along a plane orthogonal to the longitudinal direction of the tube 22. As shown in fig. 2, a plurality of (6 in the present embodiment) refrigerant flow paths 12a are formed inside the tube body 12 constituting the tube 22 and arranged in the width direction. As shown in fig. 2, the fin 13 is formed with a plurality of notches 19 having shapes corresponding to the cross-sectional shapes of the tubes 22 at predetermined intervals in the vertical direction. The pipes 22 are fitted into the notches 19, respectively, and fixed by welding.
Fig. 3 and 4 are partial sectional views of the heat exchanger 11 taken along the longitudinal direction of the tube 22, with fig. 3 showing a state before the welding step and fig. 4 showing a state after the welding step. A plurality of fins 13 are arranged in parallel along the longitudinal direction of the tube 22, and the tube 22 is inserted into the notch 19. The plurality of fins 13 are arranged in parallel with each other at a constant interval. The fin 13 has a bent portion 20 bent along the outer surface 12b of the tube 22 at the peripheral portion of the cutaway portion 19 toward one side in the thickness direction of the fin 13. The bent portion 20 can be formed by, for example, punching.
The tube 22 and the fins 13 are arranged such that the tube 22 is pierced through the plurality of fins 13 arranged at a constant interval, and the tube 22 is fitted into the notch 19 of the fin 13 and fixed by welding.
In the state before welding shown in fig. 3, the clearance between the bent portion 20 formed in the notch 19 of the fin 13 and the upper surface or the lower surface of the tube 22 is preferably 10 μm or less.
The fin 13 of the present embodiment may have the following structure: a pipe 22 is inserted into the notch 19, a slit-like through-hole is provided in the fin 13 instead of the notch 19, and the pipe 22 is inserted into the through-hole.
Hereinafter, the main components of the heat exchanger 11 will be described in more detail.
Fin
The fin 13 includes a plate-like base 3 made of aluminum or an aluminum alloy, and a hydrophilic coating film 1 provided on the 1 st surface 3a and the 2 nd surface 3b of the base 3.
< substrate >
The base material 3 is made of an alloy mainly composed of pure aluminum such as JIS1050 and the like or an aluminum alloy such as JIS 3003. The base material 3 may be an aluminum alloy obtained by adding about 2% by mass of Zn to an aluminum alloy of JIS 3003.
The substrate 3 is preferably made of a material having a lower pitting potential than the pitting potential of the tube body 12 constituting the tube 22. Corrosion of the pipe body 12 may result in leakage of refrigerant. By making the pitting potential of the base material 3 lower than that of the tube body 12, it is possible to delay preferential corrosion of the fins 13 and to generate pitting corrosion in the tube body 12.
The aluminum alloy having the above composition is melted by a conventional method, and the base material 3 is processed through a hot rolling process, a cold rolling process, a pressing process, and the like. The method for producing the substrate 3 is not particularly limited in the present invention, and a known production method can be appropriately employed.
< hydrophilic involucra >
The fin 13 has a hydrophilic coating 1 on the 1 st and 2 nd surfaces 3a and 3b of the substrate 3 and on the peripheral surfaces other than these, and the hydrophilic coating 1 is composed of a boehmite coating having a thickness of about 100 Å to 10000 Å.
The boehmite film is a film formed by immersing aluminum or an aluminum alloy in high-temperature water of 90 to 100 ℃ or by holding the aluminum or the aluminum alloy in pressurized steam.
Pure water can be used as the high-temperature water, but a small amount of ammonia water may be added to pure water. Further, deionized water may be used, and an additive such as triethanolamine may be added to adjust the pH to a slightly alkaline pH, thereby promoting the growth of the boehmite film.
The boehmite film can also be obtained by applying an alkaline or neutral coating material to the base material 3 of the aluminum fin, drying the coating material, and then washing the dried coating material with hot water or water.
The hydrophilic coating 1 made of a boehmite coating is a coating which can be referred to as a precoating coating formed on the base 3 of the fin 13 before the welding process.
The thickness of the boehmite film is preferably 100 Å to 10000 Å in order to exhibit a desired hydrophilicity after welding, not adversely affecting weldability, and not discoloring after welding.
If the thickness of the boehmite film is less than 100 Å, the water contact angle after a dry-wet repeated test described later after welding is deteriorated, and if the thickness of the boehmite film is more than 10000 Å, there is a problem that weldability when a welding coating film is used described later is deteriorated.
Pipe
As shown in fig. 3, the tube 22 has a tube body 12 and a solder layer 5 formed on an outer surface (upper surface or lower surface) 12b of the tube body 12. The tube body 12 is a flat multi-hole tube having a plurality of refrigerant flow paths 12a formed therein as shown in fig. 2. Further, as the pipe, a pipe manufactured by bending and forming an aluminum alloy welding plate can be used.
The pipe body 12 is made of an alloy mainly composed of pure aluminum such as JIS1050 and the like or an aluminum alloy such as JIS 3003. As an example, by extruding Si: 0.10 to 0.60%, Fe: 0.1 to 0.6 mass%, Mn: 0.1 to 0.6 mass%, Ti: 0.005-0.2 mass%, Cu: less than 0.1 mass%, and the balance of aluminum and inevitable impurities.
The tube 12 is preferably made of a material having a higher pitting potential than the base material 3 of the fillet 5A and the fin 13 formed in the welding step. This can start corrosion of the fillet 5A and the base material 3 of the fin 13 before the pipe body 12 starts corrosion, and can delay corrosion of the pipe body 12.
In the tubular body 12 of the tube 22 before welding shown in fig. 3, a portion of the outer surface 12b joined to the fin 13 is formed with a powder composed of Si: 1.0 to 5.0g/m2Zn-containing fluoride flux (KZnF)3）：3.0～20.0g/m2Binder (for example, acrylic resin): 0.5 to 8.5g/m2And a solder layer 5 of a composition matching the composition.
In the heat exchanger 11 before welding shown in fig. 3, the solder layer 5 of the tube 22 is located between the tube 22 and the portion (facing surface 20 a) of the bent portion 20 of the fin 13 facing the tube 22. The solder layer 5 is solidified in a state of being filled between the facing surface 20a and the tube 22 by being heated (welding process) at around 600 ℃, and then cooled, and becomes a fillet 5A (solder layer) as shown in fig. 4, and the fin 13 and the tube 22 are welded and joined.
As shown in fig. 2, the outer surface 12B of the pipe body 12 is constituted by a flat front surface (upper surface) 6A and a flat back surface (lower surface) 6B, and a 1 st side surface 6C and a 2 nd side surface 6D adjacent to the front surface 6A and the back surface 6B. The 1 st side surface 6C is located on the opening side of the notch 19 of the fin 13 and is open to the outside. The 2 nd side surface 6D is located on the opposite side of the 1 st side surface 6C and is disposed around the notch 19.
The solder layer 5 is formed, for example, on the front surface 6A and the back surface 6B of the pipe body 12 in the region of the outer surface 12B of the pipe body 12 that is in contact with the fins 13. Then, Si and Zn contained in the solder layer 5 diffuse toward the pipe body 12 at the soldering temperature on the front surface 6A and the back surface 6B of the pipe body 12 after soldering, and a sacrificial anode layer containing Si and Zn is formed on the surface layer portion of the pipe body 12.
The composition constituting the solder layer 5 will be described below.
< Si powder >
The Si powder reacts with Al of the tube body 12 constituting the tube 22 to form welding of the joining fin 13 and the tube 22, but the flux containing Zn melts with the Si powder at the time of welding to become a welding liquid.
The Zn in the flux diffuses uniformly in the solder bath and spreads uniformly over the surface of the tube 12. Since the diffusion rate of Zn in the liquid phase is significantly higher than that in the solid phase, uniform Zn diffusion is formed, and the Zn concentration in the surface direction of the surface of the pipe body 12 becomes almost uniform. Further, when diffusion in the depth direction from the surface of the pipe body 12 is observed, Si and Al become eutectic and lower the melting point, so Zn diffuses to a state of eutectic composition at the surface of the pipe body 12 and forms a sacrificial anode layer of a predetermined thickness at the surface of the pipe body 12. The corrosion resistance of the tube 22 can be improved by the formation of the sacrificial anode layer.
< amount of Si powder applied: 1.0 to 5.0g/m2＞
If the coating weight of the Si powder is less than 1.0g/m2The weld formation may be insufficient, and if the coating amount exceeds 5.0g/m2The amount of melting of the pipe increases and the wall thickness of the pipe decreases, which is not preferable. Therefore, the content of Si powder in the solder layer 5 is preferably set to 1.0 to 5.0g/m2。
< Si powder particle size: maximum particle size: d (99): less than 30 μm >
If the particle size of the Si powder in D (99) is30 μm or less, a uniform sacrificial anode layer can be formed, whereas if it exceeds 30 μm, deep erosion locally occurs, and a uniform sacrificial anode layer may not be formed. Therefore, the particle size of the Si powder is preferably 30 μm or less in the maximum particle diameter D (99). In addition, D (99) is a particle diameter of 99% of particles which are accumulated from particles small in volume ratio and become the whole. These values can be measured by laser light scattering.
< flux containing Zn, flux containing no Zn >
The Zn-containing flux has an effect of improving pitting corrosion resistance by forming a sacrificial anode layer composed of a Zn diffusion layer on the surface of the tube body 12 at the time of soldering. Further, the function of breaking the oxide film on the outer surface of the pipe body 12 at the time of welding and promoting the spreading and infiltration of the brazing filler metal is exhibited, thereby improving weldability. The Zn-containing flux has higher activity than a Zn-free flux, and therefore, even if relatively fine Si powder is used, good solderability can be obtained. The Zn-containing soldering flux can use KZnF3、ZnF3、ZnCl21 or 2 or more. A Zn-free flux may be added to the Zn-containing flux.
As the Zn-free flux, a fluoride-based flux or a potassium fluorochlorate-based flux is KAlF4Various compositions in which additives are added to a flux as a main component are known. Can exemplify K3AlF6+KAlF4 ofSubstance of composition, Cs（x）K（y）F（z）And the like. In addition, the use of a mixture of LiF, KF and CaF2、AlF3、K2SiF6And a fluoride-based flux (for example, a potassium fluorochlorate-based flux) of fluoride. A fluoride flux (for example, a potassium fluorochlorate flux) is added in addition to the Zn flux, thereby contributing to improvement of solderability.
< flux coating weight: 3.0 to 20.0g/m2＞
If the coating weight of the fluoride type flux containing Zn is less than 3.0g/m2The potential difference in the case of the heat exchanger 11 becomes low, and the sacrifice effect may not be exerted. Further, the surface oxide film of the material to be welded (the pipe body 12) is not sufficiently removed by breaking, which leads to poor welding. On the other hand, if the coating amount exceeds 20.0g/m2The potential difference becomes too large, the corrosion rate increases, and the corrosion prevention effect due to the presence of the sacrificial anode layer may become short. Therefore, it is preferable to set the coating weight of the Zn-containing fluoride type flux to 3.0 &20.0g/m2. KZnF can be used as an example of the Zn-containing fluoride type flux3. The above-mentioned flux containing no Zn can be added with a flux containing Zn.
< adhesive >
The solder layer 5 may contain a binder in addition to the Si powder and the fluoride flux containing Zn. As an example of the binder, an acrylic resin can be preferably cited.
The adhesive has the function of fixing the Si powder and the Zn-containing flux required for forming the sacrificial anode layer to the front surface 6A and the back surface 6B of the tube body 12, but if the coating amount of the adhesive is less than 0.5g/m2The Si powder or Zn flux falls off from the tube body 12 at the time of soldering, and a uniform sacrificial anode layer may not be formed. On the other hand, if the coating amount of the binder is more than 8.5g/m2Solderability is reduced due to the adhesive residue and a uniform sacrificial anode layer may not be formed. Therefore, the amount of the binder to be applied is preferably 0.5 to 8.5g/m2. In addition, the adhesive is generally evaporated by heating at the time of welding.
The method for forming the solder layer 5 composed of Si powder, flux and binder is not particularly limited in the present invention, and can be performed by an appropriate method such as a spray method, a shower method, a flow coating method, a roll coating method, a brush coating method, a dipping method, an electrostatic coating method, and the like.
The formation region of the solder layer 5 may be the entire front surface 6A, the back surface 6B, and the 2 nd side surface 6D of the pipe 12, or may be a part thereof. Although the pipe body 12 of the present embodiment does not have the solder layer 5 formed on the 1 st side surface 6C, a portion may be formed on the 1 st side surface 6C depending on the coating method. The present invention does not exclude this.
Production method
An example of a method for manufacturing the heat exchanger 11 including the fins 13 and the tubes 22 will be described below.
First, the tube 22 and the fin 13 are prepared, the hydrophilic coating 1 is formed on the entire surface of the fin 13 including the 1 st surface 3a and the 2 nd surface 3b of the base 3, and the boehmite coating having a thickness of 100 to 4000 Å is formed on the entire surface of the fin 13 by a method of holding the fin 13 in the high-temperature water or the like.
The fin 13 is formed with a notch 19 and a bent portion 20 around the notch. As the tube 22, a tube in which the solder layer 5 is formed in advance on a part of the outer surface 12b of the tube body 12 is prepared.
Next, as shown in fig. 3, a plurality of fins 13 are arranged in parallel, and the tube 22 is inserted into the notch 19.
Then, a soldering process is performed in which the solder layer 5 is heated to a temperature higher than the melting point thereof, for example, 580 to 620 ℃. The solder layer 5 formed on the outer surface 12b of the pipe body 12 is melted by heating to become a solder liquid. The welding liquid flows into the gap between the opposed surface 20a of the bent portion 20 of the fin 13 and the outer surface 12b of the tube body 12 by capillary force, and fills the gap. Further, as shown in fig. 4, the solder liquid solidifies by cooling to form a fillet 5A (solder layer). The tube 22 and the fin 13 are joined by this fillet 5A.
In the soldering, the solder layer 5 is heated to a suitable temperature in a suitable atmosphere such as an inert atmosphere to melt. In this case, the activity of the flux is improved, Zn in the flux diffuses along the wall thickness of the material to be soldered (the base material 3 of the fin 13), and in addition, the oxide film on the surface of both the solder and the material to be soldered is broken to promote wetting between the solder and the material to be soldered.
At the time of welding, a part of the matrix of the aluminum alloy constituting the tube body 12 of the tube 22 reacts with the composition of the solder layer 5 to form a weld, and the tube body 12 of the tube 22 and the fin 13 are welded. In the upper surface layer portion and the lower surface layer portion of the tube 12, Zn in the flux is diffused by soldering to form a sacrificial anode layer lower than the inside of the tube 12.
< Effect >
According to the structure of the present embodiment, good welding is formed, and a fillet 5A (solder layer) of a sufficient size is formed between the pipe body 12 and the fin 13.
The fillet 5A has a lower pitting potential than the tube 12 and the fin 13. Therefore, the tube body 12 and the fins 13 are corroded preferentially than the tube body 12 and the fins 13, and the pitting corrosion of the tube body 12 and the fins 13 can be delayed.
Even after the step of melting and solidifying solder layer 5, hydrophilic film 1 made of boehmite film remains, and hydrophilicity can be imparted to fin 13.
In the step of melting and solidifying the solder layer 5 of the tube 22 to join the fin 13 and the tube 22, it is preferable to weld the header pipe 14 to the tube 22 at the same time.
Since the hydrophilic coating film 1 made of a boehmite coating film is formed on the fin 13 after welding shown in fig. 4 through a heat treatment step at the time of welding, the hydrophilicity of the fin 13 can be improved.
The hydrophilic film 1 made of the boehmite film can maintain hydrophilicity even after a heating step at a temperature of around 600 ℃. Therefore, the hydrophilic film 1 can be formed by a precoating step of the base 3 formed on the fins 13 in advance before the heat exchanger 11 is assembled. Since a step of forming a hydrophilic coating by post-coating after welding is not necessary, the heat exchanger 11 can be provided in which the manufacturing process is simplified.
In the above embodiment, the solder layer 5 for soldering is provided on the outer surface of the tube 22 such as the front surface or the back surface, but the solder layer 5 may be omitted, and the preliminary soldering may be arranged around the predetermined portion of the tube 22 and the fin 13 to be soldered and may be used for soldering.
The tube 22 and the fin 13 can be welded and joined by melting the preliminary weld by heating at the time of welding and spreading the weld in a molten state at the boundary portion of the tube 22 and the fin 13.
Further, a structure may be adopted in which the fins 13 are constituted by a 2-layer structure of the welding plate including the core layer and the solder layer, and the solder layer is not provided in the tube 22.
In this case, the boehmite layer may be provided on one surface or both surfaces of the core layer. Alternatively, the fin 13 may be formed of a 3-layer structure (a 3-layer structure in which solder layers on both sides of the core material + boehmite layers are provided) in which solder layers having boehmite layers are provided on both sides of the core material layer are laminated.
When a welded plate is used, as an example, a core material made of a material containing Mn: 0.5 to 2.0%, Si: 1.3% or less, Fe: 0.25% or less, Cu: 0.5% or less, Zn: 4.0% or less, and having a composition of the remainder of Al and unavoidable impurities, the solder layer being composed of a composition having a composition containing, in mass%, Si: 5.0 to 13.0%, and the balance of Al and inevitable impurities.
In the above-described embodiment, the example in which the present invention is applied to the heat exchanger having the plate fin structure shown in fig. 1 and 2 is described, but the technique of the present invention may be applied to a heat exchanger having another structure, for example, a heat exchanger using a corrugated fin.
Fig. 5 is a front view showing embodiment 2 of the heat exchanger to which corrugated fins are applied.
The heat exchanger 30 according to embodiment 2 is mainly composed of header pipes 31 and 32 arranged in parallel with each other so as to be separated from each other in the right-left direction, a plurality of flat tubes 33 connected to the header pipes 31 and 32 in parallel with each other with a space therebetween and at right angles thereto, and corrugated fins (corrugated fins) 34 attached to the tubes 33. The header pipes 31, 32, the tubes 33, and the fins 34 are made of aluminum alloy. As the aluminum alloy constituting the tube 33, the same aluminum alloy as that constituting the tube 22 of the heat exchanger 11 of embodiment 1 can be used. As the aluminum alloy constituting the fins 34, the same aluminum alloy as the aluminum alloy constituting the fins 13 of the heat exchanger 11 of embodiment 1 can be used.
A plurality of slits 36 are formed at predetermined intervals in the longitudinal direction of the tubes on the side surfaces of the manifolds 31 and 32 facing each other, the end portions of the tubes 33 are inserted into the slits 36 of the manifolds 31 and 32 facing each other, and the tubes 33 are bridged between the manifolds 31 and 32. Fins 34 are disposed between a plurality of tubes 33, 33 which are disposed between header pipes 31, 32 at predetermined intervals, and these fins 34 are welded to the front or back surfaces of tubes 33.
As shown in fig. 6, a 1 st fillet weld portion 38 is formed by brazing filler metal in a portion inserted into an end portion of the tube 33 with respect to the slit 36 of the header pipes 31, 32, and the tube 33 is welded with respect to the header pipes 31, 32. In the corrugated fin 34, the 2 nd fillet 39 is formed by the brazing material in a portion between the crest portion of the wave and the front surface or the back surface of the adjacent tube 33, and the corrugated fin 34 is welded to the front surface and the back surface of the tube 33.
The fin 34 has a plate-like base material made of aluminum or an aluminum alloy and hydrophilic films provided on the 1 st and 2 nd surfaces of the base material, as in the fin 13 of the above embodiment. The hydrophilic film of this example is composed of the same hydrophilic film as the hydrophilic film 1 applied in the above embodiment.
The heat exchanger 30 of the present embodiment is manufactured by assembling the headers 31 and 32, and the plurality of tubes 33 and the plurality of fins 34 bridged therebetween to form a heat exchanger unit 41 as shown in fig. 7, and heating and welding the heat exchanger unit 41. Further, Zn diffusion layers 42 are formed on the front surface side and the back surface side of the tube 33 by heating at the time of welding.
The tube 33 before soldering is coated with a soldering coating film 37 having the same composition as the solder layer 5 described above on the front and back surfaces to which the fins 34 are joined. The tube 33 is formed of a flat multi-hole tube similar to the tube 22 described above, and has a plurality of refrigerant passages 33C formed therein, flat front surfaces (upper surfaces) 33A and back surfaces (lower surfaces) 33B, and side surfaces adjacent to the front surfaces 33A and the back surfaces 33B.
The aluminum alloy constituting the header pipes 31, 32 is preferably an aluminum alloy based on Al-Mn.
For example, it preferably contains Mn: 0.05 to 1.50%, and other elements which may include Cu: 0.05 to 0.8%, Zr: 0.05 to 0.15 percent.
Fig. 7 is a partially enlarged view of the heat exchanger block 41 showing a state in which the header pipes 31 and 32, the pipe 33, and the fin 34 are assembled using the pipe 33 having the welding coating film 37 applied to the joint surface with the fin 34, and showing a state before heat welding. In the heat exchanger module 41 shown in fig. 7, one end of the tube 33 is inserted into and fitted to the slit 36 provided in the manifold 31. Further, solder layer 43 is provided on the surface side of core material 31A of header pipes 31 and 32.
As shown in fig. 7, when the heat exchanger unit 41 including the header pipes 31 and 32, the tubes 33, and the fins 34 assembled is heated in a heating furnace or the like to a temperature equal to or higher than the melting point of the brazing material and cooled after heating, the brazing material layer 43 and the welding coating film 37 are melted and solidified, and the header pipe 31, the tubes 33, and the fins 34 are joined to each other as shown in fig. 6, thereby obtaining the heat exchanger 30 having the structure shown in fig. 5 and 6. At this time, the solder layer 43 on the inner peripheral surfaces of the header pipes 31, 32 melts and flows to the vicinity of the slit 36, and the 1 st fillet portion 38 is formed to join the header pipes 31, 32 and the pipe 33. The welding coating films 37 on the front and back surfaces of the tube 33 are melted to form Al — Si welding or Al — Si — Zn welding, and the welding coating films are caused to flow near the fins 34 by capillary force to form the 2 nd fillet portion 39, thereby joining the tube 33 and the fins 34. The solder layer 43 provided on the surface of the header pipes 31 and 32 is slightly left on the surface after soldering.
In the soldering, the solder coating 37 and the solder layer 43 are dissolved by heating to a suitable temperature in a suitable atmosphere such as an inert atmosphere in a heating furnace or the like. Thus, the activity of the flux is improved, Zn in the flux is precipitated on the surface side or the lower surface side of the material to be welded (tube 33) and diffused along the thickness thereof, and in addition, the oxide film on the surface of both the brazing material and the material to be welded is broken to promote wetting between the brazing material and the material to be welded.
The welding conditions are not particularly limited. For example, the heat exchanger unit 41 may be heated to a welding temperature (actual arrival temperature) of 580 to 620 ℃ at a temperature rise rate of 5 ℃/min or more in a nitrogen atmosphere in a heating furnace, held at the welding temperature for 30 seconds or more, and cooled at a cooling rate of 10 ℃/min or more from the welding temperature to 400 ℃.
On the upper and lower surfaces of the tube 33, Zn in the flux is diffused by soldering to form the Zn diffusion layer 42 on the surface side or the lower surface side of the tube 33, and the region subjected to the diffusion of Zn on the tube surface side or the lower surface side becomes lower than the inner side (region not subjected to the diffusion of Zn) in the wall thickness direction of the tube 33. Here, the inner side of the tube 33 in the thickness direction indicates a region deeper along the thickness direction of the tube 33 than the surface region or the back surface region of the tube 33 on which the Zn diffusion layer 42 is formed.
In the heat exchanger 30 shown in fig. 5 and 6, hydrophilic films made of boehmite films having a thickness of about 100 Å to 4000 Å are formed on both surfaces of the fins 34, and therefore, hydrophilicity similar to that of the heat exchanger 11 described above can be obtained, that is, since the hydrophilic films made of boehmite films are formed on the fins 34 after welding shown in fig. 5 and 6 through a heat treatment step at the time of welding, hydrophilicity of the fins 34 can be improved.
The hydrophilic coating film composed of the boehmite coating film can maintain hydrophilicity even after a heating step at a temperature of around 600 ℃ in welding. Therefore, the hydrophilic coating film can be formed by a precoating step of the base material formed in advance on the fins 34 before the heat exchanger 30 is assembled. Since a step of forming a hydrophilic coating by post-coating after welding is not necessary, the heat exchanger 30 can be improved in which the manufacturing process is simplified.
Further, the heat exchanger 30 can obtain excellent corrosion resistance as in the heat exchanger 11 of the above embodiment.
In addition, although the heat exchanger 30 using the corrugated fin is configured such that the solder layer 37 for soldering is provided on the outer surface of the tube 33, such as the upper surface or the lower surface, in the embodiment 2, the solder layer 37 may be omitted and the preliminary soldering may be arranged around the predetermined portion of the tube 33 and the fin 34 to be soldered.
The welding in a molten state may be dispersed at the boundary portion of the tube 33 and the fin 34 by melting the preset welding by heating at the time of welding, thereby weld-joining the tube 33 and the fin 34.
Further, a structure may be adopted in which the fins 34 are constituted by a 2-layer structure of the welding plate including the core layer and the solder layer, and the solder layer 37 is not provided in the tube 33.
In this case, the boehmite layers may be provided on both surfaces of the core layer. Alternatively, the fin 34 may be formed of a 3-layer structure (a 3-layer structure in which the core layer and the boehmite layer are provided on the solder layers on both sides) in which solder layers in which the boehmite layers are provided on both sides of the core layer are stacked.
When a welded plate is used, as an example, a core material made of a material containing Mn: 0.5 to 2.0%, Si: 1.3% or less, Fe: 0.25% or less, Cu: 1.3% or less, Zn: 4.0% or less, and having a composition of the remainder of Al and unavoidable impurities, the solder layer being composed of a composition having a composition containing, in mass%, Si: 5.0 to 13.0%, and the balance of Al and inevitable impurities.
Examples
The present invention will be described in further detail below with reference to examples, but the present invention is not limited to these examples.
Production of sample
With respect to Si-containing: 0.4 to 1.0 mass%, Mn: 1.0-2.0 mass%, Zn: 1.0 to 3.5 mass%, with the remainder being composed of unavoidable impurities and Al, is formed by immersing a hydrophilic coating film composed of a boehmite coating film of the type and thickness shown in Table 1 below in high-temperature water at 90 ℃. The film thickness of the hydrophilic coating is adjusted by adjusting the time for immersing in high-temperature water to 5 to 30 minutes.
In the case of forming a hydrophilic coating film, a coating material was used instead of the boehmite coating film, and any one of an acrylic resin, polyvinyl alcohol, carboxymethyl cellulose, and sodium silicate was applied as a precoat coating film, and then welded at 240 ℃.
"measurement of film thickness
The film thicknesses of the boehmite film and the precoated film were measured by using a depth distribution by an X-ray photoelectron spectroscopy apparatus (XPS). analysis was carried out using ULVAC-PHI, PHI5000Versa Probe III manufactured by Inc. under an X-ray source of 25W and an energy of 26eV, and a process of 0.05eV, and sputtering was carried out under conditions of an acceleration voltage of 2kV, a grating range of 2mm × 2mm, and SiO2Sputtering rate: at 4.7 nm/min. Film thickness through SiO2Scaled to a value.
Then, a tube body of a heat exchanger aluminum alloy is formed by dissolving a tube aluminum alloy containing 0.3 to 0.5 mass% of Si, 0.2 to 0.4 mass% of Mn, and the balance of unavoidable impurities and Al, and forming the alloy into a flat tube body of a heat exchanger aluminum alloy having a cross-sectional shape (a wall thickness of 0.26mm ×, a width of 17.0mm ×, and an entire thickness of 1.5 mm).
In addition, in theThe front surface (upper surface), the back surface (lower surface) and the 2 nd side surface of the tube body form solder layers. The solder layer was coated with 3g of Si powder (D (99) particle size 10 μm) and Zn-containing flux (KZnF) by roll coating3Powder: d (50) particle size 2.0 μm) 6g, a mixture of 1g of an acrylic resin binder, 3-methoxy-3-methyl-1-butanol and 16g of isopropyl alcohol as a solvent, and drying the mixture.
The heat exchanger test bodies were prepared by assembling 10-stage tubes to fins using 11 tubes and the fins (10 sheets) formed into a wave pattern by corrugation, forming temporary micro-core test bodies, and welding these test bodies in a furnace in a nitrogen atmosphere while maintaining × 3 min at 600 ℃.
Experiment
Next, using these heat exchanger test pieces, a discoloration observation test, a hydrophilicity evaluation test, and a weldability evaluation test of the fin, which are described below, were performed.
[ discoloration observation test of fins ]
A fin welded at 600 ℃ for × 3 minutes is judged to have no discoloration for fins whose color value measured by a color difference meter satisfies the range of L70-100, a: -3 to +5, b: -3 to +10, and also judged to have discoloration for fins whose color value does not satisfy the range of L70-100, a: -3 to +5, b: -3 to + 10.
[ hydrophilicity: water contact Angle after Dry and Wet trial and error ]
The test piece after welding at 600 ℃ of × 3 minutes was immersed in running water for 8 hours, then dried for 16 hours, and the water contact angle of the fin surface after 14 cycles was measured, and it was judged that the test piece had good hydrophilicity when the water contact angle was 40 ° or less.
[ weldability: fin Joint percentage evaluation test
For each fin welded and joined, the fin was peeled off from the tube, and a fin joint mark remaining on the tube surface was observed. Then, the number of unjoined portions (portions where welding was performed but no trace of joined portions remained) was counted. The test piece with 80 or more (80% or more) normal joints was judged to have good weldability by observing 100 points with respect to one test piece.
As is clear from the results shown in table 1, a heat exchanger having excellent hydrophilicity and excellent weldability as well, without causing discoloration of the fin surface, can be produced by forming a boehmite film as a precoat film on a fin, forming a micro-core test body of a heat exchanger using the fin, and welding the micro-core test body using a welding film.
The values of the contact angle after the dry-wet trial and error test are in the range of 10 to 30 °. Even in a severe test environment in which the test piece was immersed in running water for 8 hours and then dried for 16 hours and then subjected to 14 cycles, the microchip test pieces of the examples obtained excellent hydrophilicity capable of maintaining the contact angle of the fin surface at a low value.
In contrast, in comparative example No.12, since the boehmite film was too thin, the contact angle after the dry-wet trial and error was increased. The comparative example No.13 was poor in weldability because the boehmite film was too thick.
The welding of aluminium has the following characteristics: the oxide film present on the aluminum surface during the welding heat treatment is weakened by the effect of the flux, and the brazing filler metal melted on the surface is fluidized to join a plurality of portions at once. On the other hand, it is found that when the aluminum hydrated oxide film layer as the boehmite film is too thick, the effect of making the oxide film brittle cannot be sufficiently obtained by the flux contained in the solder paste, and the flow of the molten solder is inhibited, thereby deteriorating the weldability.
Comparative example No.14 is an example in which an acrylic resin was used as the precoating film instead of the boehmite film, comparative example No.15 is an example in which polyvinyl alcohol was used as the precoating film instead of the boehmite film, and comparative example No.16 is an example in which carboxymethyl cellulose was used as the precoating film instead of the boehmite film. When a film of these organic materials is used as a precoat film, each resin is damaged by heating to 600 ℃ at the time of welding, and hydrophilic damage that these resins should originally have is large.
Comparative example No.17 is an example in which sodium silicate was used as the precoating film instead of the boehmite film, and comparative example No.18 is an example in which lithium silicate was used as the precoating film instead of the boehmite film. These silicate films are materials that are more strongly heated than the films of the above resins, and therefore, the following results are obtained: although the hydrophilicity after welding is excellent, the surface of the coating film discolors and the color change increases, and the fin after welding has a defect in appearance.
From these test results, it is understood that if a boehmite film having a film thickness in a preferable range is used as a precoat film on the surface of a fin, a heat exchanger having excellent hydrophilicity, no problem of discoloration in appearance, and excellent weldability can be provided.
Industrial applicability
The aluminum fin can be provided with excellent hydrophilicity even after welding, and the surface of the hydrophilic coating film is not discolored even after heating by welding, thereby providing an aluminum fin with beautiful appearance.
Description of the reference numerals
1-hydrophilic coating, 3-substrate, 3 a-1 st face, 3B-2 nd face, 5-solder layer, 5A-fillet (solder layer), 6A-front face, 6B-back face, 6C-1 st face, 6D-2 nd face, 11-heat exchanger, 12-tube, 12 a-refrigerant flow path, 12B-outer face, 13-fin, 14-header, 15-supply tube, 16-recovery tube, 19-notch, 20-bend, 20 a-opposite face, 22-tube.
Claims (9)
1. An aluminum fin welded to an aluminum tube having a refrigerant flow passage therein,
the hydrophilic coating film is formed on at least one of the front surface and the back surface and is composed of a boehmite coating film with the thickness of 100-10000 Å.
2. The aluminum fin excellent in hydrophilicity after the welding treatment according to claim 1,
the color value of the surface provided with the hydrophilic coating is L: 70-100, a: -3 to +5, b: -3 to + 10.
3. The aluminum fin excellent in hydrophilicity after the welding treatment according to claim 1 or 2,
on the surface provided with the hydrophilic coating, the water contact angle after welding heat treatment is 40 ° or less.
4. A heat exchanger, characterized in that,
the aluminum fin as recited in any one of claims 1 to 3, which is welded in a tube made of aluminum or an aluminum alloy.
5. A heat exchanger, characterized in that,
the aluminum fin according to any one of claims 1 to 3 is a corrugated fin in which a plurality of tubes made of aluminum or an aluminum alloy are arranged in parallel, the corrugated fin is welded between the tubes, and the plurality of tubes are welded to a header pipe.
6. A heat exchanger, characterized in that,
the plurality of aluminum fins as set forth in any one of claims 1 to 3, wherein a plurality of tubes made of aluminum or an aluminum alloy through which the plurality of aluminum fins are inserted or penetrated are welded to the aluminum fins, and the plurality of tubes are welded to a header pipe, respectively.
7. The heat exchanger according to any one of claims 4 to 6,
a coating film for soldering containing Si powder and a Zn-containing flux is formed on the outer surface of a pipe body constituting the pipe before soldering, and the solder layer is formed from the coating film for soldering after soldering.
8. The heat exchanger of claim 7,
a sacrificial anode layer is formed on the surface of the tube by the diffusion of Zn contained in the welding coating film.
9. A method of manufacturing a heat exchanger by welding the aluminum fin according to any one of claims 1 to 3 to a tube having a refrigerant flow passage therein,
a welding coating film containing Si powder and a Zn-containing flux is formed on the outer surface of a tube body constituting the tube, and Si and Zn in the welding coating film are diffused to the tube side by a heat treatment at the time of welding to form a sacrificial anode layer for diffusing Zn to the outer surface side of the tube body.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2017226238 | 2017-11-24 | ||
| JP2017-226238 | 2017-11-24 | ||
| JP2018144415A JP7209487B2 (en) | 2017-11-24 | 2018-07-31 | ALUMINUM FIN AND HEAT EXCHANGER EXCELLENT IN HYDROPHILIC AFTER BRAZING PROCESS AND METHOD FOR MANUFACTURING THE SAME |
| JP2018-144415 | 2018-07-31 | ||
| PCT/JP2018/042108 WO2019102915A1 (en) | 2017-11-24 | 2018-11-14 | Aluminum fin having excellent hydrophilicity after brazing, and heat exchanger and method for producing same |
Publications (1)
| Publication Number | Publication Date |
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| CN111344530A true CN111344530A (en) | 2020-06-26 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201880075212.2A Pending CN111344530A (en) | 2017-11-24 | 2018-11-14 | Aluminum fin having excellent hydrophilicity after soldering treatment, heat exchanger, and method for manufacturing same |
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| JP (1) | JP7209487B2 (en) |
| CN (1) | CN111344530A (en) |
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| JP7376700B2 (en) * | 2020-04-22 | 2023-11-08 | Ｍａアルミニウム株式会社 | Hydrophilic paint composition, aluminum parts, aluminum plates, aluminum tubes, and heat exchangers |
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| JPS58153098A (en) * | 1982-03-09 | 1983-09-10 | Mitsubishi Alum Co Ltd | Manufacture of heat exchanging medium |
| CN101038134A (en) * | 2007-04-28 | 2007-09-19 | 珠海格力电器股份有限公司 | Heat exchanger for heat pump |
| CN101379361A (en) * | 2006-02-06 | 2009-03-04 | 松下电器产业株式会社 | Fin-tube heat exchanger |
| JP2013137153A (en) * | 2011-12-28 | 2013-07-11 | Mitsubishi Alum Co Ltd | All-aluminum heat exchanger using precoat fin material |
| CN103518117A (en) * | 2011-05-10 | 2014-01-15 | 日本轻金属株式会社 | Heat exchanger obtained from aluminum or aluminum alloy |
| CN104956175A (en) * | 2013-09-04 | 2015-09-30 | 松下知识产权经营株式会社 | Heat exchanger and cooling device using same |
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| JP2002139282A (en) * | 2000-10-31 | 2002-05-17 | Mitsubishi Electric Corp | Heat exchanger, refrigerating air conditioner and manufacturing method of heat exchanger |
| JP4413526B2 (en) * | 2003-05-06 | 2010-02-10 | 三菱アルミニウム株式会社 | Tube for heat exchanger |
| JP5600081B2 (en) * | 2011-05-10 | 2014-10-01 | 日本軽金属株式会社 | Pre-coated fin material for heat exchanger and heat exchanger |
| JP2014014740A (en) * | 2012-07-06 | 2014-01-30 | Sharp Corp | Surface treatment device |
| JP6529749B2 (en) * | 2014-11-26 | 2019-06-12 | 三菱アルミニウム株式会社 | Heat exchanger and method of manufacturing heat exchanger |
| JP2017180991A (en) * | 2016-03-31 | 2017-10-05 | 株式会社Uacj | Fin material for heat exchanger and heat exchanger |
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2018
- 2018-07-31 JP JP2018144415A patent/JP7209487B2/en active Active
- 2018-11-14 CN CN201880075212.2A patent/CN111344530A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS58153098A (en) * | 1982-03-09 | 1983-09-10 | Mitsubishi Alum Co Ltd | Manufacture of heat exchanging medium |
| CN101379361A (en) * | 2006-02-06 | 2009-03-04 | 松下电器产业株式会社 | Fin-tube heat exchanger |
| CN101038134A (en) * | 2007-04-28 | 2007-09-19 | 珠海格力电器股份有限公司 | Heat exchanger for heat pump |
| CN103518117A (en) * | 2011-05-10 | 2014-01-15 | 日本轻金属株式会社 | Heat exchanger obtained from aluminum or aluminum alloy |
| JP2013137153A (en) * | 2011-12-28 | 2013-07-11 | Mitsubishi Alum Co Ltd | All-aluminum heat exchanger using precoat fin material |
| CN104956175A (en) * | 2013-09-04 | 2015-09-30 | 松下知识产权经营株式会社 | Heat exchanger and cooling device using same |
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| JP7209487B2 (en) | 2023-01-20 |
| JP2019095182A (en) | 2019-06-20 |
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