EP0374896A2 - Flat tube condenser, manufacturing method and uses - Google Patents

Abstract

The invention relates to a flat tubular condenser for a vehicle air-conditioning unit, in which the coolant is led through flat tubes (2) subdivided into a plurality of ducts, and in cross-flow thereto ambient air is led along ribbed segments folded in a zig-zag or wavy fashion, individual flat tubes being connected in parallel in groups into the same coolant circuit through the condenser by manifolds (10) arranged at their two ends. According to the invention it is provided that the manifold sheath (62) is composed of two arcuate flat parts (66, 68) of Al or an Al alloy, which are mutually overlapping and are soldered to one another in the two overlap regions (64), that only one (the first) flat part (66) is provided with plug-in slots for receiving one flat tube (2) in each case, and that the first flat part is coated with solder for the purpose of soldering to the flat tubes and the second flat part. Furthermore, the invention relates to a method of producing the manifold sheath of a special embodiment of such a flat tube condenser, and applications. <IMAGE>

Description

The invention relates to a flat tube condenser according to the preamble of claim 1. Such a flat tube condenser is known from EP-A2 0 255 313.

According to EP-A2 0 255 313, the collector is shaped as a cylinder, which is internally coated with solder. In this case there is not always a desired limitation of the spatial shape. For example, the flow cross section can only be increased by increasing the radius. Among other things, this has an undesirable influence on the overall depth of the flat tube condenser or a corresponding flat tube evaporator. In addition, the insertion slots for the flat tubes of partition walls to form separate sections of the collector can only be produced in a relatively complicated manner, in particular by milling.

You could also make the collector from extruded profiles. Although these offer a greater spatial variety of cross-sectional design; on the other hand, however, they cannot be easily coated with solder.

The invention is based on the object of designing the collector of a flat tube condenser or flat tube evaporator in such a way that it combines the stated advantages of the two mentioned possible solutions without having the disadvantages mentioned.

This object is achieved by the characterizing features of claim 1.

With such a collector, the choice of material (suitable alloy), the thickness of the flat material and the dimensioning of the cut of the same, set any desired clear cross-section, insofar as the bending radii used for the flat pieces adequately take into account the pressure loads occurring.

This largely free cross-sectional design can be combined with a pre-coating of the unbent flat parts with solder. This solder is then used not only to connect the collector to the flat tubes inserted into the insertion slots, but also to make use of the flat parts in their two overlapping areas in additional use.

It is possible to solder only the first flat part provided with the insertion slots for the flat tubes. However, the quality of the connection of the two flat parts, or at least the security of the solder connection, can be further improved in the sense of claim 2 if the second flat part is also provided with solder. This solder can then also be used for soldering an intermediate wall, which may not be coated with solder, which is used to divide the collector into individual, separate chambers, or also end covers (see also claim 8), even if these are not included Are solder coated.

In the embodiment according to claim 3, the second flat part can be reduced to a pure lid function. However, this does not exclude that in certain embodiments, in contrast to claim 3, the first flat part overlaps the second flat part on the outside, for example if one wants to use maximum width in the first flat part for the insertion slots of the flat tubes; because in such a case the available width is increased by two material thicknesses of the first flat part.

According to claim 4, the two flat parts are also clinched to one another in the two overlapping areas in addition to their solder connection. Any known clinching method can be provided as a clinching, in particular a linear or a punctiform or zone-wise pressing, these pressing on the one hand lengthways straight circumferential lines or curved lines and on the other hand with engagement in recesses of one of the flat parts or preferably (cf. also claim 7) can only take place with deformation of closed walls.

The last-mentioned version is preferred for the structural embodiment according to claim 5. According to this, the overlap is developed into a pocket-like engagement, so that in the clinching area or overlap area two walls of one flat part encompass a third wall of the other flat part.

By means of the clinching, in particular, the solder gap can be kept as small as possible, for example with preferred hard solder, in particular AlSi7.5 to AlSi10, to less than 0.1 mm and, in addition, pre-assemble the two flat parts for their soldering as a whole and also against one Secure the relative shift yourself during the soldering process. In the special case of claim 6, a further advantage can also be achieved. On the one hand, an exposed free end of the edge section, which forms the outer wall of the insert pocket, can be used as an insertion bevel before soldering. Since this lead-in bevel is bent back in the clinched state, since the clinching takes place in the area of the previous exhibition, the area of the outer wall of the insert pocket adjoining the free end of the edge section is arched out in a linear manner toward the flat part inserted into the insert pocket and thus forms a material contact edge that narrows the soldering gap in this area to zero. This kink area recognizable by the finished collector can therefore also be used as an exit zone for the soldering flow. It is not necessary for the solder to flow into the interior of the insert pocket behind the contact edge. On the contrary, it is desirable if the insertion depth of the flat part accommodated in the insertion pocket does not extend to the bottom of the insertion pocket, but instead leaves a tolerance-compensating margin.

This scope can then also be used for the soldering of end covers and / or partitions of the collector according to claim 8 to a sufficient displacement distance when inserting the end cover and / or an intermediate wall or more of these in the receiving slot of one of the flat parts and applying the parts mentioned on to get another flat part.

In particular, the invention makes it possible to design the insertion slots and / or the receiving slots as punched slots, which can even be pre-formed in the unbent first flat piece. Both the character of the slots as punched slots and their formation on the initially unbent flat piece can be determined by microscopic examination of the collector even after it has been installed, e.g. through appropriate microscopic examinations.

So far, it has been thought concretely in cylindrical collectors for flat tube condensers to connect the flat tubes only to two opposite collectors, which are divided for flow back and forth between the collectors through the flat tubes in flow-separated compartments. The known technology mentioned makes this solution appear particularly simple and therefore inexpensive.

However, it has been shown that the same effect can also be achieved by individual collectors within the meaning of claim 11. A particularly suitable construction of such individual collectors is that of claims 1 to 10 of the invention. Because this type of construction is particularly easy to obtain in large series using bending and punching machines. It may be sufficient if the entire flat tube condenser - or flat tube evaporator - is only connected via the ribbing of the flat tubes or, if necessary, by additional holding elements, which are, however, generally unnecessary.

According to claim 12, one can even dispense with separate end covers entirely. This solution is of particular importance in the case of simple overlap of the two flat parts without forming the insertion pockets; but this solution is also possible in principle in the latter case. Then she continued of particular importance in the case of claim 11, since the formation of receiving slots for partition walls and for end covers can then be dispensed with entirely.

Finally, claims 13 and 14 relate to preferred forms of bending of the two flat parts. The free clear cross section can be easily adjusted in the case of claim 14 by appropriate choice of the length of the straight leg of the U-profile of the second flat part without having to accept significant losses in compressive strength.

As usual, the invention can be implemented with horizontally extending flat tubes. This is also the normal scope. Claim 15 also allows an alternative with a vertical arrangement of the flat tubes, which is of particular interest in certain installation conditions in the motor vehicle. So far, such condensate flow arrangements of the condensers have been avoided in order to avoid a pulsation of the refrigerant flow due to periodic blockage by liquid components of the refrigerant with subsequent breakdown of gas components. Separation of oil components of the refrigerant in the lower collector is particularly critical. At sufficiently high flow rates of the refrigerant of a flat tube condenser according to the invention (for example between 1.5 and 6 m / sec, depending on the liquid content), the flow forces continuously act on partially separating liquid and especially oil parts so that they do not accumulate up to the clogging limit. but be carried along continuously.

Alternatively, in a flat tube condenser according to the invention, a vertical profile of the flat tubes and thus a horizontal profile of the collectors can also be used favorably, in particular in the application according to claim 24 for cross-flow coolers of a vehicle, primarily a motor vehicle. Here you can see the tube-lamella units on the one hand of the vehicle radiator and on the other hand the flat tube condenser according to the invention in close proximity in the direction of the flow Arrange the direction of the ambient air one behind the other. The water boxes of the vehicle cooler, which serve as collectors, on the one hand, and the collectors of the flat tube condenser according to the invention, on the other hand, are greater in construction depth than the aforementioned tube-lamella system of each individual unit. Now, in a conventional cross-flow cooler, its water tanks run vertically, while the collectors of the flat tube condenser according to the invention run vertically in the arrangement considered here. The water boxes of the vehicle radiator and the collectors of the flat tube condenser according to the invention can thus be arranged in such a way that they include the two tube-lamella systems connected in series in a frame-like manner and thus do not assume any additional internal depth.

With the collectors of the flat tube condensers according to the invention, it is essential that the actual collector wall is not weakened or even perforated. In the construction according to the invention according to claim 5, in which an insert pocket is formed on the inner flat part when the two flat parts are connected, this insert pocket can additionally be used either for installing the entire flat tube condenser in the vehicle concerned, e.g. Motor vehicle, make usable or use as a holder for additional units. Liquid collectors, dryers for the refrigerant and the like can be considered as additional units. In this case, for example, the insert pocket in question can be left completely unmodified, for example, according to application claim 23, and can be attacked on it, for example, simply from the outside with a clamp connection or clinching. However, one can also prepare the insert pocket from the outset in the sense of claim 16 as a carrier for attaching retaining plates for fastening to a vehicle body or for receiving additional units. A preferred preparation measure is that of claim 17 with through mounting holes, which are harmless for the collector function here.

An alternative of the attachment specifies claim 18, here again in the special case of a horizontal Course of the collector or vertical course of the flat tubes. Claim 19 is not only related to the readily understandable case of vertically arranged collectors, but can also be realized with horizontally arranged collectors in the sense of claim 15; this special case of horizontally arranged collectors could even be realized with a different construction of the collectors than according to the invention. In particular, the case is generally considered that in a horizontal header located below, the refrigerant is fed vertically at one end and drawn off vertically at the other end. Liquefied refrigerant then collects not only under the force of gravity but also under centrifugal forces as a result of the U-shaped deflection at the base of the collecting tube. If the drain openings provided according to claim 19 are arranged in the partition at the bottom of the collector, liquefied refrigerant can flow horizontally to a drain. The horizontal collector at the top can be designed without drain openings in the intermediate walls.

A solder coating on the collector part is usually a roll-on layer of, for example, 10% of the material thickness. Roll-on layers of this type have relatively smooth surfaces. If you want to carry out the soldering in a modern way as vacuum soldering, however, the layer of the solder must be pickled to prevent surface oxidation, grease deposits and the like. the like. This leads to a subsequent surface roughening, which in this case can lead to problems with flat tube condensers according to claim 6, if only the usual soldering gap of 0 to 0.1 mm is left on the exposed area of the free end of the edge section of the inner flat part. Then, in this area, the surface roughness can significantly impede or even make it impossible to insert the free edge of the outer flat part into the insertion pocket. This difficulty can be avoided by the method according to claim 20. This enables the two free edges of the outer flat part to be inserted without hindrance into the two insertion pockets of the inner flat part, and the conditions for clinching and soldering then only become manufactured sluggishly. It can be consciously accepted that when the pocket is squeezed it undergoes considerable elongation. In such cases, one can get by without the exposed positions of the free ends of the edge section of the outer flat part within the meaning of claim 6, but may also partially include the form of training mentioned there.

Preferably, according to claim 21, the outer flat part is only partially inserted into the insertion pocket on the inner flat part, so that height and shape tolerances of the assembly can be compensated for in the case of the tolerance-sensitive shaped flat parts.

From DE-A1 37 44 643 it is already known to manufacture the collector of a water cooler or hot water radiator for motor vehicles from a cover and a tube sheet, both of which are deep-drawn from a non-ferrous metal. In this case, a meandering circumferential flanging must be molded on subsequently with a run-on bevel which serves for better introduction. A free edge of the tube sheet is inserted into the insert pocket formed on the cover up to the stop at the bottom of the insert pocket. Between the free edge of the tube sheet and the side walls of the insert pocket there is a solder receiving gap, the dimensions of which are left unchanged. The multiple crimping of the cover is specific to the non-ferrous metal and is difficult to transfer, for example, to Al or an Al alloy. For example, in the case of Al or an Al alloy, a relatively large gap width of the insertion pocket is provided in the sense of the method according to the invention for uninhibited insertion, while a smaller gap width is expedient for soldering. In addition, there is a risk of tearing if an aluminum or aluminum alloy sheet with solder coating is flanged several times.

Claim 22 relates to the use of the type of collector according to the invention, which has already been mentioned several times, instead for a flat tube condenser instead for a flat tube evaporator.

• Fig. 1 eine Frontansicht eines Flachrohrverflüssigers einer Fahrzeugklimaanlage in Anströmrichtung der als primäres kühlendes Fluid dienenden Umgebungsluft;
• Fig. 2 eine Draufsicht auf den Flachrohrverflüssiger gemäß Fig. 1;
• die Fig. 3 und 4 zwei Querschnitte durch den Sammler­mantel eines Flachrohrverflüssigers, z.B. gemäß den Fig. 1 und 2, in zwei alternativen Ausführungsformen mit schematisch ange­deutetem Anschluß eines Flachrohres;
• Fig. 5 eine perspektivische Expositionszeichnung zur Veranschaulichung der Montage eines Sammlermantels mitsamt den zusätzlich eingesetzten Teilen in der Ausführungsform des Samm­lermantels nach Fig. 3;
• die Fig. 6 und 7 zwei alternative Verclinchungsformen bei einem Sammlermantel gemäß Fig. 3 im Querschnitt durch einen Überlappungsbereich;
• Fig. 8 einen Querschnitt analog Fig. 7 zur Veranschau­lichung einer besonderen Bauform der Clinchverbindung nach Fig. 7 mit Phantomzeichnung von Materialerstreckungslinien vor Her­stellung der Verclinchung;
• Fig. 9 wiederum im Querschnitt durch den Überlappungs­bereich des Sammlermantels eine Zwischenphase des Herstellungs­verfahrens gemäß Anspruch 15;
• Fig. 10 ein innen liegendes Flachteil der Ausführungs­form gemäß Fig. 3 mit Anschluß einer gesonderten Zwischenwand zur Herstellung eines Flachrohrverflüssigers nach Anspruch 8;
• Fig. 11 eine schematische Ansicht eines Flachrohrver­flüssigers gemäß Fig. 1 in einer Verschaltung mit von Zwischen­wänden freien Einzelsammlern;
• die Fig. 12 und 13 je einen Längs- und einen Quer­schnitt eines Sammlers mit umlaufender Verbindung der beiden Überlappungsbereiche;
• Fig. 14 eine schematische Zeichnung zur Veranschauli­chung der möglichen Funktion einer Einstecktasche, welche am in­ nen liegenden Flachteil zur Verbindung der beiden Flachteile an­gebracht ist, als Halter;
• Fig. 15 eine Frontalansicht in Richtung der Strömung von Umgebungsluft durch einen erfindungsgemäßen Flachrohrver­flüssiger mit sich horizontal erstreckenden Sammlern und mit Nachschaltung eines Querstromkühlers eines Kraftfahrzeugs mit sich vertikal erstreckenden Wasserkästen; und
• Fig. 16 in vergrößertem Maßstab einen Teilschnitt nach der Linie XVI-XVI in Fig. 15.

The invention will now be described more schematically Drawings in several embodiments explained in more detail. Show it:

• 1 is a front view of a flat tube condenser of a vehicle air conditioning system in the flow direction of the ambient air serving as the primary cooling fluid;
• FIG. 2 shows a plan view of the flat tube condenser according to FIG. 1;
• 3 and 4 show two cross sections through the collector jacket of a flat tube condenser, for example according to FIGS. 1 and 2, in two alternative embodiments with schematically indicated connection of a flat tube;
• 5 shows a perspective exposure drawing to illustrate the assembly of a collector jacket together with the additionally used parts in the embodiment of the collector jacket according to FIG. 3;
• 6 and 7 show two alternative forms of clinching for a collector jacket according to FIG. 3 in cross section through an overlap area;
• 8 shows a cross section analogous to FIG. 7 to illustrate a special design of the clinch connection according to FIG. 7 with a phantom drawing of material extension lines before production of the clinching;
• 9, in turn, in cross section through the overlap area of the collector jacket, an intermediate phase of the production method according to claim 15;
• FIG. 10 shows an internal flat part of the embodiment according to FIG. 3 with connection of a separate partition for the production of a flat tube condenser according to claim 8;
• FIG. 11 shows a schematic view of a flat tube condenser according to FIG. 1 in a connection with individual collectors free of partition walls; FIG.
• 12 and 13 each show a longitudinal and a cross section of a collector with a circumferential connection of the two overlapping areas;
• Fig. 14 is a schematic drawing to illustrate the possible function of an insertion pocket, which on in NEN flat part is attached to connect the two flat parts, as a holder;
• 15 shows a frontal view in the direction of the flow of ambient air through a flat tube condenser according to the invention with horizontally extending collectors and with a downstream cross-flow cooler of a motor vehicle with vertically extending water boxes; and
• 16 is a partial section on an enlarged scale along the line XVI-XVI in FIG. 15th

In the flat tube condenser according to FIGS. 1 and 2, the collector 10 is designed according to the embodiment according to FIG. 3.

In the exemplary embodiments, the flat tubes are each designated 2 and the fins 4.

The ends of the flat tubes 2 are each inserted into the tube sheets of collectors 10, on each of which a connector 6 is placed on the refrigerant inlet of the flat tube condenser and a connector 8 on the side of the header 10 facing away from the fins 4 is pressure-tight at the refrigerant outlet of the flat tube condenser.

The collectors 10 serve to combine several flat tubes 2 in groups. For this one could use individual collectors 10 per group (see FIGS. 11 and 12). In a conventional manner, however, a single collector tube is used according to FIG. 1, which extends over the entire collector height and which is divided by partition walls 14 into individual collector sections which are sealed off from one another within the collector and each perform the function of an individual collector. In practice, this does not conflict with the fact that in the collector provided with the connections 6 and 8 at the heights at which the refrigerant is already partially liquefied, drain openings 12 are provided in the intermediate walls 14 for refrigerant that has already liquefied. The partitions in the other collector and the top partition of the former collector are not broken. The cross section of the drain openings 12 increases in the perforated partition walls from partition wall to partition wall speaking of the increasing mass fraction of liquefied refrigerant. This in turn serves as a valve body in order to completely or substantially close the outlet openings 12, ie at least 90% mass flow, for the gaseous phase of the refrigerant. This reduces the amount of liquid refrigerant in the lower flat tubes, so that more inner surface can be used to liquefy the refrigerant.

Both the flat tubes 2 and the fins 4 are suitably made of aluminum or an aluminum alloy. The flat tubes are expediently made of the wrought aluminum alloy AlMn1 according to DIN standard. The lamellae made of the same material or, if they are to be hardenable after soldering, can expediently also consist of AlMgSi alloy. An aluminum alloy of AlSi7.5 to AlSi10 is expediently used as the solder, the fluxes customary for such alloys being used, such as, for example, chloride- or fluoride-containing fluxes, in the simplest case, table salt suspended with commercially available additives.

In particular, it can be seen that the flat tubes 2 covered with fins 4 extend in register between two parallel collectors 10. One collector is provided with the two connectors 6 and 8 for the refrigerant to be liquefied.

The parallel flat tubes 2 each engage through a slot 36 in the collector 10, which can be seen from FIGS. 3 and 4. The two alternative embodiments of FIGS. 3 and 4 are the same with regard to the connection method of the flat tubes 2 engaging in the slots 36. In FIG. 3, only the cut through an area between adjacent flat tubes is selected, while in FIG. 4 the cut is passed through the slot 36 itself. The cuts can be transferred alternately to both embodiments of FIGS. 3 and 4.

A special feature is that the collector jacket 62 of the collector 10 consists of two curved flat surfaces that overlap one another and are soldered to one another in both overlap regions 64 parts 66 and 68 is composed of Al or an Al alloy. One, the so-called first, flat part 66 is provided with the aforementioned insertion slots 36 for receiving a flat tube 2 each, and is also coated with solder, in particular hard solder, for soldering to the flat tubes 2 and the second flat part 68. If the partitions 14 are used in the sense of FIG. 1, the solder also serves for soldering to them. The second flat part 68 essentially has a lid function supplementing the collector jacket 62; it is also preferably coated with solder, here for soldering to the first flat part 66 and possibly also with the intermediate walls 14. Likewise, the solder of both flat parts can also be used for soldering with end covers 70.

It is possible to provide the solder layers not specifically shown in the drawings locally in the area of their soldering application or only on one side of the flat part, which later forms the inside of the collector. In general, commercially available flat materials coated on both sides will be chosen to form the flat parts. These are, for example, deformed into the application form by bending and / or deep drawing.

In all of the illustrated embodiments, the second flat part 68 overlaps the first flat part on the outside, so that in the exemplary embodiments described here the first flat part 66 can also be understood as an inside flat part and the second flat part 68 as an outside flat part, without this preferred assignment being mandatory is.

The two preferred embodiments of FIGS. 3 and 4 differ first of all in the way they overlap.

The embodiment according to FIG. 4 is a simple two-layer overlap. The embodiment according to FIG. 3 is a three-layer overlap, in which in the two overlap areas 64 the inner or first flat part 66, the two free edges 72 of the outer or second flat part 68, each forming the respective edge 72 insert pocket 74 encompassing on both sides and running along the collector 10 with its edge section 76 encompasses.

In addition, two different types of clinching in the respective overlap region 64 are illustrated on the two FIGS. 3 and 4. In the embodiment according to FIG. 4, an expressly illustrated punctiform or linear indentation 78 on the free edge 72 of the outer flat part 68 engages in complementary recesses 80 on the inner flat part 66, these recesses 80 in the two-layer construction according to FIG. 8 are also formed on free edges of the inner flat part 66.

As an alternative, the cutouts 80 can also be dispensed with and the overlapping walls can be deformed together with a common embossing and thereby brought into positive engagement. In the embodiment according to FIG. 3, an indentation in the manner of indentation 78 of FIG. 4 would be formed through all three walls of the overlap in a manner not shown, without material intervention in a recess. However, an engagement in a recess can also be provided with a three-layer connection. Preferred designs of this three-layer connection are described in more detail with reference to the following figures.

3 and 4 that the second plug-in part is U-shaped with a semi-cylindrical or other curved arch part 82 and parallel legs 84 extending from this on both sides. The free cross section of the collector can be set up according to how much of the free leg 84 to form the inner cross section of the collector jacket and how much is consumed in the overlap area. You can also work with different leg lengths.

As the embodiment according to FIG. 4 shows, the first flat part 66 can also be designed with a semi-cylindrical or other curved arch part 86 with two parallel straight legs 88 extending from it. This arched part 86 can in turn not only be semi-cylindrical, but also arched differently. This is particularly clear from the also on Fig. 4 transferable vault shape according to FIG. 3, which is shaped in the manner of a dished bottom 44.

3 is that here the free legs 88 of the embodiment according to FIG. 4 are dispensed with and instead the insertion pockets 74 are formed by bending the first flat part outwards, which are rectilinearly parallel to the likewise rectilinear flat tubes 2 in the direction of Extend the fins of the flat tube condenser.

It can be seen in FIG. 3 that the free edges 72 of the legs 84 of the outer second flat part 68 preferably (but not necessarily) extend to the bottom of the respective insertion pocket 74, but instead each have an end gap 90 above the base leave the respective insert pocket free. This has several advantages. On the one hand, you can choose the clear width of the collector differently or at least compensate for tolerances. The exact setting of the clear width can be selected precisely by means of intermediate walls 14 and end covers 70 clamped between the two plug-in parts, in the manner of calibrating stops, as will be described in more detail with reference to FIG. 5. It can be seen that basically four different types of components are soldered together.

On the one hand, the two flat parts 66 and 68 are soldered to one another in the manner already explained, reference being made here to the type of overlap according to FIG. 3.

Furthermore, the flat tubes 2, which are connected to one another in a block-like manner by the fins 4, are inserted together as a structural unit into the insertion slots 36 of the first flat part. This first flat part also has, in the transition region into the insertion pockets and at the suitable location between adjacent insertion slots 36, two additional receiving slots 92, aligned with one another, for insertion feet of a partition disk-like intermediate wall 14, which divides the collector into individual departments. In a manner not shown, the same also applies to the vicinity of the two ends of the first flat part 66 corresponding receiving slots 92 to be arranged in each case after the last insertion slot 36 for the end covers 70 already mentioned earlier.

In addition, reference is made to FIG. 10, where the receiving slots 92 on the first flat part 66 are shown even more clearly in their course. It can be seen that they extend on both sides from the center of the arch part 86, which may be designed as a dished bottom 44, via the back bend into the insertion pocket 74 to a region of medium height of the insertion pocket and end there in a bottom 96. The two insertion feet 94 of the intermediate wall 14 engage in these receiving slots 92 and are accordingly also soldered in the receiving slots 92. Alternatively, one can use the free end faces 98 of the plug-in feet 94 or a belly 100 of the intermediate wall 14 running between the plug-in feet 94 complementary to the arch part 86 as a support surface on the base 96 or on the arch part 86 when assembling the two flat parts 66 and 68, the complementary part then to the arch part 82 of the other flat part 68, the arched head 102 of the intermediate wall is supported on the arch of this flat part 68. It goes without saying that the parallel flanks 104 of the intermediate wall run in solderable contact with the legs 84 of the second flat part 68.

In the event of a stop at the bottom 96, instead of the two receiving slots 92, a single continuous receiving slot 92 can optionally be provided, in which case a recessed belly 100 is then unnecessary.

As can still be seen from FIG. 5, the inner regions of the receiving slots 92 overlap the insertion slots 36.

It is understood that in the case of end covers 70, their design also corresponds to that of the intermediate walls 14, as has already been explained in detail with regard to the receiving slots 92.

Clinch connections in the design according to FIG. 8 are now considered in more detail.

6 takes over the construct tion of Fig. 4 for the two outer walls of the three-layer connection, while here the inner wall can even remain undeformed (but does not have to).

In the embodiment according to FIG. 7, on the other hand, the impression 78 of the outer wall continues in the manner already mentioned in impressions 78a and 78b of the walls lying further inside, which are pressed together in a form-fitting manner.

In addition to the link connections 106 shown, all other known types of link connections are also suitable.

The insertion of the free edges 72 of the outer flat part 68 into the respective insertion pocket 74 can in principle be simplified if the free end 108 of the edge section 76 is exposed to the outside as an insertion bevel (straight or convex). In Fig. 8, this bevel formed in the originally shaped flat piece is indicated in dashed phantom drawing. This original bevel is pressed against the relevant free edge 72 of the outer flat part when the clinch connection is made. The outer layer of the insert pocket 74 is deformed in such a way that a pronounced contact edge 110 of the edge section 76 is formed on the free edge 72 of the outer flat part 68, from which the insert pocket is approximately in its original configuration towards the bottom bulges out.

On the other hand, there are often difficulties in overcoming the surface friction when putting together such a connection of the two flat parts 66 and 68 if one only wants to trust an insertion via the insertion bevel. It has therefore proven to be very expedient, in the sense of the manufacturing method according to claim 20, to provide the insertion pocket in a first insertion phase with a gap width which is the sum of the material thickness of the inserted free edge 72 plus solder gap (range 0 to 0.1 mm) significantly exceeds such that surface roughness caused by pickling a solder layer, no longer resist assembly resistance when plugged in. Appropriately, one will choose gap widths b of at least 3/2 times the material thickness of the free edge 72, in practice the upper limit of b can be, for example, two to three material thicknesses of this free edge. Only after being plugged together are the two outer walls of the relevant insertion pocket 74 pressed together to grip the inner free edge 72, in order to be subsequently clinched and in any case soldered to one another. When the insert pocket is pressed together, its length extends.

However, the invention relates not only to collectors with intermediate walls 14 or end covers 70, but also, for example, individual collectors 114, which may have end covers 70 of the type described, but are free of intermediate walls 14.

Such individual collectors 114 can be arranged in the area of the inlet or outlet 6 or 8 (or the corresponding connecting pieces) of the refrigerant with a single group of ribbed flat tubes 2, 4 - or in the intermediate areas per group pair of such parallel connected ribbed flat tubes 2, 4 , as shown in detail in the circuit diagram of FIG. 11.

On the other hand, it is also possible to dispense entirely with end covers, as is finally shown in the embodiment according to FIGS. 12 and 13, which can be designed with or without intermediate walls 14.

In this embodiment, both flat parts 66 and 68 are advantageously deep-drawn parts. The one flat part, namely expediently the second flat part 68 as shown, is additionally deep-drawn so that end cover regions 116 are also formed during deep-drawing. These are included in the connected collector 10 in such a way that the two parallel overlap regions 64 are connected to one another in the two end regions of the collector 10 (or 114). Then not only the collector jacket, but the entire collector housing is formed from only two parts, which may be by the Partitions 14 can still be divided into departments if one does not prefer the individual collector training 114 according to FIG. 11.

The illustration according to FIG. 14 illustrates the additional possibility of using the insertion pockets 74 as carriers for attaching holding plates 122 and 124 for fastening to a vehicle body or for accommodating additional units. For this purpose, fastening holes 126 extend through each of the two insertion pockets 74, through which, for example, screws or rivets can reach, with which the holding plates 122 and 124 are fastened to the respective insertion pocket 74. The holding plate 124 has an angular shape, with fastening holes 128 again being formed on the protruding leg of the angular part. These can be used, for example, to fasten fans arranged on the angle part or, as already mentioned, collectors or dryers for the refrigerant. The other holder 122 is a flat sheet which, in turn, is provided at a distance from the relevant insertion pocket 74 with fastening holes 130 for attachment to a motor vehicle body. The respective insertion pocket 74 is thus pre-formed for the holding function by means of the fastening holes 126. In the borderline case, however, one can get by without any previous training, as was mentioned earlier.

The embodiment shown in FIG. 14 also shows the peculiarity that the fastening holes 126 pass through the end gap, so that the outer flat part 68 in turn does not have to be drilled through. This enables the fixing bores 126 to be prepared already on the inside flat part 66, while otherwise the fixing bores 126 in question would have to be made subsequently through the outside flat part 68. The embodiment according to FIG. 14 can be adjusted particularly favorably by means of the intermediate walls 14, which are not shown in FIG. 14, so that the desired length of the end gaps 90 is created.

The embodiment according to FIGS. 15 and 16, which can optionally also be combined with that of FIG. 14, be meets the special case that the two collectors 10 of the flat tube condenser run horizontally and thus its flat tubes 2 vertically. Such a flat tube condenser is combined here with a crossflow cooler of a motor vehicle, the water boxes 132 of which run vertically.

As can be seen particularly clearly in FIG. 16, the tube-lamella system consisting of the flat tubes 2 and the fins 4 of the flat tube condenser according to the invention is in flow direction of the ambient air (arrow 134) with only a small distance (double arrow 136) in terms of flow in front of the tube. Fin system made of tubes 136, in particular round tubes, but possibly also flat tubes, and fins 140 of the cross-flow cooler. Without restricting generality, the tube-lamella system of the cross-flow cooler is designed in two rows in the direction of flow of the ambient air (arrow 134). The fins 140 are preferably fastened to the tubes by mechanical widening of the tubes and are used in the flared collars of the fins 140. The tubes 138 open into a tube sheet 142 of the respective water box 132, the tubes 138 being tightly fastened to the tube sheet in the exemplary embodiment shown also by mechanical expansion, but possibly also by soldering. While the tube sheets 142 are usually made of aluminum or an aluminum alloy, they suitably complement the water tank 132 by an attached water tank cover 144, which is sealed against the associated tube sheet 142 by circular sealing cords 146 made of an elastomeric material made of natural rubber or a rubber substitute. A water tank 132 is provided on the inlet side and outlet side with respect to the cooling water (cf. FIG. 15), one water tank having a cooling water inlet 148 and the other a cooling water outlet 150. The tubes 138 run between the two water boxes 132.

The header 10 of the flat tube condenser has a greater overall depth (double arrow 152) than the associated tube / lamella system consisting of the flat tubes 2 and fins 4 (double arrow 154). Accordingly, the cross flow cooler has a tube-lamella system stem from the tubes 138 and the fins 140 with a smaller overall depth (double arrow 156) than the overall depth (double arrow 158) of the associated water box 132. In the illustrated embodiment, the overall depth is nevertheless only slightly greater than the sum of the overall depths of the two tube fins Systems plus the minimum space 136, since the manifold 10 of the flat tube condenser and the water boxes 132 of the crossflow cooler extend in a frame-like manner around the series connection of the two tube-lamella systems mentioned and thus do not take away one another from each other.

This takes into account the factual experience that in most motor vehicles the orientation of the water tanks as cross-flow coolers is determined and then the task of the air conditioning technician is to design the flat tube condenser to be installed additionally for a vehicle air conditioning system in such a way that it takes up as little additional overall depth as possible.

FIG. 15 also illustrates another possibility for mounting the flat tube condenser in the body 160 of a motor vehicle or other vehicle. For this purpose, vertically arranged stud bolts 162 are used on the outer flat part 68, which extends horizontally. These are firmly inserted into vibration-damping rubber buffers 164, which in turn are fastened to the body 160. The stud bolts 162 are expediently fastened on the flat part 68 during the soldering process, which is also used for soldering the flat tubes 2 with the fins 4 and the two flat parts 66 and 68 to one another and finally the collector 10 with the flat tubes 2. In detail, it is advisable to rivet the stud bolts temporarily and then let them run with the solder. This saves an additional positioning in the soldering mold, in which the entire flat tube condenser is soldered together in the one mentioned soldering process.

Claims (24)

1. Flat tube condenser for a refrigerant of a vehicle air conditioning system, in which the refrigerant is guided through flat tubes (2) divided into a plurality of channels (24) and in cross-flow with ambient air along longitudinally zigzag or corrugated fins (4), each of which is heat-conducting between two adjacent flat tubes are arranged, individual flat tubes being connected in groups in parallel by collectors (10) arranged at their two ends in the same refrigerant circuit through the condenser,
characterized by
that the collector jacket (62) is composed of two bent flat parts (66, 68) overlapping one another and soldered to one another in both overlap regions (64) made of Al or an Al alloy,
that only one (first) flat part (66) is provided with insertion slots (36) for receiving a flat tube (2), and
that the first flat part is coated with solder for soldering to the flat tubes and the second flat part. 2. Flat tube condenser according to claim 1, characterized in that the second flat part (68) is provided with solder for soldering to the first flat part (66). 3. Flat tube condenser according to claim 1 or 2, characterized in that the second flat part (68) overlaps the first flat part (66) lying outside. 4. Flat tube condenser according to one of claims 1 to 3, characterized in that the two flat parts (66,68) are interlocked with each other in the two overlapping areas (64). 5. Flat tube condenser according to one of claims 1 to 4, characterized in that in the two overlap areas (64) the inner flat part (66), the two free edges (72) of the outer flat part (68), each forming the respective free one With its edge section (76), the insert pocket (74) engages around the edge (72) on both sides and runs along the collector (10). 6. Flat tube condenser according to claims 4 and 5, characterized in that the free end (108) of the edge portion (76) from an extended position to form a contact edge (110) of the edge portion (76) on the outer flat part (68) this is clinched. 7. Flat tube condenser according to claim 4 and claim 5 or 6, characterized in that the clinch connection (106) compresses closed walls of the insertion pocket (74) and the outer flat part (68) engaging in them. 8. Flat tube condenser according to one of claims 1 to 7, characterized in that soldered end covers (70) and / or partitions (14) of the collector (10) are each inserted into a receiving slot (92) of one of the flat parts (66) and supported on Bottom (96) of the receiving slot (92) or on the arch part (86) of said one flat part (66) are held against the other flat part (68). 9. Flat tube condenser according to one of claims 1 to 8, characterized in that the insertion slots (36) and / or the receiving slots (92) are designed as punched slots. 10. Flat tube condenser according to one of claims 1 to 9, characterized in that the insertion slots (36) and / or the receiving slots (92) are formed in the bent first flat piece (66). 11. Flat tube condenser according to one of claims 1 to 10, characterized in that the collector (10) is divided per individual group at the inlet or outlet (6; 8) of the refrigerant or per group pair in the intermediate areas in individual collectors (114) free of partition walls . 12. Flat tube condenser according to one of claims 1 to 11, characterized in that a flat part (68) is deep-drawn to form end cover areas (116) and the two overlap areas (64) are connected to one another all around. 13. Flat tube condenser according to one of claims 1 to 12, characterized in that the central part of the first flat part (66) is shaped as a dished bottom (44). 14. Flat tube condenser according to one of claims 1 to 13, characterized in that the second flat part (68) is shaped as a U-profile (82, 84). 15. Flat tube condenser according to one of claims 1 to 14, characterized in that the collector (10) run horizontally. 16. Flat tube condenser according to one of claims 5 to 15, characterized in that the insertion pocket (74) is designed as a carrier for attaching retaining plates (122, 124) for attachment to a vehicle body or for receiving additional units. 17. Flat tube condenser according to claim 16, characterized in that the insertion pocket is provided with fastening holes (126). 18. Flat tube condenser according to one of claims 1 to 14 and claim 15, characterized in that on a flat part (68) Studs for fastening the flat tube condenser are soldered into a vehicle body. 19. Flat tube condenser according to one of claims 8 to 10, characterized in that the intermediate walls (14) are provided with drainage openings (12) for liquefied refrigerant, which are completely or substantially closed for the passage of gaseous refrigerant from liquid refrigerant accumulating during operation. 20. A method for producing the collector jacket of a flat tube condenser according to one of claims 5 to 19, characterized in that before inserting the free edges (72) of the outer flat part (68) into the insertion pockets (74) of the inner flat part (66) the gap width (b) of the respective insertion pocket (74) is chosen to be at least half greater than the material thickness of the free edge (72) to be inserted, so that after inserting the respective free edge (72) into its insertion pocket (74), this has a soldering gap dimension of 0 is compressed to 0.1 mm and that preferably a clinging is carried out on the compressed insertion pocket (74). 21. The method according to claim 20, characterized in that an end gap (90) is left as a tolerance compensation plug between the free edge (72) of the outer flat part (68) and the bottom of the insertion pocket (74). 22. Use of a flat tube condenser of the type according to one of claims 1 to 19 or the product of the method according to claim 20 as a flat tube evaporator. 23. Use of the insertion pocket (74) of a flat tube condenser according to one of claims 5 to 15 and optionally 18 or 19 as an unmodified carrier for attaching retaining plates for attachment to a vehicle body or for receiving additional units. 24. Application of the flat tube condenser according to one of claims 15 to 19 for cross-flow cooler of a vehicle.

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