EP1726906A1

EP1726906A1 - Heat exchanger

Info

Publication number: EP1726906A1
Application number: EP06114586A
Authority: EP
Inventors: Osamu Kamoshida; Yoshihiko Seno
Original assignee: Showa Denko KK
Current assignee: Resonac Holdings Corp
Priority date: 2005-05-27
Filing date: 2006-05-26
Publication date: 2006-11-29

Abstract

A heat exchanger which is favorably used as a condenser includes a pair of headers (2, 3) arranged apart from each other, and a plurality of heat exchange tubes (4) arranged between the headers (2, 3) and having opposite end portions connected to the corresponding headers (2, 3). At least one of the headers (2, 3) is partitioned by means of a partition member (8) into a plurality of header sections (2b, 2c) arranged in the longitudinal direction of the header (2). An outlet-side joint member (14) having a refrigerant channel (15) communicating with a refrigerant outlet (9), and adapted to connect a refrigerant outlet pipe is fixed to the header (2) which is partitioned into the plurality of header sections (2b, 2c). The partition member (8) is integrally formed on the outlet-side joint member (14). This heat exchanger exhibits an improvement in workability in terms of provisional fixation of a partition member.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a heat exchanger for use in a refrigeration cycle of, for example, a car air conditioner.
A known heat exchanger for use in a refrigeration cycle includes a pair of headers arranged apart from each other, and a plurality of heat exchange tubes arranged between the headers and having opposite end portions connected to the corresponding headers, and is configured such that one of the headers is partitioned by means of a partition member into two header sections arranged in a longitudinal direction of the header (refer to Japanese Patent Application Laid-Open (kokai) No. 2002-267388 ). In the heat exchanger described in the publication, the partition member is formed independent of other members and has two projection portions extending in a direction perpendicular to the longitudinal direction of the header. The partition member is inserted into a slit formed in the header, and the two projection portions are bent from directions perpendicular to the longitudinal direction of the header so as to hold the header therebetween. Thus, while being fixed to the header through crimping, the partition member is brazed to the header.
However, the heat exchanger described in the above publication involves troublesome provisional fixation of the partition member; specifically, after insertion of the partition member into the slit formed in the header, the projection portions are bent so as to fix the partition member to the header through crimping.

DISCLOSURE OF THE INVENTION

An object of the present invention is to overcome the above problems and to provide a heat exchanger which exhibits improved workability in terms of provisional fixation of a partition member.
To fulfill the above object, the present invention comprises the following modes.

1) A heat exchanger comprising a pair of headers arranged apart from each other, and a plurality of heat exchange tubes arranged between the headers and having opposite end portions connected to the corresponding headers, and configured such that at least one of the headers is partitioned by means of at least one partition member into a plurality of header sections arranged in a longitudinal direction of the header, the heat exchanger being characterized in that an other-part-attaching member is fixed to the header which is partitioned into the plurality of header sections, and the partition member is formed integral with the other-part-attaching member.
2) A heat exchanger according to par. 1), wherein the other-part-attaching member is a joint member to which piping of a refrigeration cycle is connected, and the joint member has a refrigerant channel communicating with the interior of one of the header sections.
3) A heat exchanger according to par. 2), wherein one end opening of the refrigerant channel of the joint member directly communicates with a refrigerant passage hole formed in the header section.
4) A heat exchanger according to par. 2), wherein one end opening of the refrigerant channel of the joint member and a refrigerant passage hole formed in the header section communicate with each other via a tubular communication member.
5) A heat exchanger according to par. 2), wherein a first header is partitioned into a plurality of header sections by means of partition members; a second header is partitioned into header sections which are provided in a number one fewer than the number of header sections of the first header and which are arranged such that each faces the two adjacent header sections of the first header; all of the heat exchange tubes are divided into a plurality of passes which are arranged in the longitudinal direction of the header and which each consist of a plurality of the heat exchange tubes; and one of the partition members is formed integral with the joint member.
6) A heat exchanger according to par. 2), wherein a first header and a second header are partitioned into respective header sections in the same number by means of partition members; the header sections are arranged such that at least one header section of the first header faces two adjacent header sections of the second header and such that at least one header section of the second header faces two adjacent header sections of the first header; all of the heat exchange tubes are divided into a plurality of passes which are arranged in the longitudinal direction of the header and which each consist of a plurality of the heat exchange tubes; and one of the partition members is formed integral with the joint member.
7) A heat exchanger according to par. 5) or 6), wherein a refrigerant flows in the same direction through the heat exchange tubes which constitute each of the passes, and the two adjacent passes reverse in the flow direction of the refrigerant flowing through the heat exchange tubes thereof.
8) A heat exchanger according to par. 7), wherein the number of the heat exchange tubes which constitute each of the passes reduces from one longitudinal-end side of the header toward the other longitudinal-end side of the header.
9) A heat exchanger according to par. 8), wherein the partition member formed integral with the joint member is disposed between the pass which has the fewest number of the heat exchange tubes, and the pass adjacent thereto.
10) A heat exchanger according to par. 9), wherein the joint member is adapted to connect a refrigerant outlet pipe.
11) A refrigeration cycle comprising a compressor, a condenser, a pressure-reducing device, and an evaporator and using a chlorofluoracarbon-based refrigerant, wherein the condenser is a heat exchanger according to any one of pars. 1) to 10).
12) A refrigeration cycle comprising a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between refrigerant flowing out from the gas cooler and refrigerant flowing out from the evaporator, and using a supercritical refrigerant, wherein the gas cooler is a heat exchanger according to any one of pars. 1) to 10).

According to the heat exchanger of par. 1), by means of provisionally fixing the other-part-attaching member to the header, the partition member can be provisionally fixed to the header, thereby improving workability in terms of provisional fixation of the partition member to the header. Specifically, according to an ordinary work procedure, while being provisionally fixed to the header, the other-part-attaching member undergoes soldering together with the headers, the heat exchange tubes, fins, and the like, to thereby be brazed to the header. In other words, during the course of manufacture of the heat exchanger, provisional fixation of the other-part-attaching member is routine. Since the partition member is formed integral with the other-part-attaching member, provisional fixation of the other-part-attaching member is accompanied by provisional fixation of the partition member. In contrast to the heat exchanger described in Patent Document 1 which requires independent provisional fixation of the partition member, the heat exchanger of par. 1) eliminates the need of independent provisional fixation of the partition member, thereby improving workability.
The heat exchanger according to any one of pars. 2) to 10) features a reduced number of parts; thus, workability is improved during the course of manufacture thereof. Specifically, the joint member is an indispensable part of the heat exchanger, and the partition member is formed integral with the joint member. Accordingly, as compared with the case where the joint member and the partition member are formed separately from each other, the number of parts becomes fewer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view showing the overall constitution of a first embodiment of a condenser to which a heat exchanger according to the present invention is applied. FIG. 2 is an enlarged vertical section showing a portion of the condenser of FIG. 1. FIG. 3 is an exploded perspective view showing, on an enlarged scale, a portion of a middle header section and a portion of a lower header section of a first header, and an outlet-side joint member in the condenser of FIG. 1. FIG. 4 is a view equivalent to FIG. 2, showing a second embodiment of a condenser to which a heat exchanger according to the present invention is applied.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention will next be described in detail with reference to the drawings. The embodiments are implemented by applying a heat exchanger according to the present invention to a condenser of a refrigeration cycle using a chlorofluorocarbon-based refrigerant.
In the following description, the term "aluminum" encompasses aluminum alloys in addition to pure aluminum. Also, the upper, lower, left-hand, and right-hand sides of FIG. 1 will be referred to as "upper," "lower," "left," and "right," respectively. The near side of the paper on which FIG. 1 appears (the downstream side of flow of air) is referred to as the "front," and the opposite side as the "rear."
FIG. 1 shows the overall constitution of a condenser to which a heat exchanger according to the present invention is applied. FIGS. 2 and 3 show the constitution of essential portions of the condenser.
In FIG. 1, a condenser 1 includes a first header 2 and a second header 3 which are made of aluminum, are arranged apart from and in parallel with each other in the left-right direction, and extend in the vertical direction; a plurality of flat heat exchange tubes 4 which are made of aluminum and which extend between the headers 2 and 3 and are arranged at intervals in the vertical direction while having their width directed in the front-rear direction and having opposite end portions connected to the corresponding headers 2 and 3; and corrugate fins 5 which are made of aluminum and are disposed between and brazed to the adjacent heat exchange tubes 4. Side plates 6 made of aluminum are arranged externally of the respective uppermost and lowermost heat exchange tubes 4 while being spaced apart therefrom. The corrugate fin 5 is also disposed between each of the side plates 6 and each of the uppermost and lowermost heat exchange tubes 4 while being brazed thereto.
The first header 2 is partitioned into three; i.e., upper, middle, and lower, header sections 2a, 2b, and 2c, by means of a plurality of; in the present embodiment, two, plate-like partition members 7 and 8. A refrigerant inlet (refrigerant passage hole) (not shown) is formed at an upper end portion of the upper header section 2a. The three header sections 2a, 2b, and 2c of the first header 2 reduce in length in the order of 2a, 2b, and 2c. A refrigerant outlet (refrigerant passage hole) 9 is formed at an upper end portion of the lower header section 2c (see FIG. 2). The second header 3 is partitioned into two; i.e., upper and lower, header sections 3a and 3b by means of plate-like partition members in a number one fewer than the number of the partition members 7 and 8 of the first header 2; in the present embodiment, one plate-like partition member 11. Thus, the number of the header sections 3a and 3b of the second header 3 is one fewer than the number of the header sections 2a, 2b, and 2c of the first header 2. The partition member 11 of the second header 3 is located slightly below a midpoint of the height between the partition members 7 and 8 of the first header 2.
The condenser 1 has a plurality of; in the present embodiment, four, passes―first to fourth passes 12A, 12B, 12C, and 12D, which are provided in a region above the upper partition member 7 of the first header 2, a region between the upper partition member 7 of the first header 2 and the partition member 11 of the second header 3, a region between the partition member 11 of the second header 3 and the lower partition member 8 of the first header 2, and a region below the lower partition member 8 of the first header 2, respectively, and which each consist of a plurality of the heat exchange tubes 4 juxtaposed in the vertical direction. The number of the heat exchange tubes 4 constituting each of the passes 12A to 12D reduces from one longitudinal-end side of the headers 2 and 3 toward the other longitudinal-end side of the headers 2 and 3; in the present embodiment, from the upper side of the headers 2 and 3 toward the lower side of the headers 2 and 3. A refrigerant flows in the same direction through the heat exchange tubes 4 which constitute each of the passes 12A to 12D. The two adjacent passes 12A and 12B, 12B and 12C, and 12C and 12D reverse in the flow direction of the refrigerant flowing through the heat exchange tubes 4 thereof. Accordingly, a vapor-phase refrigerant which flows into the condenser 1 through the refrigerant inlet flows through the individual passes 12A to 12D in a meandering fashion and flows out in the liquid phase from the refrigerant outlet 9.
An inlet-side joint member 13 made of aluminum is brazed to an upper end portion of the upper header section 2a of the first header 2. An unillustrated refrigerant inlet pipe is connected to the inlet-side joint member 13 by use of a fixture member made of aluminum. The inlet-side joint member 13 has a refrigerant channel (not shown) communicating with the refrigerant inlet. An outlet-side joint member 14 which is made of aluminum and serves as an other-part-attaching member is brazed to the first header 2 in such a manner as to face the middle header section 2b and the lower header section 2c. An unillustrated refrigerant outlet pipe is connected to the outlet-side joint member 14 by use of a fixture member made of aluminum. The lower partition member 8 of the first header 2 is formed integral with the outlet-side joint member 14.
As shown in FIGS. 2 and 3, a refrigerant channel 15 is formed in the outlet-side joint member 14 and leads to the refrigerant outlet 9 of the lower header section 2c of the first header 2. The refrigerant channel 15 consists of a closed-bottomed first portion 15a which extends horizontally right from the left side surface of the outlet-side joint member 14 at a position slightly above the lower partition member 8, and a through-passage-like second portion 15b which is integral with a right end portion of the first portion 15a, extends obliquely downward right toward the refrigerant outlet 9, and opens at the right side surface of the outlet-side joint member 14. The opening of the second portion 15b in the right side surface of the outlet-side joint member 14 is directly connected to the refrigerant outlet 9. The lower partition member 8 formed integral with the outlet-side joint member 14 is inserted into the first header 2 through a slit 16 formed in the first header 2 and connected to the upper end of the refrigerant outlet 9, and is brazed to the first header 2.
The above-described condenser 1, a compressor, a pressure-reducing device (expansion valve), an evaporator, and a vapor-liquid separator constitute a refrigeration cycle using a chlorofluorocarbon-based refrigerant. Such a refrigeration cycle is used as, for example, a car air conditioner of a vehicle such as an automobile.
In the condenser 1, a refrigerant from the refrigerant inlet pipe flows into the upper header section 2a of the first header 2 through the refrigerant channel of the inlet-side joint member 13 and the refrigerant inlet; the refrigerant in the upper header section 2a flows into the upper header section 3a of the second header 3 through the first pass 12A; the refrigerant in the upper header section 3a flows into the middle header section 2b of the first header 2 through the second pass 12B; the refrigerant in the middle header section 2b flows into the lower header section 3b of the second header 3 through the third pass 12C; and the refrigerant in the lower header section 3b flows into the lower header section 2c of the first header 2 through the fourth pass 12D. The refrigerant in the lower header section 2c flows out to the refrigerant outlet pipe through the refrigerant outlet 9 and the refrigerant channel 15 of the outlet-side joint member 14.
FIG. 4 shows a second embodiment of a condenser to which the heat exchanger according to the present invention is applied.
In the condenser shown in FIG. 4, the slit 16 into which the lower partition member 8 of the first header 2 is inserted is formed in the lower header section 2c at a position located above and spaced apart from the refrigerant outlet 9. A refrigerant channel 21 is formed in an outlet-side joint member 20 serving as an other-part-attaching member and leads to the refrigerant outlet 9 of the lower header section 2c of the first header 2. The refrigerant channel 21 consists of a closed-bottomed first portion 21a which extends horizontally right from the left side surface of the outlet-side joint member 20 at a position slightly above the lower partition member 8, and a through-passage-like second portion 21b which is integral with a right end portion of the first portion 21a, extends downward, and opens at the lower surface of the outlet-side joint member 20. One end portion of a tubular communication member 22 made of aluminum is inserted into the second portion 21b and is brazed to the outlet-side joint member 20. The other end portion of the tubular communication member 22 is inserted into the refrigerant outlet 9 and is brazed to the first header 2. Thus, the lower end opening of the second portion 21b of the refrigerant channel 21 of the outlet-side joint member 20 communicates with the refrigerant outlet 9 via the tubular communication member 22.
Other structural features are similar to those of the condenser 1 of the previously described first embodiment. Like parts are denoted by like reference numerals, and repeated description thereof is omitted.
As in the case of the condenser 1 of the first embodiment, the condenser of the second embodiment, a compressor, a pressure-reducing device (expansion valve), an evaporator, and a vapor-liquid separator constitute a refrigeration cycle using a chlorofluorocarbon-based refrigerant. Such a refrigeration cycle is used as, for example, a car air conditioner of a vehicle such as an automobile.
In the above-described two embodiments, the heat exchanger according to the present invention is applied to a condenser of a refrigeration cycle which includes a compressor, a condenser, a pressure-reducing device (expansion valve), an evaporator, and a vapor-liquid separator and which uses a chlorofluorocarbon-based refrigerant. However, the present invention is not limited thereto. The heat exchanger according to the present invention may be used as another type of heat exchanger; for example, as a gas cooler of a refrigeration cycle which includes a compressor, a gas cooler, an evaporator, a pressure-reducing device, a vapor-liquid separator, and an intermediate heat exchanger for performing heat exchange between refrigerant flowing out from the gas cooler and refrigerant flowing out from the evaporator and which uses a supercritical refrigerant such as CO₂. This refrigeration cycle using a supercritical refrigerant is used as, for example, a car air conditioner of a vehicle such as an automobile.
In the above-described two embodiments, the lower partition member 8 of the first header 2 is formed integral with the outlet-side joint members 14 and 20. However, the present invention is not limited thereto. Another partition member 7 or 11 may be formed integral with another other-part-attaching member; for example, the inlet-side joint member 13 or an unillustrated condenser-attaching bracket.
In the above-described two embodiments, the number of the header sections 3a and 3b of the second header 3 is one fewer than the number of the header sections 2a, 2b, and 2c of the first header 2. However, the present invention is not limited thereto. The headers 2 and 3 may be partitioned into header sections in the same number by means of partition members. In this case, a refrigerant inlet is formed in one of the headers 2 and 3, and a refrigerant outlet is formed in the other one of the headers 2 and 3.

Claims

A heat exchanger comprising a pair of headers (2, 3) arranged apart from each other, and a plurality of heat exchange tubes (4) arranged between the headers (2, 3) and having opposite end portions connected to the corresponding headers (2, 3), and configured such that at least one of the headers (2, 3) is partitioned by means of at least one partition member (8) into a plurality of header sections (2a, 2b, 2c) arranged in a longitudinal direction of the header (2), the heat exchanger being characterized in that
an other-part-attaching member (14) is fixed to the header (2) which is partitioned into the plurality of header sections (2a, 2b, 2c), and the partition member (8) is formed integral with the other-part-attaching member (14).
A heat exchanger according to claim 1, wherein the other-part-attaching member (14) is a joint member (14) to which piping of a refrigeration cycle is connected, and the joint member (14) has a refrigerant channel (15) communicating with the interior of one of the header sections (2a, 2b, 2c).
A heat exchanger according to claim 2, wherein one end opening of the refrigerant channel (15) of the joint member (14) directly communicates with a refrigerant passage hole (9) formed in the header section (2c).
A heat exchanger according to claim 2, wherein one end opening of the refrigerant channel (21) of the joint member (20) and a refrigerant passage hole (9) formed in the header section (2c) communicate with each other via a tubular communication member (22).
A heat exchanger according to claim 2, wherein a first header (2) is partitioned into a plurality of header sections (2a, 2b, 2c) by means of partition members (7, 8); a second header (3) is partitioned into header sections (3a, 3b) which are provided in a number one fewer than the number of header sections (2a, 2b, 2c) of the first header (2) and which are arranged such that each faces the two adjacent header sections (2a, 2b) (2b, 2c) of the first header (2); all of the heat exchange tubes (4) are divided into a plurality of passes (12A, 12B, 12C, 12D) which are arranged in the longitudinal direction of the header (2, 3) and which each consist of a plurality of the heat exchange tubes (4); and one of the partition members (7, 8) is formed integral with the joint member (14).
A heat exchanger according to claim 2, wherein a first header (2) and a second header (3) are partitioned into respective header sections in the same number by means of partition members; the header sections (2, 3) are arranged such that at least one header section of the first header (2) faces two adjacent header sections of the second header (3) and such that at least one header section of the second header (3) faces two adjacent header sections of the first header (2); all of the heat exchange tubes (4) are divided into a plurality of passes which are arranged in the longitudinal direction of the header and which each consist of a plurality of the heat exchange tubes; and one of the partition members is formed integral with the joint member.
A heat exchanger according to claim 5 or 6, wherein a refrigerant flows in the same direction through the heat exchange tubes (4) which constitute each of the passes (12A, 12B, 12C, 12D), and the two adjacent passes (12A, 12B) (12B, 12C) (12C, 12D) reverse in the flow direction of the refrigerant flowing through the heat exchange tubes (4) thereof.
A heat exchanger according to claim 7, wherein the number of the heat exchange tubes (4) which constitute each of the passes (12A, 12B, 12C, 12D) reduces from one longitudinal-end side of the header (2, 3) toward the other longitudinal-end side of the header (2, 3).
A heat exchanger according to claim 8, wherein the partition member (8) formed integral with the joint member (14) is disposed between the pass (2c) which has the fewest number of the heat exchange tubes (4), and the pass (2b) adjacent thereto.
A heat exchanger according to claim 9, wherein the joint member is adapted to connect a refrigerant outlet pipe.
A refrigeration cycle comprising a compressor, a condenser, a pressure-reducing device, and an evaporator and using a chlorofluorocarbon-based refrigerant, wherein the condenser is a heat exchanger according to any one of claims 1 to 10.
A refrigeration cycle comprising a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between refrigerant flowing out from the gas cooler and refrigerant flowing out from the evaporator, and using a supercritical refrigerant, wherein the gas cooler is a heat exchanger according to any one of claims 1 to 10.