JP2002250596A - Method for manufacturing stacked heat exchanger - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate shift between a side plate and an outermost intermediate plate at the time of manufacturing a stacked heat exchanger. SOLUTION: A hole 322 is made at the lower flat part 32b of a side plate 3 and the flat part 32b is placed upon the outer surface at a part of the outermost intermediate plate 2A close to the lower end. Under that state, a part of the intermediate plate 2A matching the hole 322 is deformed from the inside by means of a punch P to fix both plates 2A and 3 temporarily before brazing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated heat exchanger used as, for example, an evaporator of an automotive air conditioner.

In this specification, up, down, left, and right in FIG. 1 are referred to as up, down, left, and right, and the front refers to the near side in FIG.

[0003]

2. Description of the Related Art For example, a laminated evaporator of an air conditioner for an automobile is constructed by assembling evaporator components such as two side plates, a large number of pairs of intermediate plates, and a large number of outer fins, and restraining them with a jig. Manufactured by brazing.

[0004]

As described above, the components of the evaporator are constrained by a jig during brazing as described above. However, since the side plate and the outermost intermediate plate are different in shape, the jig is not used. There was a possibility that a displacement might occur between the two plates even if the plates were restrained.

[0005] It is an object of the present invention to prevent a deviation between a side plate and an outermost intermediate plate in manufacturing a laminated heat exchanger.

[0006]

According to the first method of manufacturing a laminated heat exchanger according to the present invention, at least one of the upper and lower ends of a side plate is provided with an inner bent portion for maintaining a distance. In addition to providing a vertical flat part for polymerization, making a hole in the flat part, overlapping the flat part on the outer surface of a predetermined part of the outermost intermediate plate, and pressurizing the part corresponding to the hole in the intermediate plate from inside in this state By deforming and caulking on the inner surface of the hole, the two plates are temporarily fixed before brazing.

As described above, if a part of the intermediate plate is caulked on the inner surface of the hole formed in the overlapping flat portion of the side plate and the two plates are temporarily fixed in advance, the two plates are joined together from assembly to brazing. There is no possibility that a gap occurs between them. Therefore, according to the first method, workability at the time of manufacturing the stacked heat exchanger is improved. In addition, according to the first method, also in the obtained heat exchanger, the bonding between the side plate and the intermediate plate is improved by the amount of caulking, and the durability can be improved accordingly. Also,
In the first method, it is only necessary to caulk a part of the intermediate plate on the inner surface of the hole of the side plate. Therefore, the degree of deformation of the intermediate plate can be made relatively small. Even if it is larger, there is no problem that the thickness of the caulked portion of the intermediate plate becomes extremely thin and fluid leakage occurs. Therefore, the first method can be advantageously applied when the thickness of the side plate is larger than the thickness of the intermediate plate.

In a second method of manufacturing a laminated heat exchanger according to the present invention, a vertical flat portion for superposition is provided on at least one of the upper and lower ends of a side plate via an inwardly bent portion for maintaining a gap. It is characterized in that both parts are temporarily fixed before brazing by overlapping the part on the outer surface of the predetermined part of the outermost intermediate plate and pressing and deforming a part of these overlapping parts from the inside under pressure. It is assumed that.

If the two plates are temporarily fixed in advance by caulking a part of the overlapping portion between the side plate and the intermediate plate as described above, there is a possibility that a displacement may occur between the two plates from the assembly to the completion of brazing. Absent. Therefore, according to the second method, workability at the time of manufacturing the stacked heat exchanger is improved. In addition, according to the second method, also in the obtained heat exchanger, the bonding between the side plate and the intermediate plate is improved by the amount of caulking, and the durability can be improved accordingly. In the case of this second method, the first method
Since the degree of deformation of the intermediate plate needs to be slightly larger than that of the method described above, the method is more advantageously applied when the thickness of the side plate is smaller than the thickness of the intermediate plate.

In the first and second manufacturing methods of the stacked heat exchanger according to the present invention, the swaged portion between the side plate and the outermost intermediate plate is provided with a fluid flow path formed on the inner surface of the outermost intermediate plate. It may be provided at a location corresponding to the forming recess.

As described above, according to the first and second methods according to the present invention, even when the caulking portion is provided at a position corresponding to the fluid flow passage forming recess of the outermost intermediate plate, There is no risk of leakage.

A third method of manufacturing a laminated heat exchanger according to the present invention is characterized in that at least one of the upper and lower ends of the side plate is provided with a vertical flat portion for superimposition via an inwardly bent portion for maintaining an interval, and At the front and rear edges of the portion of the intermediate plate that overlaps with the flat portion, the locking claws are provided in the form of front and rear overhangs, and at the portion of the flat portion that enters only a predetermined distance from the front and rear edges corresponding to the base ends of both locking claws. A hole is made, the flat part is overlapped on the outer surface of the above-mentioned part of the intermediate plate, and in this state, each locking claw is turned outward and its tip is fitted into the hole, thereby temporarily fixing both plates before brazing. It is characterized by keeping.

[0013] As described above, if the locking claws of the intermediate plate are folded outward and their tips are temporarily fitted in the holes of the side plates to temporarily fix the plates in advance, the assembly claws are completed from the assembly to the completion of brazing. There is no risk of displacement between the plates. Therefore, according to the third method, workability at the time of manufacturing the stacked heat exchanger is improved.
In addition, according to the third method, also in the obtained heat exchanger, the joining property between the side plate and the intermediate plate is improved by the amount of the engagement by the engagement claws, and the durability can be improved accordingly. .

In the third method, preferably, notches are provided in front and rear edges of the flat portion of the side plate corresponding to the base ends of the both locking claws, and the notches are turned outward in these notches. The base end of the pawl is fitted. With this configuration, the base end of the folded locking claw does not protrude.

[0015]

1 to 4 show a first embodiment of the present invention.

FIG. 1 shows a laminated evaporator of an automotive air conditioner manufactured by the first method of the present invention. The stacked evaporator (1) has 16 pairs of intermediate plates (2A) (2B) and two left and right side plates (3).
, 17 outer fins (4), 16 pairs of inner fins (5) (see FIG. 2), and a refrigerant introduction pipe connecting member (6) and a refrigerant discharge pipe connecting member (6). It is manufactured by vacuum brazing while restraining with a jig or brazing in a furnace using flux. All of the above evaporator components are made of aluminum (including pure aluminum and aluminum alloy).

The intermediate plates (2A) and (2B) are made of a brazing sheet having both surfaces clad with brazing material. Evaporator
As shown in detail in FIG. 2, the outermost intermediate plate (2A) located at the left end of (1) has an inverted U-shaped refrigerant flow path forming recess (21) on its inner surface, A refrigerant introduction hole (22) is provided at the front end of the bottom surface of (21). Coolant inlet
An outer convex portion (22a) is provided on the outer edge of (22). Outermost intermediate plate (2A) located at the right end of the evaporator (1)
Although not shown in detail, like the intermediate plate (2A), has a recess for forming a refrigerant flow path, the rear end of the bottom of the recess is similar to the coolant introduction hole (22). A coolant discharge hole is provided. An outer protrusion similar to the above-mentioned outer protrusion (22a) is also provided on the outer edge of the refrigerant discharge hole. As shown in FIG. 2, the remaining 14 inner intermediate plates (2B) have, on the inner surface, concave portions (21) for forming an inverted U-shaped refrigerant flow path and front and rear ends of the concave portions (21). Consecutive front and rear header forming recesses (23)
And These inner intermediate plates (2
1) from the left of the bottom surface of the front and rear header forming recesses (23) of FIG.
The front header forming recess (2) of the 0th inner intermediate plate (2B)
Refrigerant circulation holes (24) are formed in the bottom surface excluding the bottom surface of (3) and the bottom surface of the rear header forming concave portion (23) of the twelfth inner intermediate plate (2B) from the right. In addition, the bottom surface of the front header forming recess (23) of the tenth inner middle plate (2B) from the left and the bottom surface of the rear header forming recess (23) of the twelfth inner middle plate (2B) from the right are: Before and after headers (1
2) The partition wall of (13) is formed. Refrigerant passage holes (24) in the bottom surface of the header forming recesses (23) that are overlapped with each other
One of the outer edges has an outer convex portion (24a) that is fitted into the other refrigerant passage hole (24), and when the inner intermediate plates (2B) are overlapped by these fittings, the same plate is formed. (2B) It is ensured that no deviation occurs between the two. Also, as shown in FIG. 2, each intermediate plate (2A) (2B)
A plurality of convex portions (25) for guiding the refrigerant are provided in the folded portion at the upper end of the bottom surface of the concave portion (21) for forming the refrigerant flow path.

The intermediate plates (2A) and (2B) are brazed in a state where the concave portions (21) and (23) of the pair face each other so as to face each other, so that the intermediate plates (2A) and (2B) are placed in the evaporator (1). ,
The left and right sides of the 16 inverted U-shaped refrigerant flow paths (11) are communicated with the front ends of all the refrigerant flow paths (11), and the interior is divided into two parts by a partition wall (not shown) at a position slightly closer to the left end. The front header (12) divided into two and the rear ends of all the refrigerant flow paths (11) communicate with each other, and the inside is divided into two right and left parts by a partition wall (not shown) at a position slightly closer to the right end. A rear header (13) is formed.

The both side plates (3) also consist of a brazing sheet with brazing material clad on both sides. As shown in FIGS. 1 and 2, each side plate (3) is provided with vertical overlapping flat portions (32a) and (32b) at both upper and lower ends via an inwardly bent portion (31) for maintaining spacing. ing. Upper flat part (32a)
Has a narrow upper and lower width, and is brazed on the outer surface of the upper end portion of the outermost intermediate plate (2A). The lower flat portion (32b) has a large width in the vertical direction, and is overlapped and brazed on the outer surface of the outermost intermediate plate (2A) near the lower end. A rising wall portion (321) is formed at the front and rear edges of the lower flat portion (32b) by slitting the upper side and bending outward. A plurality of swelling portions (33) extending vertically and swelling outward are formed in parallel in a middle portion of the side plate (3) and a lower flat portion (32b). .

As shown in FIG. 1 (not shown in FIG. 2), the outer fin (4) is composed of a vertical corrugated fin in which peaks and valleys are alternately continued in the vertical direction. ) (2B) are interposed between the pair and between the outermost intermediate plate (2A) and the side plate (3) and brazed to them.

As shown in FIG. 2, the inner fin (5) is composed of a vertical corrugated fin in which peaks and valleys are alternately continuous in the front-rear direction, and forms a pair of intermediate plates (2A) (2B).
Are disposed in the front and rear straight portions of the inverted U-shaped refrigerant flow path (11) formed by the above-mentioned method, and are brazed to the plates (2A) and (2B).

The refrigerant introduction pipe connecting member (6) and the refrigerant discharge pipe connecting member (6) are, as shown in FIG. 1, formed of a metal pipe having a closed rear end. On the inner surface of the refrigerant introduction pipe connecting member (6), an outer convex portion (22a) corresponding to the refrigerant introduction hole (22) of the outermost intermediate plate (2A) located at the left end and the outer edge of the hole (22) A communication hole (61) into which is inserted is provided. Similarly, a communication hole corresponding to the refrigerant discharge hole of the outermost intermediate plate (2A) located at the right end and in which the outward convex portion of the outer edge of the hole is fitted on the inner surface of the refrigerant discharge pipe connecting member (6). Is provided. These connecting members (6) are brazed to the outer surface of the lower end of the outermost intermediate plate (2A). Although not shown, a refrigerant introduction pipe is provided at a distal end of the refrigerant introduction pipe connecting member (6), and a refrigerant discharge pipe is provided at a distal end of the refrigerant discharge pipe connecting member (6). Have been.

In the above-mentioned laminated evaporator (1), FIG.
As shown in the figure, the front header passes through the refrigerant introduction pipe connecting member (6).
The refrigerant flowing into the left side section (12A) of (12) flows through the five refrigerant flow paths (11) leading to the same section (12A) in an inverted U shape from the front end to the rear end, and the rear header (13) Flow into the left compartment (13A). Next, the refrigerant flows from the left side section (13A) of the rear header (13) to the fifth to sixth refrigerant flow paths from the left among the ten refrigerant flow paths (11) leading to the same section (13A). The road (11) flows in an inverted U shape from the rear end toward the front end, and flows into the right section (12B) of the front header (12). Further, the refrigerant flows from the right side section (12B) of the front header (12) to 11 refrigerant flow paths leading to the same section.
(11) Six refrigerant channels (1 to 6 counted from the right from the right) (1
1) flows from the front end to the rear end in an inverted U shape, and the rear header (1
It flows into the right side section (13B) of 3), and flows out therefrom via the refrigerant discharge pipe connecting member (6). The refrigerant flows through these refrigerant channels (1
1) and the front and rear headers (12) and (13), while flowing in the above-described predetermined pattern, heat exchange is performed with air flowing from the front to the rear through the air passage in which the outer fin (4) is interposed. The air is cooled.

As described above, the laminated evaporator (1) assembles the components (2A), (2B), (3), (4), (5), and (6) of the evaporator and restrains them with a jig. Although it is manufactured by brazing while brazing, the present invention is characterized in that the following steps are performed before the brazing step. That is, as shown in FIG. 3, a hole (322) is made in the lower flat portion (32b) of each side plate (3), and the flat portion (32b) is located near the lower end of the outermost intermediate plate (2A). A portion matching the hole (322) in the intermediate plate (2A) in this state, more specifically, a bottom portion of the front end portion of the recess (21) for forming the refrigerant flow path in the intermediate plate (2A). Is pressed from the inside with a punch (P) and caulked to the inner surface of the hole (322), so that both plates (2A) and (3) are temporarily fixed before brazing. Accordingly, there is no possibility that the two plates (2A) and (3) are displaced from the time of assembling to the time of completion of brazing, so that the workability during the production of the evaporator is improved. In the obtained evaporator (1), the bonding between the side plate (3) and the intermediate plate (2A) is improved by the amount of caulking, and the durability is improved accordingly. FIG.
As shown in this embodiment, in this embodiment, the side plate (3)
Although the thickness of the intermediate plate (2A) is larger than the thickness of the intermediate plate (2A), as described above, since a part of the intermediate plate (2A) is caulked to the inner surface of the hole (322) of the side plate (3), the intermediate plate The degree of deformation in (2A) is relatively small. Therefore, the problem that the thickness of the swaged portion (26) of the intermediate plate (2A) becomes extremely thin and the refrigerant leaks does not occur.

FIG. 5 shows a second embodiment of the present invention. More specifically, FIG. 5 shows a method of manufacturing a laminated evaporator of an air conditioner for an automobile according to the second method of the present invention. It shows one process. Since the structure of the evaporator obtained by this method is substantially the same as that shown in FIGS. 1 and 2, detailed description and illustration are omitted.

The second embodiment differs from the first embodiment in the following points. That is, in this embodiment, as shown in FIG. 5, the lower flat portion (32b) of each side plate (3) is overlapped with the outer surface of the lower end portion of the outermost intermediate plate (2A),
Some of these overlapping sections, more specifically, the intermediate plate (2A)
The lower flat part (32b) of the bottom part of the front end of the refrigerant flow path forming concave part (21) and the corresponding side plate (2)
The plate (2A) and (3) are temporarily fixed before brazing by crimping the portion near the leading edge from inside with a punch (P). Therefore, by this caulking,
Since there is no possibility that the two plates (2A) and (3) are displaced from assembly to completion of brazing, workability in evaporator manufacturing is improved. In addition, about the obtained evaporator,
Side plate (3) and intermediate plate (2A) for caulking
And the durability is improved accordingly.
Further, as shown in FIG. 5, in this embodiment, the degree of deformation of the intermediate plate (2A) due to caulking is greater than that of the first embodiment shown in FIG. Since the thickness of (3) is smaller than the thickness of the intermediate plate (2A), there is no problem that the thickness of the swaged portion (26) of the intermediate plate (2A) becomes extremely thin and refrigerant leakage occurs. .

FIG. 6 shows a third embodiment of the present invention. More specifically, FIG. 6 shows a method for manufacturing a laminated evaporator of an automotive air conditioner according to the third method of the present invention. It shows one process. Since the structure of the evaporator obtained by this method is substantially the same as that shown in FIGS. 1 and 2, detailed description and illustration are omitted.

The third embodiment differs from the first embodiment in the following points. That is, in this embodiment, as shown in FIG. 6, the side plate in the outermost intermediate plate (2A)
(3) Locking claws (27) are provided in a projecting manner on the front and rear edges of a portion near the lower end where the lower flat portion (32b) is overlapped with the lower flat portion (32b), and both engagements in the lower flat portion (32b) of the side plate (3) are provided. A notch (323) is provided at the front and rear edges corresponding to the base end of the pawl (27), and a square hole (3
Open 24). The lower flat part (32B) is shown in FIGS.
And the front and rear widths thereof are substantially equal to the front and rear widths of the intermediate plate (2A). Then, the lower flat part (32
b) is overlapped on the outer surface of the lower portion of the intermediate plate (2A), and in this state, each locking claw (27) is folded outward, and its base end is fitted into the notch (323), and Hole part
By fitting into (324), both plates (2A) and (3) are temporarily fixed before brazing. By locking the locking claw (27) by folding, both plates are assembled from assembly to brazing.
(2A) (3) Because there is no risk of misalignment between
Workability during evaporator production is improved. Also, for the obtained evaporator, the joining property between the side plate (3) and the intermediate plate (2A) is improved by the amount of the locking by folding the locking claw (27), and the durability is improved accordingly. I have.

In the first to third embodiments, only the lower flat portion (32b) of the upper and lower flat portions (32a) (32b) of the side plate (3) is swaged or locked. Although the temporary fixing with the plate (2A) is performed, the vertical width of the upper flat portion (32a) of the side plate (3) may be wider depending on the shape of the intermediate plate (2A), In that case, the temporary fixing with the intermediate plate (2A) by caulking or locking may be performed only on the upper flat portion (32a) or on both the upper and lower flat portions (32a) (32b). Of course it is good. In the first and second embodiments, caulking is performed only at one location, but it is a matter of course that caulking may be performed at a plurality of locations.

The orientation when using the laminated evaporator (1) manufactured by the method according to the present invention is not limited to the state shown in FIG. 1
May be used in a state of being rotated 90 degrees or 180 degrees clockwise or counterclockwise around a horizontal axis extending in the front-rear direction from the state described above, that is, in a horizontal or upside down state.

[Brief description of the drawings]

FIG. 1 shows a first embodiment of the present invention,
It is an upper perspective view of the whole stack type evaporator.

FIG. 2 is a downward exploded perspective view of a part of the stacked evaporator.

FIG. 3 shows a first method of manufacturing the laminated evaporator according to the first embodiment.
4A and 4B show a process, in which FIG. 4A is an exploded perspective view in a state before temporary fixing, and FIG. 4B is a sectional view of a main part in a state after temporary fixing.

FIG. 4 is a diagram illustrating a flow of a refrigerant in a stacked evaporator according to the first embodiment.

FIG. 5 shows a method 1 of manufacturing the laminated evaporator according to the second embodiment.
4A and 4B show a process, in which FIG. 4A is an exploded perspective view in a state before temporary fixing, and FIG. 4B is a sectional view of a main part in a state after temporary fixing.

FIG. 6 shows a first method of manufacturing the laminated evaporator according to the third embodiment.
4A and 4B show a process, in which FIG. 4A is an exploded perspective view in a state before temporary fixing, and FIG.

[Explanation of symbols]

 (1): Stacked evaporator (2A): Outermost intermediate plate (21): Refrigerant channel forming recess (26): Caulked portion (3): Side plate (32b): Lower flat portion (322) : Hole (P): Punch

Claims (4)

[Claims] At least one of upper and lower ends of a side plate is provided with a vertical flat portion for superimposition via an inwardly bent portion for maintaining a gap, a hole is made in the flat portion, and the flat portion is formed at an outermost intermediate portion. Lay on the outer surface of the predetermined part of the plate,
In this state, the portion corresponding to the hole in the intermediate plate is deformed by pressurizing from the inside and caulked to the inner surface of the hole, so that both plates are temporarily fixed before brazing, a stacked heat exchanger. Manufacturing method. 2. A vertical flat portion for superimposition is provided on at least one of the upper and lower ends of the side plate via an inwardly bent portion for holding a space, and the flat portion is overlapped on a predetermined portion of an outermost intermediate plate. A method for manufacturing a laminated heat exchanger, comprising temporarily fixing both of the plates before brazing by deforming a part of the overlapped portion under pressure from the inside. 3. A caulking portion between the side plate and the outermost intermediate plate is provided at a position corresponding to a fluid flow passage forming recess formed on an inner surface of the outermost intermediate plate. Item 3. The method for producing a laminated heat exchanger according to Item 1 or 2. 4. A vertical flat portion for superimposition is provided on at least one of the upper and lower ends of the side plate via an inwardly bent portion for spacing, and the front and rear edges of a portion of the outermost intermediate plate that overlaps the flat portion. And a hole is formed in a flat portion of the flat plate at a predetermined distance from a front and rear edge portion corresponding to a base end of both locking claws, and a flat portion is formed on an outer surface of the portion of the intermediate plate. Characterized in that, in this state, each of the locking claws is folded outward, and the tips are fitted into the holes, so that both plates are temporarily fixed before brazing. Manufacturing method.