JP2007120812A - Heat exchanger and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To avoid a brazing defect of an end of a tube and a tube insertion hole rim by securing a necessary amount of brazing material in a brazing portion of the end of the tube and the tube insertion hole rim, while improving production efficiency by improving workability in insertion of the end of the tube in a tube insertion hole of a header tank. <P>SOLUTION: The header tank is composed of a header plate 15 and a tank plate. The tube insertion holes 15c, 15d larger than outline shapes of the ends of the tubes 10, 11 are formed in the header plate 15. After fitting a die 40 in an inner side of the header plate 15, the ends of the tubes 10, 11 are inserted into the tube insertion holes 15c, 15d. The tube insertion hole 15c rim of the header plate 15 is deformed toward an inner side of the tube insertion hole 15c to form a deformed part 15e, and an outer face of the tube 10 is brought into contact with the tube insertion hole 15c rim. Then, it is transferred into a furnace for brazing. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a heat exchanger used, for example, in an air conditioner mounted on an automobile.

  Conventionally, as this type of heat exchanger, there has been known a heat exchanger in which a core is constituted by a tube through which a heat exchange medium flows and heat transfer fins, and header tanks are provided at both ends of the tube of the core. (For example, refer to Patent Document 1). This heat exchanger is configured so that the heat exchange medium that has flowed into one header tank flows into the tube to exchange heat with external air, and then flows into the other header tank.

When manufacturing the heat exchanger of Patent Document 1, first, a tube insertion hole is formed in the header tank, and an end portion of the tube is inserted and held in the tube insertion hole. In this state, the whole is heated to melt the brazing filler metal on the outer surface of the header tank and the outer surface of the tube and spread it between the periphery of the tube insertion hole and the end of the tube. Then, the end of the tube is brazed to the periphery of the tube insertion hole by cooling and solidifying the brazing material.
JP 2002-103027 A

  However, in the heat exchanger in which the end of the tube is brazed to the periphery of the tube insertion hole as in Patent Document 1, the brazing material melted at the time of brazing is exchanged between the periphery of the tube insertion hole and the end of the tube. There is a demand to make these gaps small because it is necessary to spread them in between. On the other hand, when inserting the end of the tube into the tube insertion hole of the header tank before brazing, if the gap between the periphery of the tube insertion hole and the end of the tube is small, the operation of inserting the end of the tube becomes difficult. Therefore, there is a demand to increase this gap because production efficiency deteriorates. In other words, if the gap between the periphery of the tube insertion hole and the end of the tube is made large enough to improve the workability of inserting the end of the tube, the brazing material melted during brazing will be inserted into the tube. Without bracing between the hole periphery and the tube end, the brazed part between the tube end and the tube insertion hole periphery may not be blocked by the brazing material, which may cause a brazing failure. is there.

  The present invention has been made in view of such a point, and the object of the present invention is to make the workability of inserting the end of the tube with a large gap between the periphery of the tube insertion hole of the header tank and the end of the tube. In order to improve the production efficiency and improve the production efficiency, a necessary amount of brazing material can be secured at the brazed portion between the periphery of the tube insertion hole and the end portion of the tube, thereby avoiding poor brazing.

  In order to achieve the above object, according to the first aspect of the present invention, as the invention of the heat exchanger manufacturing method, after inserting the end of the tube into the tube insertion hole, the periphery of the tube insertion hole of the header tank Modified to inward.

  Specifically, the heat exchange includes a tube through which the heat exchange medium flows and a header tank to which an end of the tube is connected, and is configured to exchange heat between the heat exchange medium flowing through the tube and external air. A tube insertion hole larger than the outer shape of the end of the tube is formed in the peripheral wall portion of the header tank, and then the end of the tube is inserted into the tube insertion hole. The periphery of the tube insertion hole of the header tank is deformed inward of the tube insertion hole, and then the end of the tube is brazed to the periphery of the tube insertion hole of the header tank.

  According to this configuration, when the gap between the tube insertion hole periphery of the header tank and the end of the tube is increased, the tube insertion hole periphery of the header tank is deformed inward of the tube insertion hole after the tube is inserted. As a result, the gap between the tube insertion hole periphery and the end of the tube is narrowed so that the periphery of the tube insertion hole is brought close to the end of the tube so that the molten brazing material flows easily during brazing, or the tube insertion hole At least a part of the periphery is brought into contact with the end of the tube, so that the molten brazing material can be easily flowed during brazing. As a result, a necessary amount of brazing material is secured in the brazed portion between the periphery of the tube insertion hole and the end of the tube.

  In the invention of claim 2, in the invention of claim 1, a flat tube having a long cross-sectional shape in the external air flow direction is prepared as the tube, and the periphery of the tube insertion hole of the header tank is positioned at the end of the tube in the external air flow direction. It is set as the structure made to deform | transform toward a part.

  According to this configuration, the brazing material melted at the time of brazing flows along the end portion of the tube in the direction of external air flow and flows to the outer surface of the tube. Thereby, also in a heat exchanger using a flat tube, a necessary amount of brazing material is secured at the brazed portion between the tube insertion hole periphery and the end portion of the tube.

  According to a third aspect of the present invention, in the first or second aspect of the present invention, a tube insertion hole is formed in the half-shaped first header tank constituent member, and an end portion of the tube is formed in the tube insertion hole of the first header tank constituent member. , And after placing the mold inside the first header tank component, the periphery of the tube insertion hole of the first header tank component is deformed inward of the tube insertion hole, and then the mold is After removing from the first header tank constituent member, the header tank is constructed by combining the second header tank constituent member with the first header tank constituent member.

  According to this configuration, when the periphery of the tube insertion hole of the first header tank constituent member is deformed, the shape of the first header tank constituent member can be maintained in the mold, and the first header tank constituent member can be used. Deformation is suppressed. And a header tank is obtained by combining a 2nd header tank structural member with this 1st header tank structural member.

  According to a fourth aspect of the present invention, in any one of the first to third aspects of the present invention, after inserting tube ends into a large number of tube insertion holes formed in the header tank, the large number of tube insertion holes of the header tank. The periphery is deformed at a time inward of the tube insertion hole.

  According to this configuration, when manufacturing a heat exchanger having a large number of tubes, it is possible to reduce the man-hours required to deform the periphery of the tube insertion hole of the header tank.

  In the invention of claim 5, as a heat exchanger invention, the header tank is provided with a deformed portion in which the periphery of the tube insertion hole is deformed inward of the tube insertion hole.

  Specifically, the heat exchange includes a tube through which the heat exchange medium flows and a header tank to which an end of the tube is connected, and is configured to exchange heat between the heat exchange medium flowing through the tube and external air. The header tank is provided with a deformed portion in which the periphery of the tube insertion hole is deformed inward of the tube insertion hole, and the end of the tube is brazed to the periphery of the tube insertion hole. The configuration.

  According to this configuration, when the tube insertion hole is made larger than the outer shape of the end portion of the tube at the time of manufacturing the heat exchanger, the periphery of the tube insertion hole and the end portion of the tube are brought close to each other to braze the brazing material. Or at least a part of the periphery of the tube insertion hole is brought into contact with the end of the tube to facilitate the flow of the brazing material during brazing.

  According to the first aspect of the present invention, after inserting the end of the tube into the tube insertion hole, the periphery of the tube insertion hole of the header tank is deformed inward of the tube insertion hole. If the gap between the periphery and the end of the tube is increased to improve the insertion efficiency of the end of the tube and improve the production efficiency, the brazing portion between the periphery of the tube insertion hole and the end of the tube The required amount of brazing material can be secured, and brazing defects can be avoided.

  According to the invention of claim 2, when the tube is a flat tube, the peripheral edge of the tube insertion hole can be deformed by a simple method of deforming the peripheral edge of the tube insertion hole of the header tank toward the end of the tube in the direction of external air flow. And the end of the tube can be securely brazed over the entire circumference.

  According to the invention of claim 3, since the periphery of the tube insertion hole is deformed after the mold is arranged inside the first header tank constituent member, unnecessary deformation of the first header tank constituent member is suppressed. Thus, the header tank can be shaped as desired.

  According to the invention of claim 4, since the periphery of a large number of tube insertion holes of the header tank is deformed at a time, when manufacturing a heat exchanger having a large number of tubes, the number of manufacturing steps can be reduced and Cost can be lowered.

  According to the fifth aspect of the present invention, the header tank is provided with the deformed portion in which the periphery of the tube insertion hole is deformed inward of the tube insertion hole, so that the periphery of the tube insertion hole of the header tank and the end of the tube When the gap is made large to improve the insertion efficiency of the end portion of the tube and improve the production efficiency, it is possible to avoid poor brazing between the periphery of the tube insertion hole and the end portion of the tube.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiment is merely illustrative in nature, and is not intended to limit the present invention, its application, or its use.

  FIG. 1 shows a heat exchanger 1 according to an embodiment of the present invention. In the description of this embodiment, a case will be described in which the heat exchanger 1 is a refrigerant evaporator that constitutes one element of a refrigeration cycle of an automotive air conditioner. Although not shown, the heat exchanger 1 is disposed inside an air conditioning unit casing provided in the instrument panel of the passenger compartment.

  The heat exchanger 1 includes a core 2, first and second header tanks 3 and 4 disposed at both ends (upper and lower ends of FIG. 1), and both end portions of the core 2 (see FIG. 1 and left and right end portions).

  The core 2 is configured by alternately arranging a large number of tubes 10 and 11 (shown in FIG. 2) and fins 12 in a direction substantially perpendicular to the flow direction of the external air. Fins 12 are positioned at both left and right ends of the core 2. The core 2 includes an upstream core portion 2a positioned on the upstream side in the external air flow direction and a downstream core portion 2b positioned on the downstream side in the external air flow direction. The upstream core portion 2a is composed of the upstream tube 10 and the fins 12 arranged near the upstream side in the external air flow direction, and the downstream core portion 2b is arranged near the downstream side in the external air flow direction. The downstream tube 11 and the fin 12 are configured.

  The upstream tube 10 is a flat plate-like tube having a long cross-sectional shape in the flow direction of the external air, and is formed by extruding an aluminum alloy. The cross-sectional shape of the upstream tube 10 is substantially the same over both ends in the longitudinal direction. As shown in FIG. 3, the upstream end surface of the upstream tube 10 (indicated by arrow Y) has two slopes extending so that the upstream end surface is positioned upstream as it goes to the central portion in the thickness direction of the upstream tube 10. It is comprised by the surface 10a. These two inclined surfaces 10a are continuous at a substantially central portion in the thickness direction of the upstream tube 10, and a portion where the two inclined surfaces 10a are continuous is formed of a curved surface. The downstream end surface of the upstream tube 10 in the direction of external air flow is configured with two inclined surfaces 10b extending so as to be positioned on the downstream side toward the central portion in the thickness direction of the upstream tube 10. These inclined surfaces 10b are also continuous at a substantially central portion in the thickness direction of the upstream tube 10, and a portion where the two inclined surfaces 10b are continuous is formed of a curved surface. The upstream side and the downstream side of the inner surface of the upstream tube 10 in the direction of external air flow are formed corresponding to the inclined surfaces 10a and 10b.

  In the upstream tube 10, a plurality of partition walls 10 c formed so as to connect both side walls in the thickness direction of the upstream tube 10 are provided. These partition walls 10 c are arranged at substantially equal intervals in the direction of the external air flow of the upstream tube 10, and extend across both longitudinal ends of the upstream tube 10. In addition, on the inner surfaces of both side walls in the thickness direction of the upstream tube 10, a large number of protrusions 10 d that protrude toward the flow path R in the tube 10 and extend across both longitudinal ends of the upstream tube 10 are provided. ing. This protrusion 10d is for increasing the contact area with the refrigerant flowing through the flow path R. In this embodiment, the dimension of the upstream tube 10 in the direction of external air flow is 16.0 mm, and the dimension in the thickness direction is 2.4 mm. However, these dimensions can be freely determined depending on the use and size of the heat exchanger 1. It can be set. The downstream tube 11 is configured in the same manner as the upstream tube 10.

  As shown in FIG. 1, the fin 12 is a corrugated fin having a waveform continuous in the vertical direction when viewed in the flow direction of the external air, and is formed by forming a thin plate made of aluminum alloy clad with a brazing material. Is. The fins 12 are continuous from the upstream side to the downstream side of the external air flow of the core 2. The left end of the corrugated portion of the fin 12 is brazed to the outer surfaces of the upstream tube 10 and the downstream tube 11 adjacent to the left side, while the upstream tube 10 and the downstream tube 11 of the corrugated portion are adjacent to the right side. It is brazed to the outside of the.

  The end plate 5 is formed by press-molding a plate material made of an aluminum alloy. The left end plate 5 is brazed to the fin 12 located at the left end of the core 2. Further, the right end plate 5 is brazed to the fin 12 located at the right end of the core 2.

  As shown in FIG. 2, the first header tank 3 has a cylindrical shape that extends from the upstream side to the downstream side of the external air flow in the core 2 and extends in the vicinity of both ends in the arrangement direction of the tubes 10 and 11 and the fins 12. Is formed. The first header tank 3 includes a half-shaped first header plate 15 constituting the lower half of the first header tank 3 and a half-shaped first tank plate 16 constituting the upper half. ing. The first header plate 15 is a first header tank constituent member of the present invention, and the first tank plate 16 is a second header tank constituent member of the present invention.

  The first header plate 15 is formed by press-molding an aluminum alloy plate material clad with a brazing material into a channel shape that opens upward. The first header plate 15 includes a core side wall portion 15a formed so as to extend in the left-right direction along the upper end portion of the core 2, and a pair that rises upward from the upstream side and the downstream side of the external air flow of the core side wall portion 15a. Side wall portion 15b.

  As shown in FIG. 4, a number of upstream tube insertion holes 15 c into which end portions of the upstream tube 10 are inserted are formed on the upstream side of the core side wall portion 15 a so as to correspond to the interval between the tubes 10. Has been. The upstream tube insertion hole 15 c is configured by a slit that extends in the external air flow direction corresponding to the outer shape of the upstream tube 10. In this embodiment, the dimension of the upstream tube insertion hole 15c in the external air flow direction is 16.1 mm and the dimension in the thickness direction is 2.5 mm. However, these dimensions depend on the use and size of the heat exchanger 1. It can be set freely.

  Since the dimensions of the upstream tube 10 and the upstream tube insertion hole 15c are set as described above, as shown in FIG. 3, between the end of the upstream tube 10 and the peripheral edge of the upstream tube insertion hole 15c. A gap S is formed. This gap S is for improving the workability of inserting the end of the upstream tube 10 into the upstream tube insertion hole 15c, and can be freely set according to the above dimensions.

  Also, as shown in FIGS. 1 and 3, the first header plate 15 is deformed so as to be recessed toward the inner side of the upstream tube insertion hole 15c at the periphery of each upstream tube insertion hole 15c. A portion 15e is provided. The first deforming portion 15e is formed after the upstream tube 10 is inserted, and is provided only at a portion corresponding to the substantially central portion in the tube 10 thickness direction on the upstream side end surface of the upstream air flow of the upstream tube 10. ing. By providing the first deforming portion 15e, both ends of the external air flow of the upstream tube 10 and the peripheral edge of the upstream tube insertion hole 15c are brought into contact with each other.

  In addition, a large number of downstream tube insertion holes 15d into which the end portions of the downstream tubes 11 are inserted are formed on the downstream side of the core side wall portion 15a in the same manner as the upstream tube insertion holes 15c.

  The first tank plate 16 is formed by press-molding an aluminum alloy plate material clad with a brazing material into a channel shape that opens downward. As shown in FIG. 2, the first tank plate 16 includes an upper wall portion 16a and a pair of side wall portions 16b extending downward from the upstream side and the downstream side of the external air flow of the upper wall portion 16a. The pair of side wall portions 16b is disposed between the side wall portions 15c of the first header plate 15 and brazed to the inner surface of the side wall portion 15c.

  A partition plate 19 is provided inside the first header tank 3 at a substantially central portion in the external air flow direction. The partition plate 19 extends across the left and right ends of the first header tank 3 and partitions the inside of the first header tank 3 into an upstream side and a downstream side in the external air flow direction.

  A plate-like first closing member 20 that closes the openings at both ends is fitted into the left and right ends of the first header tank 3. The first closing member 20 is brazed to the first header plate 15 and the first tank plate 16. A refrigerant supply pipe 21 is attached to the left first closing member 20 on the downstream side of the external air flow, and a refrigerant discharge pipe 22 is attached to the upstream side. The refrigerant supply pipe 21 communicates with a space on the downstream side of the external air flow of the first header tank 3, and an expansion valve block that incorporates an expansion valve (not shown) on the refrigerant flow upstream side of the refrigerant supply pipe 21. Is connected. The refrigerant discharge pipe 22 communicates with the space on the upstream side of the external air flow of the first header tank 3.

  The second header tank 4 is configured in the same manner as the first header tank 3. That is, as shown in FIGS. 1 and 2, the second header tank 4 includes a second header plate 24, a second tank plate 25, and a second closing member 26 that closes the openings at the left and right ends. A second deforming portion 24e is provided on the periphery of the upstream side tube insertion hole 24c of the second header plate 24. The second header tank 4 is not provided with a partition plate.

  Next, the case where external air is cooled with the heat exchanger 1 comprised as mentioned above is demonstrated. First, the flow of the refrigerant in the heat exchanger 1 will be described. The refrigerant that has expanded through the expansion valve block flows into the space on the downstream side of the external air flow of the first header tank 3 from the refrigerant supply pipe 21. The refrigerant flowing into the downstream space flows into the downstream tube 11, flows downward, and flows into the second header tank 4. The refrigerant flowing into the second header tank 4 moves to the upstream side of the external air flow in the second header tank 4, flows into the upstream tube 10, flows upward, and flows to the external air flow of the first header tank 3. It flows into the upstream space. The refrigerant flowing into the upstream space is discharged from the refrigerant discharge pipe 22 to the outside.

  On the other hand, the external air is cooled by the tubes 10 and 11 and the fins 12 when passing through the core 2. At this time, condensed water is generated on the outer surfaces of the tubes 10 and 11 and the surfaces of the fins 12. The condensed water flows downward through the tubes 10 and 11 and the fins 12 and is drained.

  Next, the case where the heat exchanger 1 comprised as mentioned above is manufactured is demonstrated. First, the first header plate 15 and the second header plate 24 are formed. The first and second header plates 15 and 24 are provided with upstream tube insertion holes 15c and 24c and a downstream tube insertion hole 15d.

  On the other hand, the tubes 10 and 11 and the fins 12 are alternately arranged to constitute the core 2, and the end plates 5 are arranged on the left and right ends of the core 2 so that the tubes 10, 11, the fins 12 and the end plate 5 are bound together. Bundled by (not shown). Further, the first tank plate 16 and the second tank plate 25 are also formed. In addition, the order of the process of shape | molding the 1st header plate 15 and the 2nd header plate 24, the process of comprising the core 2, and the process of shape | molding the 1st dunk plate 16 and the 2nd tank plate 25 may be arbitrary.

  Next, as shown in FIGS. 5 and 6, the first header plate 15 is attached to the first mold 40 and the second header plate 24 is attached to the second mold 41. The first mold 40 includes a fitting portion 40a having a shape that fits inside the first header plate 15 and a gripping portion 40b. The fitting part 40a is formed in a prismatic shape. In a state where the first header plate 15 is fitted into the fitting portion 40a, both longitudinal ends of the fitting portion 40a protrude outward from the left and right ends of the first header plate 15, respectively. The gripping part 40 b side also protrudes from the open part of the first header plate 15. As shown in FIG. 4, the fitting portion 40a is provided with a deformed portion forming surface 40c, which is a concave surface for forming the first deformable portion 15e, corresponding to the location where the first deformable portion 15e is formed. ing. A concave surface 40d having the same shape as the deformed portion molding surface 40c is provided on the opposite side of the fitting portion 40a from the deformed portion forming surface 40c. A groove 40e is formed in a portion of the fitting portion 40a corresponding to the end portions of the tubes 10 and 11 so as to escape the end portions. Moreover, the said holding | grip part 40b is formed in the column shape larger than the fitting part 40a. The second mold 41 has the same structure as the first mold 40, and includes a fitting portion 41a, a gripping portion 41b, a deformed portion molding surface (not shown), a concave surface (not shown), and a groove (not shown). It has.

  While attaching the first header plate 15 to the first mold 40 and attaching the second header plate 24 to the second mold 41, the core 2 is fixed so as not to move. The mold 2 41 is moved, and as shown in FIGS. 7 and 8, the end portions of the upstream tube 10 and the downstream tube 11 are inserted into the upstream tube insertion holes 15c and 24c and the downstream tube insertion hole 15d, respectively. . At this time, since the clearance S between the upstream tube insertion holes 15c, 24c and the end of the upstream tube 10 is sufficiently secured, the insertion operation is easy. The same applies when the end of the downstream tube 11 is inserted. The core 2, the first header plate 15 and the second header plate 24 are arranged so that the upstream side of the external air flow is on the upper side.

  Next, as shown in FIGS. 4 and 8, the first deforming portion 15 e is formed on the first header plate 15 using the first forming tool 45, and the second forming tool 46 is used on the second header plate 24. A second deformation portion 24e is formed. The first forming tool 45 includes a columnar base portion 45a and a protruding portion 45b protruding from the base portion 45a. The protrusions 45b are for pressing the peripheral edge of the upstream tube insertion hole 15c to form the first deformable portions 15e, and are provided at a large number of intervals corresponding to the number of the first deformable portions 15e. . The tip shape of the protrusion 45d is formed substantially the same as the tip shape of the minus driver. The tip positions of these protrusions 45b are aligned so as to be positioned on substantially the same plane.

  The base portion 45 a has a shape that is long in the left-right direction of the first header plate 15. The first forming tool 45 is arranged with the tip of the projecting portion 45b facing downward, and in this state, the base portion 45a is attached to an advancing / retreating drive device (not shown). This advance / retreat drive is configured to move the first forming tool 45 in the vertical direction. In addition, the 2nd shaping | molding tool 46 is the same structure as the 1st shaping | molding tool 45, and is provided with the base 46a and many protrusion parts 46b.

  When the first deforming portion 15e is formed on the first header plate 15, as shown in FIG. 4 (a), the first header plate is located directly below each protruding portion 45b of the raised first forming tool 45. 15, the formation location of the first deformable portion 15 e is positioned. Then, as shown in FIG. 4B, the first forming tool 45 is moved downward by the advance / retreat driving device to strongly press the tip of the projecting portion 45b against the place where the first deformable portion 15e is formed, and then FIG. As shown in c), it is separated from the formation site. Thereby, many 1st deformation | transformation parts 15e are formed at once. When the first deforming portion 15e is formed, the second forming tool 46 is moved by the advance / retreat driving device to simultaneously form the second deforming portion 24e. By forming the first deformation portion 15e and the second deformation portion 24e, both ends of the upstream tube 10 in the external air flow direction come into contact with the peripheral edges of the upstream tube insertion holes 15c and 24c, as shown in FIG.

  When the first and second deforming portions 15e and 24e are formed, downward force from the first and second forming tools 45 and 46 acts on the first and second header plates 15 and 24. At this time, since the shapes of the first and second header plates 15 and 24 are maintained by the first and second molds 40 and 41, unnecessary deformation is suppressed.

  Then, the first mold 40 is removed from the first header plate 15, and the second mold 41 is removed from the second header plate 24. The first tank plate 16 is assembled to the first header plate 15, and the first closing member 20 is further assembled. The second tank plate 25 and the second closing member 26 are also assembled to the second header plate 24.

  Thereafter, the core 2, the first header tank 3 and the second header tank 4 are integrated, and the upstream tube 10 is placed on the upper side and conveyed into a brazing furnace (not shown). In this furnace, the brazing material of each part melts. At this time, since both ends of the upstream tube 10 in the external air flow direction are in contact with the peripheral edge of the upstream tube insertion hole 15c, the brazing material clad on the first header plate 15 is removed from the upstream tube 10 from this contact portion. Flowing on the outside. As a result, a necessary amount of brazing material is secured in the brazed portion between the peripheral edge of the upstream tube insertion hole 15 c and the end of the upstream tube 10. At the time of brazing, since the downstream tube 11 is positioned below the upstream tube 10, a sufficient amount of brazing material flows on the outer surface of the downstream tube 11 from above. Therefore, it is possible to secure a necessary amount of brazing material at the brazed portion between the peripheral edge of the downstream tube insertion hole 15d and the end of the downstream tube 11 without forming the deformed portions 15e and 24e as described above. It has become.

  As described above, in this embodiment, after inserting the end portion of the upstream tube 10 into the upstream tube insertion holes 15c and 24c, the peripheral edges of the upstream tube insertion holes 15c and 24c of the header tanks 3 and 4 are connected to the tube. Since the insertion holes 15c and 24c are deformed inwardly, the gap S between the peripheral edge of the tube insertion holes 15c and 24c and the end of the upstream tube 10 is made large so that the workability of inserting the end of the tube 10 is good. In the case where the production efficiency is improved, it is possible to avoid poor brazing between the periphery of the tube insertion holes 15c, 24c and the end of the tube 10.

  Moreover, since the brazing failure can be avoided by a simple method of deforming a part of the peripheral edge of the upstream tube insertion holes 15c, 24c in this way, the manufacturing cost can be reduced.

  In addition, since the first and second molds 40 and 41 are disposed inside the first and second header plates 15 and 24, the first and second deformable portions 15e and 24e are formed. Unnecessary deformation of the second header plates 15, 24 can be suppressed, and the first and second header tanks 3, 4 can be made to have the desired shapes.

  Further, since the first and second deformable portions 15e and 24e are formed at a time, the number of manufacturing steps can be reduced and the manufacturing cost can be reduced.

  In this embodiment, the first and second deformable portions 15e and 24e are formed so that both ends of the upstream tube 10 in the external air flow direction are brought into contact with the peripheral edges of the upstream tube insertion holes 15c and 24c. However, a gap S narrower than the gap immediately after insertion may be formed between the upstream tube 10 and the upstream tube insertion holes 15c, 24c without contacting them. In this case, the molten brazing material easily flows from the portion where the gap S is narrow to the outer surface of the upstream tube 10, and joins the peripheral edge of the upstream tube insertion holes 15 c and 24 c and the end of the upstream tube 10. Necessary amount of brazing material can be secured in the attachment part.

  Further, in this embodiment, since the upstream side tube 10 is placed on the upper side and conveyed into the furnace, the first and second deformations are formed at the upstream air flow upstream end of the peripheral edge of the upstream side tube insertion holes 15c and 24c. On the contrary, when the tube is transported into the furnace with the downstream tube 11 on the upper side, the downstream end of the external air flow around the periphery of the downstream tube insertion hole 15d is formed. What is necessary is just to make it form a 1st and 2nd deformation | transformation part in a part.

  Moreover, you may make it form the 1st deformation | transformation part 15e and the 2nd deformation | transformation part 24e one by one, without forming at once.

  Moreover, although this embodiment demonstrated the case where the tubes 10 and 11 were arrange | positioned 2 rows by the external air flow upstream and downstream, this invention is like the modification shown to FIG. The present invention can also be applied to a case where the tubes 50 are in a single row. The header tank 51 of this modification is formed by forming an aluminum alloy plate into a cylindrical shape. As shown in FIG. 10, both end surfaces of the tube 50 in the direction of external air flow are arcuate surfaces. A deformed portion 51b is formed at the outer air flow upstream end of the periphery of the tube insertion hole 51a of the header tank 51. When manufacturing the heat exchanger 1 of this modification, as shown in FIG. 9, after inserting the end of the tube 50 into the tube insertion hole 51a of the header tank 51, the protrusion 45b of the first forming tool 45 is inserted. Thus, the deformed portion 51b is formed.

  Further, the upstream tube 10 and the upstream tube insertion hole 15c have a clearance S between the end of the upstream tube 10 and the peripheral edge of the upstream tube insertion hole 15c, for example, 0.03 mm or more and 0.30 mm or less. Each dimension is preferably set. By ensuring the clearance S of 0.03 mm or more, the upstream tube 10 can be inserted easily. If the clearance S is too wide, the upstream tube 10 and the upstream tube insertion hole 15c are inserted. Although it is conceivable that the brazing material will be cut, it is possible to prevent the brazing material from being cut by setting the gap S to 0.30 mm or less, and brazing can be ensured.

  Moreover, although this embodiment demonstrated the case where the heat exchanger 1 was a refrigerant | coolant evaporator, this invention can be applied to various heat exchangers, such as a refrigerant condenser and a radiator of a vehicle.

  As described above, the method for manufacturing a heat exchanger according to the present invention is suitable for manufacturing, for example, a heat exchanger for an air conditioner mounted on an automobile.

It is the figure which looked at the heat exchanger which concerns on embodiment of this invention from the external air flow downstream. It is a left view of a heat exchanger. It is the figure which looked at the 1st header tank of the state where the tube was inserted in the tube insertion hole from the core side. FIG. 8 is a cross-sectional view taken along line AA in FIG. 7, (a) shows a state where a tube is inserted into the tube insertion hole, and (b) moves the first forming tool downward to form a first deforming portion. (C) is a figure which shows the state which moved the 1st shaping | molding tool upwards. FIG. 2 is a view corresponding to FIG. 1 showing a state in which the first and second header plates are fitted to the first and second molds and arranged on both sides of the core. FIG. 3 is a view corresponding to FIG. 2 showing a state in which the first and second header plates are fitted to the first and second molds and arranged on both sides of the core. It is FIG. 1 equivalent view of the state which inserted the tube in the tube insertion hole, and formed the deformation | transformation part. FIG. 3 is a view corresponding to FIG. 2 immediately after forming a deformed portion by inserting a tube into the tube insertion hole. FIG. 6 is a view corresponding to FIG. 4 according to a modification of the embodiment. FIG. 4 is a view corresponding to FIG. 3 according to a modification of the embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Heat exchanger 2 Core 3 1st header tank 10 Upstream tube 11 Downstream tube 12 Fin 15 1st header plate (1st header tank structural member)
15c Tube insertion hole 15d Tube insertion hole 15e Deformation part 16 2nd tank plate (2nd header tank structural member)
40 Type 1

Claims (5)

A heat exchanger manufacturing method comprising a tube through which a heat exchange medium flows and a header tank to which an end of the tube is connected, and configured to exchange heat between the heat exchange medium flowing through the tube and external air. There,
A tube insertion hole larger than the outer shape of the end of the tube is formed in the peripheral wall of the header tank,
Next, the end of the tube is inserted into the tube insertion hole,
Thereafter, the periphery of the tube insertion hole of the header tank is deformed inward of the tube insertion hole,
Thereafter, the end of the tube is brazed to the periphery of the tube insertion hole of the header tank. In the manufacturing method of the heat exchanger of Claim 1,
As a tube, prepare a flat tube having a long cross-sectional shape in the external air flow direction,
A method of manufacturing a heat exchanger, wherein the periphery of a tube insertion hole of a header tank is deformed toward an end of the tube in the direction of external air flow. In the manufacturing method of the heat exchanger of Claim 1 or 2,
A tube insertion hole is formed in the halved first header tank component,
After inserting the end of the tube into the tube insertion hole of the first header tank constituent member and arranging the mold inside the first header tank constituent member, the periphery of the tube insertion hole of the first header tank constituent member is Deform inward of the tube insertion hole,
Then, after removing the said mold from the said 1st header tank structural member, it combines the 2nd header tank structural member with the said 1st header tank structural member, and comprises a header tank, The manufacturing method of the heat exchanger characterized by the above-mentioned . In the manufacturing method of the heat exchanger as described in any one of Claim 1 to 3,
After inserting the end of each tube into a number of tube insertion holes formed in the header tank,
A method of manufacturing a heat exchanger, wherein the periphery of a plurality of tube insertion holes of the header tank is deformed at a time inward of the tube insertion holes. A heat exchanger comprising a tube through which a heat exchange medium flows and a header tank to which an end of the tube is connected, and configured to exchange heat between the heat exchange medium flowing through the tube and external air,
The header tank is provided with a deformed portion in which the periphery of the tube insertion hole is deformed inward of the tube insertion hole,
An end of the tube is brazed to the periphery of the tube insertion hole.

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