JP2007240104A - Intercooler structure and manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an itnercooler capable of improving cooling performance while preventing fatigue breakage of a radiator tube. <P>SOLUTION: This intercooler 1 for cooling air supercharged and raised in temperature including a pair of tanks 10 and 20 and a radiator tube 30 mutually connecting the tanks 10 comprises insert holes 121a and 221a for inserting the radiator tube 30, formed in the tanks 10 and 20; connection parts 61 and 62 connecting the inserted radiator tube 30 to the tanks 10 and 20 by brazing; and resin parts 14 and 24 formed on the connection parts 61 and 62, which are fluid when charged, and hardened with the lapse of time to enhance the fixing force of the radiator tube 30 to the tanks 10 and 20. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a structure of an intercooler and a manufacturing method thereof.

  The temperature of air supercharged by a turbocharger such as a turbocharger rises during the compression process. Since the combustion characteristics deteriorate when the air temperature rises excessively, a technique for increasing the air charging efficiency by reducing the air temperature with an air-cooled or water-cooled intercooler is widely known.

Patent Document 1 discloses an intercooler in which a plurality of partition plates having vent holes are arranged inside a tank. Thereby, in the intercooler described in Patent Document 1, noise when air flows into the tank can be reduced, and the mechanical strength of the header tank itself can be improved.
Japanese Utility Model Publication No. 6-012390

  However, in the device described in Patent Document 1, even if the mechanical strength of the tank can be improved by the partition plate, the cooling performance of the intercooler cannot be improved. The supercharger changes suddenly from a substantially stopped state to a high supercharged state according to the operating state of the engine. For this reason, the pressure change of the air sent to an intercooler becomes large, and a vibration and a stress generate | occur | produce in an intercooler resulting from this air pressure change. In the conventional intercooler, there is a problem that the heat radiating tube is fatigued by this vibration and stress.

  Therefore, an object of the present invention is to provide an intercooler that can prevent fatigue destruction of a heat radiating tube and improve cooling performance.

  The present invention is an intercooler that includes a pair of tanks and a heat radiating pipe that communicates with the tanks, and cools the air that has been supercharged to raise the temperature, and is formed in the tank and has an insertion hole into which the heat radiating pipe is inserted. And a connecting part for connecting the inserted heat radiating pipe to the tank by brazing, and formed at the connecting part, which has fluidity when filled, and hardens with the passage of time, increasing the fixing force of the heat radiating pipe to the tank A resin portion.

  In the intercooler of the present invention, the connecting portion of the heat radiating tube is fixed not only by brazing but also by a resin portion. Therefore, the vibration and stress of the intercooler resulting from the pressure of the supercharged air can be reduced. This makes it possible to prevent the heat radiating tube from being fatigued.

  Moreover, since the stress generated in the vicinity of the connection portion of the heat radiating tube is reduced, the wall of the heat radiating tube of the intercooler can be made thin. Thereby, the cooling efficiency of the heat radiating pipe is increased, and the cooling performance of the intercooler can be improved.

(First embodiment)
Hereinafter, a first embodiment will be described with reference to the drawings.

  FIG. 1 is an external view showing a first embodiment of an intercooler according to the present invention. 1A is a front view, FIG. 1B is a right side view, and FIG. 1C is a bottom view.

  The intercooler 1 includes a pair of tanks 10 and 20, a heat radiating pipe 30, and fins 40. Air heated to high temperature by a turbocharger or the like flows from the upper tank 10 of the intercooler 1 through the heat radiating pipe 30, is cooled when passing through the heat radiating pipe 30, and reaches the lower tank 20.

  The upper tank 10 includes a tank body 11 and a tank lid portion 12. An inflow pipe 51 is formed on the side of the tank body 11. The supercharged air flows from the inflow pipe 51 into the upper tank 10. An insertion hole 121 a for inserting the heat radiating pipe 30 is formed in the tank lid portion 12 of the upper tank 10.

  The lower tank 20 has the same configuration as the upper tank 10. The lower tank 20 includes a tank body 21 and a tank lid portion 22. An outflow pipe 52 is formed on the side of the tank body 21. The outflow pipe 52 is formed on the side opposite to the inflow pipe 51 (right side in the drawing in the present embodiment). The outflow pipe 52 allows air that has flowed into the lower tank 20 from the heat radiating pipe 30 to flow into an intake manifold (not shown). In addition, an insertion hole 221a for inserting the heat radiating pipe 30 is formed in the tank lid portion 22 of the lower tank 20.

  Details of the configuration of the tank lid portions 12 and 22 of the upper tank 10 and the lower tank 20 will be described later.

  A plurality of the heat radiating tubes 30 are provided between the pair of tanks 10 and 20. In the first embodiment, for ease of explanation, a case where the number of the radiating tubes 30 is six is illustrated. The heat radiating pipe 30 is inserted into the insertion holes 121a and 221a formed in the tank lid portions 12 and 22 of the upper tank 10 and the lower tank 20 at equal intervals. The heat radiating pipe 30 is brazed between the insertion holes 121a and 221a in order to keep the inside of the upper tank 10 and the lower tank 20 airtight.

  The fins 40 are formed between the adjacent heat radiating pipes 30 and brazed along the side surfaces of the heat radiating pipes 30. The fin 40 is, for example, a corrugated fin. And the fin 40 transfers the heat | fever of the high temperature air which flows through the thermal radiation pipe 30, and radiates it.

  FIG. 2 is a cross-sectional view showing the internal structure of the intercooler 1.

  The tank lid portion 12 of the upper tank 10 is press-molded, and a convex portion 122 is formed around the flat surface portion 121 (an insertion surface on which the insertion hole 121a of the heat radiating tube 30 is formed). In the flat portion 121, insertion holes 121a for inserting the heat radiating tube 30 are drilled at equal intervals. Further, a sealing material 13 for keeping the upper tank 10 airtight is inserted inside the convex portion 122 of the tank lid portion 12. The upper tank 10 is formed by fitting the tank lid portion 12 to the tank body 11.

  The tank lid portion 22 of the lower tank 20 has the same structure as the tank lid portion 12. The tank lid portion 22 of the lower tank is press-molded, and a convex portion 222 is formed around the flat portion 221 (insertion surface on which the insertion hole 221a of the heat radiating tube 30 is formed). In the flat part 221, insertion holes 221a for inserting the heat radiating tube 30 are formed at equal intervals. Further, a sealing material 23 for keeping the airtightness of the lower tank 20 is inserted inside the convex portion 222. The lower tank 20 is formed by fitting the tank lid portion 22 to the tank body 21.

  The heat radiating pipe 30 is inserted into the insertion holes 121 a and 221 a of the tank lid portions 12 and 22 of the upper tank 10 and the lower tank 20. The heat radiating pipe 30 is brazed to the tank lid parts 12 and 22 by connection parts 61 and 62 in order to keep the inside of the upper tank 10 and the lower tank 20 airtight. Then, the fillers 14 and 24 are filled to a height substantially equal to the upper surface of the convex portions 122 and 222 of the tank lid portions 12 and 22. These fillers 14 and 24 contain, for example, metal powder, are made of an epoxy resin material having fluidity, and are cured when a predetermined time elapses. In this way, the heat radiating pipe 30 is fixed to the tank lid portions 12 and 22.

  Such an intercooler 1 is manufactured as follows.

  First, the tank lids 12 and 22 including the flat portions 121 and 221 and the convex portions 122 and 222 for preventing the filler from flowing out are fitted to the tank bodies 11 and 21 to fit the pair of tanks 10 and 20. Form. And the thermal radiation pipe | tube 30 is inserted in the insertion holes 121a and 221a of the plane parts 121 and 221 of the tank cover parts 12 and 22 so that it may communicate with this tank 10 and 20 (insertion process).

  The heat radiating pipe 30 is brazed by the insertion holes 121a and 221a of the flat portions 121 and 221 of the tank lid portions 12 and 22 (a brazing step). Further, the fins 40 are installed by brazing between the adjacent heat radiating tubes 30.

  In this way, after the intercooler 1 is manufactured, the filling material 24 is filled into the tank lid portion 22 on the side where the convex portion 222 of the lower tank 20 is formed (filling step). After the filler 24 is cured, the filling material 14 is filled into the tank lid portion 12 on the side where the convex portion 122 of the upper tank 10 is formed and is cured (a filling step).

  Next, the operation of the intercooler 1 of the first embodiment will be described.

  Air that has been supercharged by a turbocharger or the like and heated to high temperature flows into the upper tank 10 through an inflow pipe 51 connected to the tank body 11. The air that has flowed into the upper tank 10 flows into a plurality of heat radiating pipes 30 that communicate with the upper tank 10. The heat radiating pipe 30 is cooled by the fins 40 that are cooled by the outside air that flows when the vehicle travels. Therefore, the high-temperature air flowing through the heat radiating pipe 30 is cooled by heat exchange when passing through the heat radiating pipe 30.

  The air cooled by the heat radiating pipe 30 flows into the lower tank 20. The air flowing into the lower tank 20 passes through an outflow pipe 52 connected to the tank body 21, is guided to an intake manifold (not shown), and is supplied to the engine.

  In the intercooler 1, the air inside the lower tank 20 becomes cooler than the air inside the upper tank 10, and the air charging efficiency is increased. Therefore, the internal pressure of the lower tank 20 is lower than the internal pressure of the upper tank 10. Further, a large amount of air that has flowed into the upper tank 10 flows into the heat radiating pipe 30 on the side close to the inflow pipe 51. Therefore, the internal pressure received by the upper tank 10 by the supercharged air decreases as the distance from the inflow pipe 51 increases. In the lower tank 20, the air flowing out from the respective heat radiating pipes 30 concentrates on the outflow pipes 52, so that the internal pressure received by the lower tank 20 increases as it approaches the outflow pipes 52. Thus, in the intercooler 1, the pressure received by the constituent members such as the upper tank 10, the lower tank 20, and the heat radiating pipe 30 due to the supercharged air becomes uneven.

  Further, the supercharger changes suddenly from a substantially stopped state to a high supercharged state according to the operating state of the engine. For this reason, the pressure change of the air sent to an intercooler becomes large. Due to this change in air pressure, vibration is generated in the intercooler.

  Stress is generated in the intercooler 1 due to this non-uniform pressure and vibration. That is, in FIG. 1A, stress is generated in the direction in which the upper tank 10 and the lower tank 20 of the intercooler 1 are twisted, and in FIG. 1B, the upper tank 10 and the lower tank 20 are the same. Stress is generated to bend in the direction. Further, in FIG. 1C, stress is generated so that both ends of the upper and lower tanks 10 and 20 themselves bend.

  FIG. 7 is an enlarged schematic view of the vicinity of the connection portion 62 of the heat radiating pipe 30 on the lower tank 20 side in the conventional intercooler 1.

  In the conventional intercooler 1, the heat radiating pipe 30 penetrates the tank lid portion 22 and is brazed by the insertion hole 221a. As shown in FIG. 7, the connecting portion 62 to which the heat radiating tube 2 is brazed has an acute angle shape. Therefore, the stress generated by the deformation of the intercooler 1 tends to concentrate. Therefore, in the conventional intercooler 1, if stress is repeatedly input, the heat radiating tube 30 may be fatigued near the connection portion 62.

  Therefore, in the intercooler 1 of the present invention, not only the heat radiating pipe 30 is brazed to the tank lid parts 12 and 22 by the connection parts 61 and 62 but also the vicinity of the connection parts 62 and 62 of the heat radiating pipe 30 is filled with the filler 14 and 24 to fix.

  FIG. 3A is an enlarged schematic view of the vicinity of the connecting portion 62 of the heat radiating pipe 30 on the lower tank 20 side in the first embodiment of the intercooler 1. FIG. 3B is a schematic diagram showing a BB cross section in FIG. The structure of the connection portion 61 of the heat radiating pipe 30 on the upper tank 10 side is the same as that of the connection portion 62 of the heat radiating pipe 30 on the lower tank 20 side, and therefore the description thereof is omitted.

  As shown in FIG. 3A, the heat radiating pipe 30 penetrates the tank lid portion 22 and is brazed by the insertion hole 221a. In addition, the tank lid portion 22 is filled with the filler 24 to a height approximately equal to the upper surface of the convex portion 222 of the tank lid portion 22. The filler 24 hardens when a predetermined time elapses after being filled, and fixes the vicinity of the connection portion 62 of the heat radiating tube 30.

  As shown in FIGS. 3A and 3B, the filler 24 is filled up to the connecting portion 62 of the heat radiating pipe 30 and the gap between the adjacent heat radiating pipes 30. Therefore, in order to uniformly fill the tank lid 22 with the filler 24, it is desirable to use a filler having a viscosity of 20 Pa · s or less.

  Thus, by fixing the vicinity of the connection portion 62 of the heat radiating tube 30 with the fillers 14 and 24, twisting and deflection due to the stress generated in the intercooler 1 are suppressed. In addition, since the elastic modulus of the cured fillers 14 and 24 is smaller than that of iron, aluminum, or the like, even if stress occurs in the intercooler 1, the stress is concentrated in the vicinity of the connection portion 62 of the heat radiating tube 30. To ease.

  As described above, the following effects can be obtained in the first embodiment.

  In the intercooler 1 of the first embodiment, the connecting portions 61 and 62 of the heat radiating pipe 30 are not only brazed but also fixed by the fillers 14 and 24. Therefore, it is possible to reduce vibration and stress generated in the intercooler 1 due to the pressure of the supercharged air. Further, since the elastic modulus of the cured fillers 14 and 24 is smaller than that of aluminum or the like, it is possible to alleviate stress concentration on the connection portions 61 and 62 of the heat radiating tube 30. Thereby, the stress concentrated on the vicinity of the connection parts 61 and 62 of the heat radiating tube 30 is reduced, and the heat radiating tube 30 can prevent fatigue failure.

  Moreover, since the stress which arises in the vicinity of the connection parts 61 and 62 of the heat radiating tube 30 is reduced and fatigue failure of the heat radiating tube 30 is suppressed, the tube wall of the heat radiating tube 30 of the intercooler 1 can be made thinner. Thereby, the cooling efficiency of the heat radiating tube 30 can be increased, and the cooling performance of the intercooler 1 can be improved.

(Second Embodiment)
FIG. 4 is a schematic diagram showing a second embodiment of the intercooler 1. FIG. 4A is an enlarged schematic view of the vicinity of the connection portion 62 of the heat radiating pipe 30 on the lower tank 20 side. FIG. 4B is a diagram illustrating a BB cross section in FIG.

  The configuration of the second embodiment of the intercooler 1 is substantially the same as that of the first embodiment, but is partially different in the structure in the vicinity of the connection portion 62 of the heat radiating tube 30. That is, the protrusion 221b is provided on the flat surface portion 221 between the adjacent heat radiating tubes 30, and the difference will be described below. Note that the configuration of the connection portion 61 of the heat radiating pipe 30 on the upper tank 10 side is the same as the configuration of the connection portion 62 on the lower tank 20 side, and is omitted.

  As shown in FIG. 4A, the heat radiating pipe 30 penetrates the tank lid portion 22 and is brazed by the insertion hole 221a. Further, between the adjacent heat radiating tubes 30, a protruding portion 221 b is formed to protrude from the flat surface portion 221 of the tank lid portion 22. The projecting portion 221b is integrally formed with the flat surface portion 221 by press working when the tank lid portion 22 is manufactured.

  The tank lid portion 22 is filled with the filler 24 so as to be approximately the same height as the protrusion 221 b and lower than the height of the convex portion 222 of the tank lid portion 22. The filler 24 hardens when a predetermined time elapses after being filled, and fixes the vicinity of the connection portion 62 of the heat radiating tube 30. Note that the filler 24 may be filled to the same height as the convex portion 222, as in the first embodiment.

  Further, both ends in the longitudinal direction of the protruding portion 221b have a gap 25 between the protruding portion 222 as shown in FIG. Thereby, even if the filler 24 is poured into the tank lid portion 22, the flow of the filler 24 is not hindered by the protruding portion 221 b, and the filler 24 can be uniformly filled into the tank lid portion 22.

  As described above, the following effects can be obtained in the second embodiment.

  In the intercooler 1 of the second embodiment, the projecting portion 221 b is integrally formed on the flat surface portion 221 between the adjacent heat radiating tubes 30 and the filler 24 is filled.

  Thereby, even if the amount of the filler 24 is smaller than that in the first embodiment, not only the same effect as in the first embodiment can be obtained, but also the fatigue breakage of the heat radiating tube 30 due to the deformation of the intercooler 1 can be further improved. It becomes possible to prevent reliably.

(Third embodiment)
FIG. 5 is an enlarged schematic view of the vicinity of the connection portion 62 of the heat radiating pipe 30 of the lower tank 20 of the intercooler 1 according to the third embodiment.

  The configuration of the third embodiment of the intercooler 1 is substantially the same as that of the first embodiment, but is partially different in the structure in the vicinity of the connection portion 62 of the heat radiating tube 30. That is, the plane plate 221 between the adjacent heat radiating tubes 30 is provided with the partition plate 221c, and the difference will be described below. Note that the configuration of the connecting portion 61 of the heat radiating pipe 30 on the upper tank 10 side is the same as the configuration of the connecting portion 62 of the radiating pipe 30 on the lower tank 20 side, and is omitted.

  As shown in FIG. 5, the heat radiating tube 30 penetrates the tank lid portion 22 and is brazed by the insertion hole 221a. The partition plate 221c is installed vertically from the plane portion 221 between the adjacent heat radiating tubes 30. The partition plate 221c is installed on the flat surface portion 221 by brazing, but may be integrally formed on the flat surface portion 221 by press working when the tank lid portion 22 is manufactured.

  In the third embodiment, the filler 24 is filled in the tank lid portion 22 so as to be substantially the same as the height of the partition plate 221c and lower than the height of the convex portion 222 of the tank lid portion 20. Note that the filler 24 may be filled to substantially the same height as the convex portion 222, as in the first embodiment.

  Further, both ends of the partition plate 221c in the longitudinal direction have gaps between the convex portions 222 as in the second embodiment. Thereby, even if the filler 24 is poured into the tank lid portion 22, the flow of the filler 24 is not hindered by the partition plate 221 c, and the filler 24 can be uniformly filled into the tank lid portion 22.

  As described above, the following effects can be obtained in the third embodiment.

  In the intercooler 1 of the third embodiment, the partition plate 221c is installed on the flat surface portion 221 between the adjacent heat radiating tubes 30, and the tank lid portion 22 is filled with the filler 24. Thereby, the intercooler 1 which concerns on 3rd Embodiment can acquire the effect similar to 2nd Embodiment.

(Fourth embodiment)
FIG. 6 is an enlarged schematic view of the vicinity of the connection portion 62 of the heat radiating pipe 30 on the lower tank 20 side of the intercooler 1 according to the fourth embodiment.

  The configuration of the fourth embodiment of the intercooler 1 is substantially the same as that of the third embodiment, but is partially different in the shape of the partition plate 221d. That is, the partition plate 221d is provided so as to protrude from the filler 24, and the difference will be described below. Note that the configuration of the connecting portion 61 of the heat radiating pipe 30 on the upper tank 10 side is the same as the configuration of the connecting portion 62 of the radiating pipe 30 on the lower tank 20 side, and is omitted.

  As shown in FIG. 6, the heat radiating pipe 30 penetrates the tank lid portion 22 and is brazed by the insertion hole 221a. The partition plate 221d is installed vertically from the flat surface portion 221 between the adjacent heat radiating tubes 30. The partition plate 221d is installed on the flat surface portion 221 by brazing, but may be integrally formed on the flat surface portion 221 by press working when the tank lid portion 22 is manufactured.

  In the fourth embodiment, the filler 24 is filled in the tank lid portion 22 so as to be lower than the height of the convex portion 222 of the tank lid portion 20. Note that the filler 24 may be filled to the same height as the convex portion 222, as in the first embodiment.

  The partition plate 221d is formed so as to protrude from the filler 24. Therefore, the partition plate 221d is cooled by the air flow when the vehicle travels, like the fins 3. Further, both ends in the longitudinal direction of the partition plate 221d have gaps between the convex portions 222 as in the second embodiment. Thereby, even if the filler 24 is poured into the tank lid portion 22, the flow of the filler 24 is not hindered by the partition plate 221 d, and the filler 24 can be uniformly filled into the tank lid portion 22.

  As described above, the following effects can be obtained in the fourth embodiment.

  In the intercooler 1 of the fourth embodiment, a partition plate 221 d is provided on the tank lid portion 22 between the adjacent radiating pipes 30 so as to protrude from the filler 24. Thereby, the intercooler 1 according to the fourth embodiment can obtain the same effects as those of the first embodiment.

  Moreover, since the partition plate 221d is cooled by the air flow when the vehicle travels, the temperature of the air that is supercharged and becomes high temperature can be further reduced. Thereby, it becomes possible to further improve the cooling performance of the intercooler 1.

  It is obvious that the present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the technical idea. For example, in the second embodiment, similarly to the fourth embodiment, the protruding portion may be formed to protrude from the filler.

BRIEF DESCRIPTION OF THE DRAWINGS It is an external view which shows 1st Embodiment of the intercooler by this invention. It is sectional drawing of 1st Embodiment of an intercooler. It is the schematic which expanded the connection part of the heat sink similarly. It is the schematic which expanded the connection part of the heat sink in 2nd Embodiment of an intercooler. It is the schematic which expanded the connection part of the heat sink in 3rd Embodiment of an intercooler. It is the schematic which expanded the connection part of the heat sink in 4th Embodiment of an intercooler. It is the schematic which expanded the connection part of the heat sink in the conventional intercooler.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Intercooler 10 Upper tank 20 Lower tank 30 Radiation pipe 40 Fin 12, 22 Tank cover part 121,221 Plane part (insertion surface)
121a, 221a Insertion holes 122, 222 Convex part (wall part)
221b Protruding part (protruding member)
221c Partition plate (protruding member)
221d Partition plate (protruding member)
14, 24 Filler (resin part)
61, 62 connection

Claims (9)

An intercooler that includes a pair of tanks and a heat radiating pipe that communicates with the tanks, and cools air that has been supercharged and heated up,
An insertion hole formed in the tank and into which the heat radiating pipe is inserted;
A connecting portion for connecting the inserted heat radiating pipe to the tank by brazing;
A resin part formed in the connection part, having fluidity at the time of filling, hardening with time, and increasing the fixing force of the radiator pipe to the tank;
An intercooler characterized by comprising: The tank has an insertion surface in which the insertion hole is formed, and a wall portion formed around the insertion surface so that the resin having fluidity does not flow out.
The intercooler according to claim 1. The insertion surface of the tank has a protruding member between the adjacent heat radiating pipes,
The intercooler according to claim 2. Between the longitudinal ends of the protruding member and the wall of the tank, there is a gap that does not hinder the flow of the resin having fluidity,
The intercooler according to claim 3. The protruding member is formed to protrude from the resin portion so as to be cooled by the flow of air during vehicle travel.
The intercooler according to claim 3 or 4, characterized in that. The protruding member is integrally formed on the insertion surface of the tank.
The intercooler according to any one of claims 3 to 5, wherein the intercooler is provided. The resin portion is formed up to substantially the same height as the tank wall.
The intercooler according to any one of claims 2 to 6, wherein the intercooler is provided. The resin part contains metal powder and is made of an epoxy resin material having fluidity, and is cured when a predetermined time elapses.
The intercooler according to any one of claims 1 to 7, wherein An intercooler manufacturing method for manufacturing an intercooler that includes a pair of tanks and a heat radiating pipe that communicates with the tanks and that cools air that has been supercharged and heated.
An insertion step of inserting the heat radiating pipe into an insertion hole formed in the tank;
A brazing step of fixing the inserted heat radiation pipe to the tank;
Filling the brazed portion brazed in the brazing step with a resin that has fluidity at the time of filling and hardens over time, and increases the fixing force of the heat radiating pipe to the tank; and
A method for manufacturing an intercooler, comprising:

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